Effect of lead elimination by adding nickel to brass on mechanical properties through a permanent casting process

Engineering manufacturing materials to produce environmentally friendly brass alloys by reducing the content of harmful elements such as Pb and energy consumption efficiency of the smelting process while maintaining the mechanical properties of the alloy is a significant effort for the manufacturing industry to reduce problems related to health and environmental impacts. The composition of Cu-Zn-Ni alloys and the fabrication process affect the mechanical properties of the alloys. Therefore, efforts are needed to reduce harmful elements such as Pb by adding Ni to brass alloys and reducing smelting energy consumption. This study analyzes the impact of adding nickel to brass as a substitute for lead made through a permanent casting process. It will also explore the effects of alloy melting below the melting point on brass alloys' characteristics and mechanical properties. The object of this study is brass alloy with the addition of nickel with variations of Ni1 %, Ni2 %, Ni3 %, and Ni4 %, which is also an independent variable, and the dependent variable is the decrease in lead and mechanical properties of brass alloys. The fabrication process is carried out by a permanent casting process with a maximum temperature of 1000 °C, a waiting time of 1 to 2 hours, and printing for testing specimens. The results showed that the element Pb in the brass alloy to which Ni was added decreased from the addition of 1 % Ni by weight of 2.454 % to 2.127 % with the addition of 4 % Ni or a decrease of about 7.6 %, with a regression value of 0.8397. The microstructure results showed that the distribution of leads had decreased in line with the addition of nickel elements from 1 % to 4 %. The grain size has increased with the addition of Ni from 24 μm to 31 μm. The tensile strength increased from 161.8 MPa in brass with the addition of Ni 4 % to 179.3 MPa, and the yield strength increased from 144.2 MPa in brass with the addition of Ni 4 % to 168.6 MPa. Based on the test results, the addition of nickel can reduce the lead element, which impacts increasing strength as a substitute for lead. This research provides an environmentally friendly material alternative, such as nickel as a substitute for lead in brass, through an efficient casting process in energy use. It produces alloys that have good mechanical properties for sustainable industrial needs