Aluminum Bronze casting, Aluminium Bronze Fittings

Aluminum Bronze casting, Aluminium Bronze Fittings, Aluminium Bronze Machined Parts, Aluminum Bronze Threaded Fittings

Top Quality Aluminum Bronze Casting, Aluminium Bronze Fittings, Aluminium Bronze Machined Parts, Aluminum Bronze Threaded Fittings, Aluminum Bronze Casting Foundry 

Price: US$ 11.90/kilogram

We are one of the leading manufacturers and exporters of Aluminum Bronze components from India. We have been supplying Aluminium Bronze castings, machined parts, and threaded fittings to the world market for many decades. Known for their superior strength, excellent corrosion resistance, and wear properties, Aluminum Bronze alloys are preferred in the marine, oil & gas, aerospace, chemical, and heavy engineering sectors. Our facility is equipped with advanced casting furnaces, CNC machines, pressure testing setups, and quality control labs to ensure world-class output. We serve global customers with made-to-print components, including flanges, bushings, valve bodies, pump impellers, threaded inserts, and marine fittings. Our Aluminum Bronze products conform to global standards such as ASTM B148, BS 1400 AB2, DIN 1705, JIS H5120, and GB/T 1176.

Aluminum Bronze Casting We produce high-integrity Aluminum Bronze castings using sand casting, centrifugal casting, and investment casting techniques. Alloys used include C95400, C95500, and C95800 (US grades), AB1 and AB2 (UK grades), DIN G-CuAl10Ni5Fe4 (Germany), and ZCuAl9Fe4Ni4Mn2 (China). These castings exhibit high tensile strength, low magnetic permeability, and superior seawater resistance. Typical parts include marine propellers, pump bodies, valve housings, gear blanks, and bearing sleeves. We offer castings from 50 grams to 500 kg with dimensional tolerances as per ISO 8062 CT6–CT8.

Aluminium Bronze Fittings Our Aluminium Bronze Fittings are used in aggressive environments where strength and corrosion resistance are essential. These include flanged fittings, reducers, elbows, tees, and stub ends made from cast or forged AB2 or C95800. Sizes range from ½” to 12″ with pressure ratings from PN10 to PN40 or ANSI 150–600#. These fittings are CNC machined and hydro-tested. Common applications include seawater lines, oil rig installations, desalination plants, and chemical transfer units. Threads comply with BSP, NPT, and ISO standards.

Aluminium Bronze Machined Parts Precision-machined components are made from forged or cast blanks of Aluminum Bronze using multi-axis CNC lathes and milling machines. Parts include wear plates, worm wheels, pump inserts, thrust washers, bushings, and structural connectors. We machine to tight tolerances (±0.05 mm) and offer turned, milled, and threaded configurations with surface finishes up to Ra 0.8 μm. 3D models and 2D drawings are accepted in all standard formats. Heat treatment and anti-galling coating (MoS2 or PTFE) are available as options.

Aluminum Bronze Threaded Fittings Threaded inserts, hose fittings, and valve connectors made from AB2 and C63000 offer superior pressure handling and galling resistance. We supply male and female threaded fittings in BSP, NPT, and Metric threads. Thread tolerance is Class 2B/3A as per ASME B1.1 and ISO 965. Threaded fittings undergo dimensional inspection, thread gauging, and pressure testing up to 600 psi. Finish includes passivation, oiling, or Nickel plating on request.

Material Properties and Grades

Standard Sizes (Example)

Overview of Aluminium Bronze Alloys

Aluminium Bronze represents a sophisticated family of Copper alloys containing 5-14% Aluminium as the primary alloying element, often with additional elements such as iron, nickel, manganese, and silicon to enhance specific properties. These premium engineering alloys offer an exceptional combination of characteristics that make them ideal for critical applications where standard materials would fail:

• Superior Corrosion Resistance: Exceptional performance in seawater, brackish water, and many chemical environments
• High Mechanical Strength: Tensile strengths comparable to medium-carbon steels
• Excellent Wear Resistance: Outstanding friction properties and galling resistance
• Good Thermal Conductivity: Effective heat dissipation for thermal applications
• Non-sparking Properties: Intrinsically safe for hazardous environments
• Biofouling Resistance: Natural resistance to marine growth and microbial colonization

The distinctive golden color of Aluminium Bronze makes it immediately recognizable, while its exceptional durability in demanding environments has established it as the premium material choice for applications where failure is not an option.

