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Lead Free Brass Forgings
Lead Free Brass Forgings
Electrical Accessories India manufactures precision Lead Free Brass forgings for electrical OEMs, EPC contractors, power utilities, valve manufacturers, and industrial distributors. Our lead-free Brass hot forgings are produced from certified alloys including UNS C69300 (ECO BRASS), CW724R (CuZn21Si3P), CW617N (DZR hot forging Brass – reduced lead variant), and ISO 228-compliant hot-forging Brass grades with lead content meeting RoHS 2, REACH, NSF/ANSI 61, California AB1953, and ELV Directive compliance requirements. Parts range from simple forged blanks to fully CNC finish-machined, threaded, and plated components ready for assembly. Price: US$ 11.50/kg ex-works India.
Product Overview
Lead Free Brass Forgings: Process and Alloy Overview
Hot Brass forging involves heating Brass billets to the hot-working temperature range (650–800°C) and pressing or impacting them into closed dies to produce near-net-shape components with superior mechanical properties, grain refinement, and surface density compared to casting or machining from bar stock. Lead Free Brass forgings use alloys such as C69300 (ECO BRASS), CW724R (CuZn21Si3P), or dezincification-resistant hot-forging grades with lead below 0.09%. The forging process eliminates internal porosity, refines grain structure, and improves fatigue strength and pressure-tight integrity — critical for valve bodies, fittings, and structural electrical components.
Valve Bodies, Fittings, and Flow Components
Lead Free Brass forged valve bodies are the primary application category. Products include: ball valve bodies (DN8 – DN50), gate valve bodies, globe valve bodies, butterfly valve disc components, check valve housings, pressure relief valve bodies, gas meter valve bodies, solenoid valve bodies, thermostatic mixing valve bodies, manifold block forgings, distribution manifold forgings, and hydraulic valve bodies. All are forged to near-net-shape and finish-machined to ISO 228 (BSP) or ASME B1.20.1 (NPT) thread standards. Pressure ratings to PN40 (40 bar).
Electrical Hardware Forgings
Lead Free Brass forgings for electrical applications include: cable lug blanks (copper tube crimping lugs), earth bar sections, busbar connectors, substation connector bodies, tap connector bodies, dead-end compression connector blanks, mid-span compression sleeve forgings, cable gland bodies (large metric sizes, Pg, NPT), ground rod clamp bodies, tower bolt blanks (stainless steel assembly), transmission line hardware forgings, and earthing electrode clamp bodies. All electrical forgings are supplied to IEC 61238-1, IEC 61284, or customer drawings.
Plumbing, Gas, and HVAC Forgings
NSF/ANSI 61 and AB1953 compliant Lead Free Brass forgings for plumbing and gas systems: hot-forged ball valve bodies, gas valve bodies, service valve bodies, meter valve bodies, gas regulator bodies, irrigation valve bodies, backflow preventer housings, water meter bodies, pipe elbow forgings (90°, 45°, street elbows), pipe tee forgings, straight coupling bodies, union bodies, and manifold collector forgings. ECO BRASS C69300 and CW724R are the preferred alloys for these applications to satisfy AB1953 (<0.25% weighted average Pb) requirements.
Automotive and Industrial Forgings
ELV-compliant Lead Free Brass forgings for automotive and industrial applications: hydraulic junction block forgings, hydraulic manifold block forgings, pneumatic valve body forgings, transmission control valve bodies, ABS block forgings, power steering fitting forgings, fuel system T-piece forgings, engine coolant fitting forgings, turbocharger fitting bodies, and air conditioning system valve bodies. IMDS data and PPAP Level 1–3 documentation available for automotive OEM supply.
Structural and Mechanical Forgings
Heavy-duty Lead Free Brass forgings for structural applications include: hose end fittings (GHT, BSP, NST, Camlock), swivel joint bodies, high-pressure hydraulic fitting forgings (up to 700 bar rated), fire hose coupling bodies, firefighting equipment components, marine deck fitting bodies, ship seacock forgings, rudder hardware forgings, and pressure vessel nozzle forgings. These components require forged grain structure for fracture resistance at elevated working pressures.
Precision Finish-Machined Forgings
All Lead Free Brass forgings from Electrical Accessories India can be supplied as: rough forgings (scale-cleaned, as-forged condition), semi-machined forgings (major bores and faces machined), or fully finish-machined and threaded components (complete to drawing). CNC finishing operations include: turning, boring, milling, drilling, tapping (BSP, NPT, metric, inch), thread rolling, reaming, broaching, and knurling. CMM dimensional verification on all finish-machined critical dimensions. Surface treatments: nickel plating, tin plating, chromate passivation, powder coating available.
