C95500 Nickel Aluminum Bronze Permanent Mold Casting represents one of the highest-performance alloys available for permanent mold casting, combining exceptional mechanical strength with superior corrosion resistance in the most demanding industrial and marine environments. Conex Casting specializes in manufacturing precision C95500 permanent mold castings that meet ASTM B148 and UNS C95500 specifications, delivering components that outperform conventional bronze alloys in critical applications requiring both high strength and long-term reliability.
What is C95500 Nickel Aluminum Bronze?
C95500 is a Nickel Aluminum Bronze alloy with the nominal composition of 81% Copper (Cu), 11% Aluminum (Al), 4% Iron (Fe), and 4% Nickel (Ni). This composition places C95500 among the strongest commercially available copper-based alloys, with tensile strength values reaching 110,000–120,000 psi in the permanent mold cast condition. The addition of nickel refines the microstructure, improves mechanical properties, and significantly enhances corrosion resistance compared to standard aluminum bronze grades such as C95400.
The alloy conforms to the following international standards:
- ASTM B148 – Standard Specification for Aluminum-Bronze Sand Castings (also applied to permanent mold)
- UNS C95500 – Unified Numbering System designation
- BS 1400 AB2 – British Standard for aluminum bronze castings
- DIN 1714 CuAl10Ni5Fe4 – German standard for nickel aluminum bronze
- JIS H5120 CAC703 – Japanese casting standard
C95500 Chemical Composition
| Element | Composition (%) |
|---|---|
| Copper (Cu) | 78.0 min |
| Aluminum (Al) | 10.0 – 11.5 |
| Iron (Fe) | 3.0 – 5.0 |
| Nickel (Ni) | 3.5 – 5.5 |
| Manganese (Mn) | 3.5 max |
| Others | 0.5 max |
Mechanical Properties of C95500 Permanent Mold Castings
| Property | Value (Typical – Permanent Mold) |
|---|---|
| Tensile Strength | 110,000 – 120,000 psi (758 – 827 MPa) |
| Yield Strength (0.2% offset) | 62,000 – 75,000 psi (427 – 517 MPa) |
| Elongation (%) | 6 – 12% |
| Brinell Hardness (HBW) | 195 – 240 |
| Density | 0.272 lb/in³ (7.53 g/cm³) |
| Melting Range | 1895 – 1930°F (1035 – 1054°C) |
| Thermal Conductivity | 21 BTU/hr·ft·°F (36 W/m·K) |
The permanent mold casting process enhances these properties by 10–20% compared to sand casting, due to faster cooling rates producing a finer grain structure and denser microstructure.
Advantages of C95500 for Permanent Mold Casting
- Exceptional Corrosion Resistance: Outperforms standard aluminum bronze in seawater, acidic environments, and chemical process streams due to the nickel content forming a stable protective oxide layer.
- High Strength: Tensile strength approaching low-alloy steels, enabling weight-efficient designs in structural and high-load applications.
- Excellent Wear Resistance: The hard beta phase in the microstructure provides superior resistance to sliding wear, making C95500 ideal for gear, bearing, and cam applications.
- Spark Resistance: Non-sparking characteristic qualifies C95500 for use in hazardous and explosive atmospheres, including offshore oil and gas installations.
- Dimensional Accuracy: The permanent mold process achieves as-cast tolerances of ±0.015 inches, reducing secondary machining requirements and lowering total part cost.
- Pressure Tightness: The dense microstructure of permanent mold castings ensures leak-free performance in high-pressure hydraulic and seawater systems.
Typical Applications of C95500 Permanent Mold Castings
C95500 nickel aluminum bronze is specified for demanding applications across marine, industrial, and defense sectors where maximum performance is required:
- Marine Propulsion: Propeller hubs, shaft bushings, rudder pintles, and strut bearings for naval and commercial vessels
- Subsea Equipment: Valve bodies, actuator housings, and connector blocks for offshore oil and gas platforms
- Pump Components: Impellers, volute casings, and wear rings for seawater handling and chemical process pumps
- Naval Hardware: Deck fittings, bollards, cleats, and structural brackets on warships and patrol vessels
- Aerospace Bushings: Flight control mechanism bushings and actuator components requiring high fatigue resistance
- Industrial Gears: Worm gears, helical gears, and gear blanks in high-load machinery
- Hydraulic Manifolds: High-pressure valve bodies and manifold blocks where leak integrity is critical
- Mining Equipment: Wear plates, guide shoes, and bearing components in abrasive mining environments
C95500 vs. C95400: Key Differences
While both C95500 and C95400 Aluminum Bronze belong to the aluminum bronze family and are used in similar applications, C95500 offers superior performance due to its nickel addition:
| Property | C95500 (Ni-Al Bronze) | C95400 (Al Bronze) |
|---|---|---|
| Nickel Content | 3.5 – 5.5% | None |
| Tensile Strength | 110,000 – 120,000 psi | 85,000 – 95,000 psi |
| Corrosion Resistance | Excellent (superior) | Very Good |
| Cost | Higher | Lower |
| Preferred Applications | Naval, offshore, high-stress | Industrial, marine, general |
Manufacturing Process for C95500 Permanent Mold Castings
Our C95500 permanent mold casting process follows a rigorous sequence to ensure metallurgical integrity and dimensional precision:
- Alloy Preparation: C95500 is melted in electric induction furnaces at 1950–2050°F (1066–1121°C), with all alloying additions controlled by spectrographic analysis before pouring.
- Degassing: Nitrogen purging removes dissolved hydrogen, preventing gas porosity in finished castings.
- Mold Preparation: Steel molds preheated to 400–600°F (204–316°C) and coated with proprietary ceramic release agents prevent alloy adhesion and control cooling rate.
- Gravity Pouring: Controlled fill rate minimizes turbulence and oxide inclusions, critical with high-aluminum alloys prone to dross formation.
- Controlled Solidification: Directional solidification from mold walls inward produces a uniform, sound structure with minimal shrinkage porosity.
- Heat Treatment: Optional annealing at 1200°F (649°C) relieves residual stress; solution treatment and quench can further optimize mechanical properties.
Quality Assurance and Testing
All C95500 permanent mold castings from Conex Casting are subject to comprehensive quality control:
- Spectrographic chemical analysis verifying alloy composition meets ASTM B148 requirements
- Mechanical property testing (tensile, yield strength, elongation, hardness) on heat-specific test bars
- Radiographic (X-ray) or ultrasonic inspection for internal soundness on pressure-critical components
- Dimensional inspection using coordinate measuring machines (CMM)
- Pressure testing on hydraulic and marine components as specified
- Material Test Reports (MTR) and Certificates of Conformance supplied with every shipment
Why Choose Conex Casting for C95500 Permanent Mold Castings?
Conex Casting brings three decades of experience manufacturing high-performance bronze castings for global customers. Our C95500 capabilities include:
- Casting weights from 0.5 lb to 150 lb (0.23 kg to 68 kg)
- Maximum dimension up to 36 inches
- In-house CNC machining, grinding, and heat treatment
- Compliance with ASTM B148, BS 1400, DIN 1714, JIS H5120
- Lead time of 4–6 weeks for new tooling, 3–4 weeks for repeat orders
- Export to USA, UK, Canada, Australia, and 50+ countries
Explore our complete range of Bronze Permanent Mold Casting capabilities, or contact us today at sales@conex-casting.com or +91-22-43449300 to request a quote for your C95500 casting requirements.