Aluminum Bronze Casting Material Grades and International Specifications

Aluminium Bronze is manufactured in various compositions according to international standards, each optimized for specific applications:

US Grades (ASTM/UNS)

UK Grades (BS)

German Grades (DIN)

Chinese/Japanese Grades

Material Properties Comparison

Aluminium Bronze Castings

Aluminium Bronze castings represent the foundational category of our product range, utilizing advanced metallurgical expertise to transform premium alloys into precision components with complex geometries. Our casting capabilities span from intricate valve components weighing a few hundred grams to massive marine propellers exceeding 1,000 kg. The excellent fluidity of properly formulated Aluminium Bronze alloys enables us to achieve exceptional detail reproduction and dimensional accuracy while minimizing porosity and other casting defects.

Manufacturing Process for Aluminium Bronze Castings

Our comprehensive manufacturing process ensures consistent quality across all our Aluminium Bronze castings:

1. Material Engineering: Alloy composition is carefully formulated based on application requirements, with precise control of alloying elements, particularly aluminium, iron, nickel, and manganese.
2. Melting and Alloying: Premium virgin and recycled materials are melted in induction furnaces under protective atmospheres to prevent oxidation and maintain precise composition control.
3. Casting Technology: Multiple casting methods are employed depending on component complexity, size, and quality requirements:
   • Sand Casting: For large components and complex geometries
   • Investment Casting: For highest precision and surface finish requirements
   • Centrifugal Casting: For cylindrical components like bushings and liners
   • Continuous Casting: For production of stock material for machining
4. Heat Treatment: Castings undergo specialized heat treatment cycles to optimize mechanical properties, including:
   • Solution annealing: 760-850°C followed by controlled cooling
   • Precipitation hardening: 400-550°C with precise time control
   • Stress relief: 260-350°C to eliminate residual stresses
5. Quality Verification: Comprehensive testing including:
   • Chemical composition analysis
   • Mechanical property testing
   • Non-destructive examination (radiography, ultrasonic, dye penetrant)
   • Dimensional inspection
   • Surface quality assessment

AB1 Bronze Casting
AB1 is a British Standard (BS 1400:1985) Aluminium Bronze alloy known for its excellent general corrosion resistance and moderate mechanical strength. It typically contains 9–11% Aluminium, with small additions of Iron and Manganese to improve strength and resistance to scaling. AB1 is ideal for sand casting and is widely used in non-critical marine and industrial components where seawater exposure or mildly corrosive conditions exist. Components such as valve bodies, pump casings, and low-pressure fittings are commonly made from AB1. It offers good machinability and accepts various surface treatments including oiling, tinning, or passivation. The alloy is cost-effective and suitable for applications where moderate stress and long-term corrosion resistance are priorities.

AB2 Bronze Casting
AB2 is a higher-grade Aluminium Bronze alloy defined under BS 1400 and is used for applications requiring superior mechanical strength, fatigue resistance, and excellent performance in aggressive environments, particularly seawater. AB2 typically has 10–12% Aluminium and higher content of Nickel and Iron compared to AB1, giving it increased tensile strength (up to 690 MPa) and better resistance to pitting and cavitation. AB2 castings are preferred for marine hardware, propellers, pump impellers, and valve parts where durability under stress and exposure to saltwater are essential. The alloy exhibits lower magnetic permeability and better wear resistance, making it ideal for defense, shipbuilding, and offshore drilling systems. AB2 can be produced using sand or investment casting and is often finished with anti-corrosion coatings or precision machining to tight tolerances.

Aluminum Bronze Sand Casting

Aluminum Bronze sand casting represents the most versatile and widely employed casting method for this premium alloy family, utilizing traditional foundry techniques enhanced with specialized knowledge of Copper alloy metallurgy. In this process, sand molds are created using specially formulated molding compounds with precise clay and moisture content to accommodate the higher pouring temperatures (1050-1150°C) and fluidity characteristics of Aluminum Bronze alloys. The process begins with pattern making, where wooden, metal, or polymer patterns slightly larger than the finished part (accounting for shrinkage rates of 1.5-2.0%) create the mold cavity in compacted sand. Gating and risering systems require particular attention, with larger than normal risers to compensate for the relatively high solidification shrinkage of Aluminum Bronze. During pouring, controlled pouring temperatures and protective flux coverings minimize oxidation and hydrogen absorption. The sand casting method allows for complex geometries with internal passages and is particularly suitable for creating large components like marine propellers, pump casings, and valve bodies weighing from a few kilograms to several tons. While offering lower dimensional precision than other methods (typical tolerances of ±1.5mm per 300mm), sand casting provides the most economical approach for medium to large Aluminum Bronze components and remains the foundation of production for this alloy family.