Forging Dies, Tooling, and Prototypes
Electrical Accessories India provides turnkey forging and machining services including die design (DXF/STEP), die manufacture in H13 hot-work die steel, prototype forgings (5–50 pcs for first-article qualification), and production tooling to customer IP ownership. Die life: typically 80,000–150,000 shots for Brass forgings. Tooling investment is amortised over agreed production volumes. Full reverse engineering from samples or physical prototypes using 3D scanning is available for legacy component replacement.
Key Features
- Lead-Free Forging Alloys: C69300 ECO BRASS, CW724R, and DZR hot-forging grades – all Pb <0.09%, fully RoHS/REACH/NSF compliant.
- Superior Mechanical Properties: Forged Brass achieves 20–30% higher fatigue strength vs. machined bar stock due to refined grain structure and elimination of internal porosity.
- Pressure-Tight Integrity: Forged components are inherently leak-tight at hydraulic pressures; suitable for PN40, PN63, PN100 rated systems without additional sealing.
- Near-Net-Shape Efficiency: Forging reduces material waste vs. machining from solid bar; lower material cost for complex 3D geometries.
- Wide Size Range: Forgings from 10 g to 15 kg per component; DN8 to DN150 valve bodies; custom sizes available.
- Complete Supply: From rough forging to fully machined, threaded, tested, and plated component — single-source supply.
- Price: US$ 11.50/kg ex-works India, ISO 9001:2015 certified.
Hot Forging Process and Quality
The hot forging process for Lead Free Brass begins with billet preparation: certified C69300 or CW724R rod/billet is cut to accurate volume by cold-saw or shearing. Billets are induction-heated to 700–780°C (lead-free Brass working temperature range). Hot forging is performed on closed-die mechanical or hydraulic presses (500–2000 kN). Flash removal by trimming die or milling. Surface shot-blasted to Sa 2.5 (ISO 8501-1). Heat treatment (if required for annealing or stress relief): 300–400°C/1 hour. Dimensional inspection by CMM on forging envelope. Alloy verification by XRF. Forging approvals: first-article dimensional report, hardness check, and visual inspection per ASTM E112 grain size assessment.
Dezincification Resistance of Lead-Free Brass Forgings
C69300 ECO BRASS and CW724R forgings pass ISO 6509 dezincification resistance test (maximum dezincification depth <200 μm in 1% CuCl₂ / 75°C / 24 hours). This makes them suitable for potable water systems in all water chemistries including chlorinated, softened, and aggressive groundwater. DZR classification per BS 2872 and EN 12163. C69300 and CW724R forgings provide class DZR performance, outperforming conventional CuZn40Pb2 forging Brass (CW617N) in corrosive environments, with the added advantage of full lead-free regulatory compliance.
Pressure Testing and Quality Assurance
Finish-machined Lead Free Brass valve bodies and fittings are hydraulically pressure tested per EN 12518 (hydrostatic test pressure = 1.5× rated working pressure). Test media: water with corrosion inhibitor. Test duration: 30 seconds minimum per EN standard; extended 2-minute tests available on request. Test certificates (hydrostatic test reports) provided with each batch for valve body and high-pressure fitting orders. PMI (Positive Material Identification) by XRF on 100% of forgings upon customer request.
International Standards Compliance
Lead Free Brass forgings from Electrical Accessories India are manufactured and tested to: ASTM B283 (Copper alloy forgings), ASTM B124 (Copper and Copper alloy forgings – general), EN 12165 (Wrought Copper alloys – forgings), EN 12420 (Copper alloy forgings), RoHS 2 Directive 2011/65/EU, REACH Regulation EC 1907/2006, NSF/ANSI 61 (drinking water components), California AB1953 (low-lead plumbing), ELV Directive 2000/53/EC, and BS EN 1563 for material properties.
