C95400 Aluminum Bronze Permanent Mold Casting delivers an exceptional combination of high mechanical strength, superior corrosion resistance, and outstanding wear performance at a cost-effective price point. Conex Casting manufactures precision C95400 permanent mold castings conforming to ASTM B148 and UNS C95400 specifications, supplying high-quality aluminum bronze components to marine, industrial, oil and gas, and general engineering customers worldwide.
What is C95400 Aluminum Bronze?
C95400 is a standard Aluminum Bronze alloy with the nominal composition of 85% Copper (Cu), 11% Aluminum (Al), and 4% Iron (Fe). This alloy represents an outstanding balance of properties — tensile strength of 85,000–95,000 psi, excellent corrosion resistance in seawater and aggressive chemical environments, and good machinability — making it the most widely used aluminum bronze grade in the foundry industry. The iron addition refines grain structure, increases strength, and improves wear resistance compared to binary copper-aluminum alloys.
C95400 conforms to the following international specifications:
- ASTM B148 – Standard Specification for Aluminum-Bronze Sand Castings (applied to permanent mold)
- UNS C95400 – Unified Numbering System designation
- BS 1400 AB1 – British Standard for aluminum bronze castings
- DIN 1714 CuAl10Fe3 – German standard for aluminum bronze
- JIS H5120 CAC702 – Japanese casting standard
- IS 305 – Indian standard for copper alloy castings
C95400 Chemical Composition
| Element | Composition (%) |
|---|---|
| Copper (Cu) | 83.0 min (remainder) |
| Aluminum (Al) | 10.0 – 11.5 |
| Iron (Fe) | 3.0 – 5.0 |
| Manganese (Mn) | 0.50 max |
| Silicon (Si) | 0.25 max |
| Others | 0.50 max |
Mechanical Properties of C95400 Permanent Mold Castings
| Property | Value (Typical – Permanent Mold) |
|---|---|
| Tensile Strength | 85,000 – 95,000 psi (586 – 655 MPa) |
| Yield Strength (0.2% offset) | 35,000 – 50,000 psi (241 – 345 MPa) |
| Elongation (%) | 12 – 18% |
| Brinell Hardness (HBW) | 160 – 190 |
| Density | 0.276 lb/in³ (7.64 g/cm³) |
| Melting Range | 1895 – 2020°F (1035 – 1104°C) |
| Thermal Conductivity | 33 BTU/hr·ft·°F (57 W/m·K) |
Permanent mold casting enhances C95400 mechanical properties by 15–25% over sand cast equivalents, due to the rapid solidification producing a refined, dense microstructure with reduced porosity and improved fatigue resistance.
Advantages of C95400 for Permanent Mold Casting
- High Strength-to-Weight Ratio: Tensile strength approaching medium-grade carbon steels while maintaining bronze’s corrosion resistance and non-magnetic properties.
- Excellent Corrosion Resistance: Outstanding performance in seawater, dilute acids, alkalis, and many industrial chemicals due to the formation of a stable aluminum oxide protective film.
- Superior Wear Resistance: The iron-containing alpha-beta microstructure provides excellent sliding wear resistance, ideal for gear, cam, and bearing applications operating under heavy loads.
- Non-Sparking: Safe for use in explosive atmospheres and hazardous classified areas in oil and gas, chemical, and mining industries.
- Good Machinability: Can be efficiently machined to final dimensions using standard carbide tooling, reducing total manufactured cost.
- Dimensional Consistency: Permanent mold casting achieves as-cast tolerances of ±0.015 inches, significantly tighter than sand casting and reducing secondary operations.
- Cost Effectiveness: C95400 offers the performance of Nickel Aluminum Bronze (C95500) for many applications at a lower material cost, making it the preferred choice for medium-duty industrial and marine components.