Aluminum Bronze Investment Casting

Aluminum Bronze investment casting, also known as lost wax casting, delivers the highest precision and surface quality achievable for complex Aluminum Bronze components. This sophisticated process begins with creating wax patterns that precisely replicate the desired component, including intricate details impossible to achieve through other casting methods. The wax patterns are assembled onto a “tree” structure, then repeatedly dipped in ceramic slurry and stuccoed with progressively coarser materials to build a robust shell. Once dried, the molds undergo dewaxing in autoclaves, followed by firing at 900-1100°C to burn out any residual wax and strengthen the ceramic shell. Molten Aluminum Bronze, typically prepared in small induction furnaces for precise composition control, is then poured into the preheated ceramic shells (500-600°C) to minimize thermal shock and ensure complete filling of thin sections. After solidification and cooling, the ceramic shell is removed through mechanical breakdown and chemical cleaning. This method achieves remarkable dimensional accuracy (±0.2mm for small components) and exceptional surface finish (3.2-1.6 Ra), making it ideal for precision components like impellers, turbine blades, and specialized hardware. While investment casting carries higher production costs than sand casting, it delivers near-net-shape components that minimize subsequent machining, creating value for complex, high-precision Aluminum Bronze parts with intricate geometries or demanding surface finish requirements.

Aluminum Bronze Permanent Mold Casting

Aluminum Bronze permanent mold casting utilizes reusable metal molds, typically constructed from heat-resistant tool steel or cast iron, to produce components with superior dimensional accuracy and surface finish compared to sand casting methods. The molds receive careful design attention, incorporating proper draft angles (typically 1-3°), optimized gating systems, and strategically placed cooling channels to control solidification patterns. Before each casting cycle, the mold surfaces receive a specialized refractory coating that prevents the molten Aluminum Bronze from adhering to the mold while also regulating heat transfer rates. Molds are preheated to 200-350°C to ensure proper metal flow, prevent premature solidification, and minimize thermal shock to the mold material. Molten Aluminum Bronze, prepared in induction furnaces to precise compositions, flows into the mold cavity either through gravity pouring or low-pressure injection. Once solidified, the castings are ejected using mechanical ejector pins built into the mold assembly. This method delivers components with excellent density, minimal porosity, and consistent mechanical properties, achieving dimensional tolerances of approximately ±0.5mm per 300mm and surface finishes of 3.2-6.3 Ra. Permanent mold casting is particularly well-suited for medium-sized components (typically 0.1-15 kg) produced in moderate to high volumes, such as valve bodies, pump components, and gear blanks. While requiring higher initial tooling investment than sand casting, the method offers excellent economics for appropriate production volumes while delivering enhanced quality and consistency.

Aluminum Bronze Centrifugal Casting

Aluminum Bronze centrifugal casting harnesses centrifugal force to create tubular components with exceptional density and mechanical properties. In this specialized process, molten Aluminum Bronze is poured into a rapidly rotating cylindrical mold (typically 600-1200 RPM depending on diameter), where centrifugal force drives the metal against the mold wall with pressures exceeding 100G. This intense force eliminates gas porosity, compacts the microstructure, and pushes lighter non-metallic inclusions toward the inner diameter, which is typically machined away in finished components. The molds, constructed from steel or graphite, are preheated to 300-400°C and coated with specialized refractory coatings to prevent metal adhesion. Careful control of pouring temperature (typically 1100-1150°C), rotation speed, and cooling rate is essential to achieve optimal grain structure and mechanical properties. Centrifugal casting produces cylindrical components with exceptional concentricity, density, and mechanical strength, making it the preferred method for manufacturing Aluminum Bronze bushings, bearing sleeves, gear blanks, and cylindrical liners. The process creates a beneficial directional solidification pattern from outside to inside, with fine equiaxed grains near the outer diameter grading to more columnar structures internally. Products manufactured through this method exhibit 15-20% higher tensile strength and significantly improved wear resistance compared to static-cast equivalents of the same alloy, making centrifugal casting the premium manufacturing method for critical rotating and wear-resistant Aluminum Bronze components.