Technical Specifications
| Alloy Grade | Designation | Pb Max | Hot Forgeability | Key Standard | Compliance |
|---|---|---|---|---|---|
| C69300 (ECO BRASS) | CuZn21Si3Mn2Al | 0.09% | Excellent | ASTM B283, B124 | RoHS, REACH, NSF, AB1953, ELV |
| CW724R | CuZn21Si3P | 0.09% | Very Good | EN 12165, EN 12420 | RoHS, REACH, NSF, ELV |
| CW617N (reduced Pb) | CuZn40Pb2 (Pb reduced to 0.09%) | 0.09% | Excellent (purpose-developed) | EN 12165 | RoHS, REACH, ELV |
| Price: US$ 11.50/kg ex-works India | |||||
Forging Mechanical Properties
| Property | C69300 Forging | CW724R Forging | Test Standard |
|---|---|---|---|
| Tensile Strength (UTS) | 450 – 550 MPa | 440 – 540 MPa | ISO 6892-1 |
| 0.2% Proof Stress | 200 – 350 MPa | 180 – 320 MPa | ISO 6892-1 |
| Elongation A50 | ≥ 15% | ≥ 12% | ISO 6892-1 |
| Brinell Hardness | 100 – 130 HB | 95 – 125 HB | ISO 6506-1 |
| Impact Toughness | > 35 J (Charpy) | > 30 J (Charpy) | ISO 148-1 |
| Dezincification (ISO 6509) | < 200 μm DZR | < 200 μm DZR | ISO 6509 |
International Equivalent Standards for Forging Brass
| Standard | Designation | Country |
|---|---|---|
| ASTM B283 / B124 | C69300 (ECO BRASS) | USA |
| EN 12165 / EN 12420 | CW724R / CuZn21Si3P | Europe (EU) |
| BS 2872 | CZ132 (approximate) | United Kingdom |
| JIS H 5120 | CAC604 (approximate) | Japan |
| GB/T 13819 | ZHSi80-3 (approximate) | China |
| GOST 17711 | ЛЦС 50-1 (similar) | Russia / CIS |
| IS 291 | LTB 2 (similar) | India |
Product Types / Variants
| Forging Type | Alloy | Weight Range | Typical Product |
|---|---|---|---|
| Small Forgings (rough) | C69300 / CW724R | 10 g – 200 g | Cable gland bodies, connector inserts |
| Medium Forgings (semi-machined) | C69300 / CW724R | 200 g – 2 kg | Valve bodies DN8–DN25, manifold sections |
| Large Forgings (finish-machined) | C69300 / CW617N LF | 2 kg – 15 kg | Valve bodies DN32–DN100, heavy fittings |
| Forged Fasteners | C69300 / CW724R | 5 g – 500 g | Heavy hex bolts, studbolts, flanged nuts |
| Forged Blanks (to be machined) | Any lead-free grade | As required | Pump bodies, actuator housings |
Applications by Industry
| Industry | Lead Free Brass Forged Components |
|---|---|
| Electrical / Power Distribution | Cable lug bodies, busbar connectors, earth terminal forgings, overhead line hardware |
| Potable Water (NSF/AB1953) | Ball valve bodies, manifold collector forgings, meter body forgings, union bodies |
| Gas Distribution | Gas meter valve bodies, service tee forgings, regulator body forgings |
| Oil & Gas / Process | High-pressure fitting forgings, manifold blocks, instrumentation junction boxes |
| Automotive (ELV) | Hydraulic junction blocks, ABS valve bodies, power steering fittings |
| HVAC / Refrigeration | Valve bodies, manifold forgings, refrigerant service fitting bodies |
| Marine / Offshore | Seacock bodies, deck fitting forgings, through-hull fittings |
| Fire Protection | Hose coupling bodies, nozzle bodies, sprinkler heads |
Manufacturing Process
Material: Certified C69300 or CW724R billet/rod with EN 10204 3.1 MTC. Step 1 – Billet preparation: precision-sawn billets with volume tolerance ±2%. Step 2 – Induction heating to 700–780°C (contact pyrometer verification). Step 3 – Hot forging on 500–2,000 kN hydraulic/mechanical press in closed dies (H13 die steel, nitride-hardened). Step 4 – Flash trimming in trimming die or by milling. Step 5 – Shot-blasting (steel shot, Sa 2.5). Step 6 – Dimensional inspection of forgings on CMM (10% AQL sampling). Step 7 – CNC finish-machining (turning, drilling, tapping, milling) to customer drawing. Step 8 – Thread gauging (100% go/no-go). Step 9 – Hydraulic pressure test (valve bodies and high-pressure fittings). Step 10 – Surface treatment (plating / passivation as specified). Step 11 – Final inspection (CMM, visual, hardness spot-check). Step 12 – Packing with desiccant, moisture barrier, and export marking.
Quality Standards and Certifications
| Standard / Certification | Scope |
|---|---|
| ISO 9001:2015 | Quality Management System |
| ASTM B283 / ASTM B124 | Copper alloy forgings |
| EN 12165 / EN 12420 | Copper alloy forgings (European) |
| RoHS 2 (2011/65/EU) | Lead-free compliance – Pb <0.09% |
| REACH (EC 1907/2006) | SVHC compliance |
| NSF/ANSI 61 | Potable water contact |
| California AB1953 | Lead-free plumbing (<0.25% weighted Pb) |
| ISO 6509 | Dezincification resistance test |
| EN 12518 | Hydrostatic pressure test (valve bodies) |
| EN 10204 3.1 | Material test certificates |
Why Choose Electrical Accessories India for Lead Free Brass Forgings
Electrical Accessories India combines in-house hot forging, CNC machining, pressure testing, and surface treatment to provide a complete turnkey solution for Lead Free Brass forged components. Our technical team has deep expertise in alloy selection, die design, and process optimisation for C69300 ECO BRASS and CW724R forgings. We maintain dedicated material storage and processing lines for lead-free alloys to prevent contamination. Competitive pricing at US$ 11.50/kg ex-works India, ISO 9001:2015 certified quality system, and full regulatory compliance documentation (RoHS, REACH, NSF, AB1953, ELV) make us a preferred supplier to electrical OEMs, valve manufacturers, and plumbing product companies globally.
