Influence of casting parameters on the surface and mechanical properties of leaded brass alloys: mechanistic insights

Leaded brass alloys are extensively used in mechanical applications due to their excellent machinability and durability. This study explores the impact of casting parameters, particularly the mold material and cooling rate, on the microstructure and mechanical properties of leaded brass alloys. Focus is placed on the formation of the β′-phase during casting and its influence on hardness and overall mechanical response. The alloys were cast in different chill molds made of steel, iron, silica sand, marble, and clay to observe variations in cooling rate. Hardness testing, X-ray diffraction analysis, and von Mises stress calculation were employed to investigate the mechanical properties and phase structure. The results show that the cooling rate significantly affects the microstructure, with a correlation between the β′-phase content and the alloy’s hardness. This study provides insights into how thermal and chemical factors during casting influence the performance of leaded brass alloys, contributing to the optimization of casting processes in industrial applications.