Aluminum Bronze Green Sand Casting

Aluminum Bronze green sand casting represents the most traditional and economical casting approach, utilizing a mixture of silica sand, clay (typically bentonite), and moisture to create molds without baking or chemical setting. The term “green” refers to the mold’s uncured, damp state during metal pouring, not the color of the sand mixture. This versatile process begins with compacting the green sand mixture around patterns in a flask, creating impressions that form the casting cavity. For Aluminum Bronze casting, the sand mixture requires precisely controlled moisture content (typically 3-4%) and clay percentage (7-9%) to withstand the high pouring temperatures while maintaining sufficient permeability for gas escape. Special considerations for Aluminum Bronze include using finer-grained sand for improved surface finish, adding carbonaceous additives to reduce metal-sand reactions, and creating larger-than-normal vent channels to accommodate the gases generated during solidification. Gating systems require careful design to minimize turbulence, with filters often incorporated to trap inclusions. The green sand method offers the lowest tooling costs and greatest flexibility for prototype or low-volume production, making it ideal for custom architectural elements, decorative components, and one-off mechanical parts. While providing less dimensional precision than other methods (typical tolerances of ±2mm per 300mm), green sand casting remains the most adaptable and cost-effective approach for short-run or custom Aluminum Bronze components, particularly when combined with skilled pattern making and foundry practices.

Typical Aluminium Bronze Castings

Our foundry specializes in a wide range of Aluminium Bronze castings for critical applications:

Performance Characteristics

Aluminium Bronze castings deliver exceptional performance metrics essential for demanding applications:

• Corrosion Resistance: Corrosion rates in seawater typically <0.025mm/year
• Mechanical Strength: Tensile strengths ranging from 550-750 MPa depending on alloy and heat treatment
• Wear Resistance: Friction coefficients typically 0.10-0.15 against steel
• Impact Resistance: Superior toughness compared to cast iron or standard bronze
• Elevated Temperature Capability: Maintains mechanical properties up to 300°C
• Thermal Conductivity: Approximately 50 W/m·K, enabling effective heat dissipation
• Fatigue Resistance: Endurance limit typically 40-45% of tensile strength

Industries Using Aluminum Bronze Components

• Shipbuilding & Marine
• Oil & Gas (Offshore and Downstream)
• Defense and Aerospace
• Power Generation (Hydro and Thermal)
• Process Industry (Acids, Seawater, etc.)

Tolerances and Turnaround

• Casting tolerances: ISO 8062 CT6–CT8
• Machining: ±0.05 mm
• Thread: Class 2B (Unified), ISO 965
• Delivery: 4–6 weeks depending on volume and customization

Performance Metrics

• Temperature Range: –50°C to +250°C
• Max Pressure: 40 bar (flanged), 600 psi (threaded)
• Thermal Conductivity: 42–54 W/mK
• Wear Resistance: Very High (suitable for bearings and wear plates)

Common Questions and Answers

1. Do you support international thread standards? – Yes, BSP, NPT, ISO, and custom threads.
2. Can you supply pressure test certificates? – Absolutely, hydro/pneumatic tests are documented.
3. What are your casting weight capabilities? – From 50 g to 500 kg.
4. Do you offer 3.1 Material Certificates? – Yes, with chemical and mechanical data.
5. What packaging do you offer? – PE wrap, carton box, and seaworthy wooden cases.
6. Do you offer Nickel- or Tin-plated finish? – Yes, on request.
7. What is your MOQ? – Flexible depending on part complexity.
8. Can you reverse engineer from samples? – Yes, using 3D scanning and CAD modeling.
9. How do you ensure quality? – 100% inspection, in-house lab, and external NABL labs.
10. Do you ship globally? – Yes, with all export compliance handled.

Why Choose Us We combine over three decades of export experience, global customer handling, and technical know-how to deliver unmatched service. Our agility in handling low volumes, tight deadlines, and custom needs makes us the preferred supplier of Aluminum Bronze components from India. Customers value our fast response, drawing consultation, branded packaging, and long-standing reliability.

Customer Testimonial “The quality and consistency of the Aluminum Bronze bushings we received from you have been outstanding. The communication and timely updates made it a smooth experience.”
– Daniel Hughes, Ohio, USA

Glossary of Terms

• Aluminum Bronze: A Copper-based alloy containing 5–12% Aluminium, known for high strength and corrosion resistance.
• AB2: British standard grade for high-strength Aluminium Bronze casting.
• C95400/C95800: US standard designations for common Aluminium Bronze alloys.
• BSP/NPT: Thread standards – British Standard Pipe, National Pipe Tapered.
• CNC Machining: Precision cutting using computer-controlled machines.

Related Terms Aluminium Bronze Valve Bodies, C95400 Fittings, Aluminium Bronze Bushings, Machined Bronze Inserts, Threaded Bronze Connectors, Nickel Plated Bronze Parts

Packaging and Shipping All parts are individually wrapped with corrosion-inhibiting PE, boxed and palletized for export. Wooden crates with fumigation, custom barcoded labeling, and logos are available. We ship globally via air or sea freight from India.

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