Copper, Brass and Bronze Forging

Brass Aluminum Forging Enterprises will design, engineer, and manufacture copper, brass and bronze forgings to your company’s specifications, no matter how intricate or complex.

Copper is considered a semi-precious, nonferrous metal with hundreds of applications in many areas including its significant use in manufacturing. Its most noteworthy properties include its superior heat transferability, high ductility, thermal and electrical conductivity and resistance to corrosion. BA Forging has years of successful forging experience using raw copper material to produce welding clamps, electrical contactors and switch components.

Brass and Bronze are among the most well-known families of copper-base alloys. Brass is typically a combination of copper and zinc. Hot brass forging provides for superior density and freedom from flaws, along with dimensional accuracy for duplication of parts.

Bronze is predominantly copper combined with tin, aluminum, silicon or beryllium. Bronze is harder than pure iron and is more resistant to corrosion. Bronze is also harder than pure copper, and over time has been used for weapons, armor and tools.

Closed-die forging, often referred to as impression-die forging, is a

manufacturing process where metal is pressed, pounded or squeezed under great pressure in between two dies to produce high-strength parts. Because the dies restrict the flow of the metal, the forging process is the best option for intricate designs and close tolerances. Closed-die forging has the capability of producing an almost limitless variety of shapes with a range in weight from just a few ounces to more than 25 pounds. Both symmetrical and asymmetrical parts can be created with closed-die forging.

Closed-die forging, the process most widely used by BA Forging, is the most cost effective forging process for high-volume production. The initial costs for the tooling and the equipment may be higher, but it can be an excellent investment long-term as the recurring costs of the parts is very low.

Some of the numerous advantages to copper, brass and bronze forging includes close tolerances, strength, leak resistance and low overall costs.

A forging produced in a steel die with close tolerances offers several benefits including part dimensions that are held closer and show minimal variation from part to part.

When forging, metal is placed under extreme pressure which produces a very dense and refined grain structure. The directional alignment through the forging process yields maximum strength, ductility and resistance to impact and fatigue. The dense non-porous forged metal also allows for thinner sections without the risk of leaks due to flaws and voids. Thinner forged parts often result in lighter weight and lower cost per piece compared to other forming processes.

Mass production of forged parts offers maximum savings for BA Forging clients. Conversely, smaller quantities of copper alloy forgings can prove to be the most economical when specific design problems, such as leak integrity, close tolerances, high strength with low weight, and non-symmetrical shape, must be resolved.

Copper forgings also have non-magnetic properties and non-sparking characteristics that are favorable for the automotive electrical components, aerospace, energy and defense industries.

Brass Aluminum Forging Enterprises takes great pride in producing high-quality, closed-die brass and copper forged parts, specifically in the areas of automotive electrical components, aerospace, energy and defense industries. For over 80 years, our diverse customer base has trusted us to be part of their team, allowing us to help them create the often complex products they design. After thoroughly reviewing the specs in our APQP product review process, we work together with our clients to provide them with creative solutions for their unique designs.