Metal alloys like brass and bronze are widely employed in everyday items. Brass is an alloy of copper and zinc, whereas bronze is primarily an alloy of copper, typically mixed with tin but occasionally with additional metals. These two alloys have a variety of uses because of their characteristics.
They are both widely used copper alloy materials for valves, but they have distinct properties, temperature ranges, applications, and price points. Here is a detailed guide that can help people understand the differences between brass vs bronze ball valves.
What Is Bronze Valve
One of the original metal alloys is bronze, and it was first used around 3500 BC. Metal workers created a strong, pliable material out of copper and tin that would not shatter easily. With the exception of the decreased lead content and sporadic additions of manganese, nickel, and aluminum, bronze has not undergone much alteration.
This material can only be used to create parts by casting them into a mold or by milling a pre-cast bronze ingot. Small holes and rough, porous surfaces can be seen on bronze, which happens because of the casting procedure. Bronze alloys have the potential to hold a polish and are less abrasive when certain additives are added.
Elevated ductility, resistance to corrosion, and affordability are just a few of the advantages of bronze. Bronze valves can be used for plenty of things, such as flow direction control, safety relief, and flow shut-off. For use with potable water, lead-free bronze ball valve types are available, but they must adhere to or surpass the lead requirements imposed by the Clean Water Act.
What Is Brass Valve
Brass is more recent than bronze, and it was first recognized in 500 BC. Although mostly made of copper and zinc, it is incredibly adaptable. There are numerous brass alloys with a variety of characteristics. Additionally, brass is flexible and simple to deal with. This facilitates casting, forging, heat extrusion, and cold drawing.
Similar to bronze, brass has good resistance to corrosion but is more prone to breakdown if used with high chlorine levels. The key advantage of brass valves is the metal’s significantly less lead content. Because of this, brass is typically harmless for applications involving drinking water. Brass valves can also be used as shut-off valves in natural gas pipelines.
Brass valves are excellent for applications involving potable water and natural gas. Brass can be cast or machined since it is very malleable. Brass valves are considered to be superior to bronze valves in terms of durability and performance. In order to acquire the best brass valves, buy them from a reliable ball valve manufacturer.
Bronze Valve Vs Brass Valve: Main Differences
Check out the primary differences between bronze and brass valves.
Durability
Brass and bronze valves are both strong and long-lasting in terms of durability. Brass valves, however, are a little better than bronze valves. Compared to bronze, brass is a more durable, strong, flexible substance. Brass can be harmed by high chlorine and salt levels, although bronze is preferable in this circumstance. To improve stability, consider the media first before selecting a valve.
Heat Endurance
High temperatures are not a problem for brass or bronze valves. Brass melts at 1710 degrees Fahrenheit (930 degrees Celsius), while bronze melts at 1590 degrees Fahrenheit (865 degrees Celsius). Therefore, brass has a somewhat higher thermal tolerance than bronze. Brass performs well in hot temperatures but is less effective in cold ones.
Manufacturing Technologies
Here is the main difference between bronze valve vs brass valve when it comes to the manufacturing methodologies.
- Brass
Casting, forging, hot extrusion, and cold drawing are all methods for making brass parts and components. Due to the increased compactness of the metallographic structure, there is a high demand for forging components rather than casting them, which results in the lack of porosity, decreased size tolerance, and smooth surface. Brass is utilized in the under-pressure gas sectors to show that it is free of flaws.
- Bronze
Only casting or a mechanical procedure for discarding semi-finished metal from casting can produce parts and components. The end effect is a surface that is rough and jagged. The component’s quality produced by forging cannot be guaranteed or maintained by the casting procedure.
There are some drawbacks to casting, such as the development of shrinkage voids, porosity, liquation, and segregation. Because of the process variability, it is particularly challenging to identify and mitigate these flaws. Leaks, structural collapse, corrosion, and a jagged surface are the end outcomes.
Metal Mash
The amount of metal the valve combines with the media is referred to as metal mash. Brass has 2% to 3% lead, while bronze contains 5% or more. Bronze scatters additional metal in the media since it has extra information. Therefore, brass valves are better to be used with potable water. The Clean Water Act‘s lead requirements are met by a few producers who use lead-free materials.
Media And Uses
When deciding between bronze and brass valves, this aspect is very crucial. For particular uses, they both have different strengths and limitations that vary. The finest option for plumbing and potable water applications is the brass valve. Additionally, it works flawlessly with the oil and natural gas industry. The food and beverage applications might be concerned.
Bronze valves have the negative ability to introduce lead into drinking water. However, it would be acceptable to utilize a bronze valve made without lead. It fits in some way with the plumbing industry and other industrial sectors. Considering that the bronze valves are more resistant to corrosion in salty applications, they excel in maritime sectors.
Corrosion Resistance
- Brass
When utilized in hydrothermal sanitary applications, brass has exceptional corrosion resistance. However, brass can become stressed and corroded if the water contains a lot of chlorine. Dezincification is the procedure of particular zinc leaching from brass alloys with above 15% zinc when there is moisture and oxygen.
It is preferable in this situation to utilize dezincification-resistant brass. For use with potable water, the DZR material has been developed for pipe fittings and valves. By employing a specific surface protection coating, brass corrosion cracking can be resisted.
- Bronze
The dezincification corrosion resistance of bronze is normally extremely good. However, it is not immune to localized corrosion caused by metallurgical flaws. The corrosion cracking is tolerable in bronze, but it does not happen to it at all.