Frequently Asked Questions (FAQ)
What alloys are used for Lead Free Brass forgings?
The primary alloys are UNS C69300 (ECO BRASS, ASTM B283), CW724R (CuZn21Si3P, EN 12165), and lead-free variants of hot-forging Brass grades. All contain Pb <0.09% by weight.
What is the price of Lead Free Brass forgings?
Standard pricing is US$ 11.50 per kilogram ex-works India for Brass alloys, subject to part weight, complexity, forging die amortisation, and finish-machining requirements. Request a quotation with your drawing for a detailed price.
What is the weight range available for Lead Free Brass forgings?
We produce forgings from 10 grams (small connector bodies) to 15 kilograms (large valve bodies DN80–DN100). Larger special forgings can be arranged through our forging partners for weights up to 50 kg.
Are Lead Free Brass forgings suitable for potable water (drinking water) applications?
Yes. C69300 ECO BRASS and CW724R forgings comply with NSF/ANSI 61, California AB1953 (<0.25% weighted average Pb), Vermont Act 193, and EN 15664-1. They are approved for ball valve bodies, manifold components, and fittings in potable water systems in the USA, EU, UK, Canada, and Australia.
Can Lead Free Brass forgings replace CW617N (conventional hot forging Brass) parts?
Yes, as functional replacements. Dimensions, thread standards, and pressure ratings are identical. CW617N conventional grade contains up to 2.5% Pb — non-compliant with RoHS for many applications. C69300 or CW724R lead-free forgings provide equivalent or better corrosion resistance with full regulatory compliance.
What thread standards can be machined into forged components?
We machine BSP (BSPP/BSPT), NPT, NPTF, Metric (ISO), UNC, G (ISO 228), and Pg (conduit) threads. We also machine DIN 3902 (ORFS face seal), SAE J514 (JIC 37°), and custom thread profiles to customer drawings.
Do you provide pressure testing for Lead Free Brass forgings?
Yes. Valve bodies and high-pressure fittings are hydrostatically tested at 1.5× rated pressure per EN 12518. Test reports are supplied with each order. Helium leak testing is available for critical applications.
What is the lead time for Lead Free Brass forgings?
For new tooling: 6–8 weeks (die design, manufacture, prototype, first article). For repeat orders with existing tooling: 4–6 weeks. Expedite services (2–3 weeks) available for stocked standard forging blanks with CNC machining.
What surface finishes are available for Lead Free Brass forgings?
As-forged, shot-blasted, bright machined, nickel plated, tin plated, silver plated, chromate passivated, or powder coated. Lead-free plating processes only (no Pb-Sn plating).
Do you export Lead Free Brass forgings?
Yes. We supply to valve manufacturers, electrical OEMs, plumbing product companies, and industrial distributors in Europe (DE, UK, FR, IT, NL), Middle East (UAE, SA, QA), Americas (USA, CA, BR), Asia-Pacific (AU, SG, MY), and Africa (ZA, NG). Full export documentation provided.
International Terms and Equivalents
| Language | Equivalent Terms |
|---|---|
| Spanish (Español) | Forjas de latón sin plomo, Piezas forjadas de latón libre de plomo, Estampado en caliente de latón sin plomo |
| Russian (Русский) | Поковки из безсвинцовой латуни, Кованые детали из латуни без свинца, Горячая штамповка безсвинцовой латуни |
| French (Français) | Forges en laiton sans plomb, Pièces forgées en laiton sans plomb, Estampage à chaud laiton sans plomb |
| Portuguese (Português) | Forjados de latão sem chumbo, Peças forjadas em latão livre de chumbo, Forjamento a quente de latão sem chumbo |
| Italian (Italiano) | Forgiati in ottone senza piombo, Pezzi forgiati in ottone senza piombo, Stampaggio a caldo ottone senza piombo |
Related Products / Internal Links
- CW724R (CuZn21Si3P) Lead Free Brass Machined Parts
- UNS C69300 ECO BRASS Lead Free Brass Machined Parts
- Lead Free Brass Screw Machine Parts
- Brass Forging Parts (Standard)
- Brass Hot Forged Parts
- Lead Free Brass Casting and Lead Free Machined Castings
Request a Quote – Lead Free Brass Forgings
Electrical Accessories India – ISO 9001:2015 certified manufacturer of Lead Free Brass hot forgings. Alloys: C69300 ECO BRASS, CW724R. Price: US$ 11.50/kg ex-works India. RoHS / REACH / NSF / AB1953 / ELV compliant. Forging weights 10 g – 15 kg. Export worldwide.
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