Typical Applications of C95400 Permanent Mold Castings
C95400 Aluminum Bronze is specified across a broad range of industries where strength, corrosion resistance, and wear performance are required simultaneously:
- Marine Hardware: Propeller hubs, propeller blades, stern tube bushings, sea cocks, and hull fittings for commercial and recreational vessels
- Pump Industry: Impellers, pump housings, diffusers, and wear rings for seawater, freshwater, and industrial fluid handling systems
- Valve Manufacturing: Valve bodies, bonnets, discs, and seats for marine, industrial, and water treatment applications
- Gears and Worm Wheels: Worm gear blanks, bevel gears, and spur gears in heavy-duty machinery where bronze on steel operation reduces friction and wear
- Bearing and Bushing Components: Sleeve bearings, thrust washers, and wear plates in high-load, low-speed machinery
- Oil and Gas Equipment: Valve trim, choke bodies, and non-sparking tools for use in explosive atmospheres
- Water Treatment: Valve bodies, pump components, and instrumentation housings in desalination, municipal water, and wastewater treatment plants
- Mining Equipment: Crusher jaws, wear liners, guide shoes, and conveyor components subject to abrasive wear
- Architectural Bronze: Structural fittings, heavy-duty door hardware, and decorative elements requiring both strength and corrosion resistance
C95400 vs. C95500: Choosing the Right Alloy
C95400 and C95500 Nickel Aluminum Bronze are closely related alloys. The right choice depends on your application requirements and budget:
| Consideration | Choose C95400 | Choose C95500 |
|---|---|---|
| Budget | Cost-sensitive projects | Performance-critical projects |
| Strength Requirement | Up to ~95,000 psi tensile | Up to ~120,000 psi tensile |
| Corrosion Environment | General marine and industrial | Severe marine / offshore / chemical |
| Applications | Commercial marine, pumps, valves, gears | Naval, subsea, aerospace, high-duty |
| International Specs | ASTM B148, BS AB1, DIN CuAl10Fe3 | ASTM B148, BS AB2, DIN CuAl10Ni5Fe4 |
Manufacturing Process for C95400 Permanent Mold Castings
Conex Casting’s C95400 production process is optimized for both quality and consistency:
- Induction Melting: C95400 is melted at 1960–2050°F (1071–1121°C) in electric induction furnaces with real-time temperature monitoring to maintain optimal pouring temperature.
- Composition Verification: Spectrographic analysis of each heat confirms chemistry before pouring, ensuring compliance with ASTM B148 composition limits.
- Degassing: Inert gas purging reduces dissolved hydrogen, preventing gas porosity in finished castings.
- Mold Design and Preparation: Steel molds are designed with proper gating and risering to promote directional solidification, preheated to 400–600°F (204–316°C) and coated with ceramic release agents.
- Controlled Pouring: Skilled operators control pour rate to minimize oxide inclusions — a particular concern with high-aluminum alloys that readily form aluminum oxide dross.
- Post-Cast Processing: Gate and riser removal, shot blasting, dimensional inspection, and optional heat treatment (stress relief or solution anneal) as required by specification.
Quality Standards and Testing
Every C95400 casting from Conex Casting undergoes rigorous quality verification:
- Chemical analysis by optical emission spectrometry (OES) confirming ASTM B148 composition compliance
- Mechanical testing on poured test bars: tensile strength, yield strength, elongation, and Brinell hardness
- Dimensional inspection using CMM for critical features
- Non-destructive testing (radiographic and/or ultrasonic) for pressure-retaining components
- Hydrostatic pressure testing on valve bodies and pump castings as specified
- Full material certification (Mill Test Report / Certificate of Conformance) shipped with every order
C95400 Casting Capabilities at Conex Casting
- Casting weight range: 0.3 lb to 150 lb (0.14 kg to 68 kg)
- Maximum casting dimension: 36 inches (914 mm)
- As-cast dimensional tolerance: ±0.015 inches (±0.38 mm)
- Surface finish: 125–250 µin Ra as-cast; 32–63 µin Ra machined
- In-house 3, 4, and 5-axis CNC machining available
- Standard lead time: 4–6 weeks (new tooling); 3–4 weeks (repeat orders)
- Minimum order quantity: 25 pieces
For the full range of our bronze casting capabilities, visit our Bronze Permanent Mold Casting page. To request a quote for C95400 castings, contact us at sales@conex-casting.com or call +91-22-43449300. We respond to all inquiries within 24 hours.