Melting Point
The temperature at which a specific solid substance transforms from a solid to a liquid is known as the melting point. The melting point of bronze is 1590 degrees Fahrenheit (865 degrees Celsius). Whereas the melting point of brass is 1710 degrees Fahrenheit (930 degrees Celsius).
Machinability
- Brass
Brass is one of the most commonly utilized substances in the valve industry because of how easily it can be worked and how well it adapts to automation machinery. Elevated cutting speeds shorten the manufacturing process, which inevitably lowers production expenses. The components’ flat surface makes it possible to polish and varnish them for a relatively low cost.
- Bronze
Even though there is lead content, bronze has a weaker ability to adapt to mechanized machinery compared to brass. Surface flaws and roughness are present on some components, especially those made by casting, which results in pressure loss. The surface is less polished and brilliant after the galvanic process.
Color And Interface
For brass and bronze, copper is the primary component, but the combination of the other components determines the color. The primary hue of the brass valve is typically a dull pale yellow tint, almost resembling gold. However, the reddish-brown color is present in bronze valves. Nevertheless, they can have additional finishes, such as chrome plating. To fit the valve interface with the chosen application, it is better to select the natural color or several finishes.
Properties
- Brass
The primary alloying component of brass is zinc, which is a copper alloy. Brass is split into common copper and specialty brass based on its chemical makeup. It is appropriate for the production of plates, tubes, rods, wires, and other components like condenser tubes and heat pipes, because of its exceptional plasticity.
Zinc and copper are less malleable than brass. It seeps when it is melted and possesses a low melting point (900 degrees Celsius), making it simple to cast in molds. Brass is resistant to wear and corrosion due to the iron, aluminum, silicon, and manganese alloys that make up its composition. These valves are vulnerable to stress cracking if ammonia is present.
Based on the specific usage, both alloys have different compositions. For example, cartridge brass, which was utilized to build gun cartridges, had a 30% of zinc substance. Naval brasses were utilized for a variety of purposes on boats and contained up to 39.7% of zinc substances. 52 components of copper, 30 components of nickel, 12 components of zinc, 5 components of lead, and one component of bismuth make up the bronze alloy known as bismuth bronze.
- Bronze
Brittle and hard describe bronze. The percentage of tin in the alloy determines the temperature at which it melts, which is somewhat greater than 950 degrees Celsius. In addition to being a superior heat and electrical conductor than most steel, bronze also withstands corrosion and metal fatigue effectively compared to steel.
Bronze contains copper alloys that encompass aluminum, beryllium, manganese, silicon, lead, and other elements in addition to copper and tin. This substance is accessible in a variety of variants, such as lead bronze, silicon bronze, and many more. Cast bronze and pressure-treated bronze are additional divisions of bronze.
It is non-magnetic and retains a high elastic limit and fatigue limit with excellent wear resistance. It shows resistance to corrosion, has decent electrical and thermal conductivity, and does not create when exposed to crash spark. Tin bronze is utilized extensively in shipbuilding, machinery, chemical, instrumentation, and other sectors, primarily for the production of corrosion-resistant and wear-resistant magnetic and elastic components as well as wear-resistant and machinery components.
Composition
The copper and zinc alloy is known as brass. Bronze is an alloy of tin, copper, and occasionally other elements like phosphorus, aluminum, manganese, or silicon. However, copper is the main component of bronze.
Cost
As not all parts are priced the same, the cost topic is crucial to this analysis. When comparing the two metals, brass is three to four times less expensive compared to bronze. It is due to the zinc substance being less expensive than brass, which makes it more inexpensive.
Additionally, brass’s supple surface and its ability to be machined help in keeping finishing expenses low during the production of valves. On the other hand, bronze parts are costly and demand further polish due to their jagged exterior polishing, which raises the price.
Are Brass Valves Better Than Bronze Valves
When it comes to performance and durability, Brass valves are often known to be better compared to bronze valves. The bronze valves have some drawbacks, which make brass valves better than them. Bronze has a rough and porous surface, is sensitive to gradual degradation, and occasionally has high lead content.
The primary drawback of brass valves is that they can decompose when exposed to high levels of chlorine. Other than that, they are relatively corrosion-resistant. They have little to no lead levels. In addition, the brass valves are very durable and malleable.
Brass is very resistant to corrosion, however, the zinc content can be broken down by elevated chlorine levels. Due to that, brass is ideal for several media, such as natural gas. Brass is a far better option than bronze for potable water since it normally has significantly lower amounts of lead compared to bronze.
How To Choose Between Brass Valves And Bronze Valves
Brass valves, like bronze, have an elevated level of corrosion resistance, which is why they are frequently employed in the petrochemical and marine sectors. Brass cutoff valves and ball valves are also commonly employed in the natural gas business, where it has been discovered that these materials can tolerate fire exposure just as well as more expensive stainless steel alternatives.
Make sure to choose brass valves if they are to be used in the following applications:
- Air and liquid shut-off
- Natural gas shut-off
- Flow direction control
- Potable water
- Flow Control
Bronze valves are frequently employed in high-performance applications and the petrochemical industry, especially in marine situations where low levels of corrosion are necessary.
Make sure to choose bronze valves if they are to be used in the following applications:
- Petrochemical
- Marine
- Safety relief
- Flow direction control
- Flow shut-off
- Flow Control
Conclusion
With this comparison guide, it has become clear that both the brass and bronze valves are used for a variety of applications in different fields. However, brass valves are a bit better than bronze valves considering their durability and performance.
However, it is better to choose between brass and bronze valves based on the media, purpose, environment, and desired applications. For acquiring various types of sturdy and high-quality valves, remember to contact an experienced industrial valve manufacturer.
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