We "just" change the material...
... is quicker said than done.
Even the development of a product requires a high level of expertise. Nevertheless, even the experts sometimes reach their limits when it comes to selecting the optimum material. And this is exactly where BEULCO's material consulting comes in.
Together with our customers, we look for the perfect material for the individual product.
Date: 25.9.2023 | Reading time: 10. Min.
Complex decisions with know-how
Choosing the right brass material for a component is a complex decision that is influenced by various factors. In addition to mechanical properties and resistance, a large number of standards, regulations, approvals and environmental aspects also play a role.
Below you will find the five most important factors that should be considered when selecting a suitable material.
The key factors in material selection
Mechanical properties:
The mechanical properties of a brass material are of crucial importance. The workability of the material must be guaranteed in order to be able to manufacture the required components. This includes aspects such as strength, hardness, toughness and elasticity. The material must meet the mechanical requirements of the component in order to ensure successful and durable function.
Corrosion resistance:
Resistance to corrosion, particularly stress corrosion cracking and dezincification, is another crucial factor. The environment in which the component is used can be exposed to aggressive substances that can affect service life and performance. Choosing a brass material with high corrosion resistance is therefore essential to ensure long-term functionality and minimize maintenance costs.
Suitability for the application:
The material must meet the specific requirements of the component in question and the needs of the customer. This includes aspects such as thermal stability, electrical properties and wear resistance. The right choice ensures that the component functions optimally in its intended application and meets the requirements of the end user.
Standards and directives:
Compliance with standards and directives is essential to ensure the quality and safety of the component. This includes national regulations such as the Drinking Water Ordinance in Germany, Europe-wide directives such as the Drinking Water Directive and legal regulations such as REACH. These standards not only regulate the lead release of the material into drinking water, but also the maximum permissible lead content in the component. Compliance with these regulations is crucial in order to meet legal standards and gain consumer confidence.
Environmental aspects and sustainability:
The increasing importance of environmental aspects and sustainability means that the choice of brass material must also take ecological criteria into account. Materials should be recyclable and environmentally friendly in order to minimize the ecological footprint. Companies that rely on sustainable materials can not only meet legal requirements, but also build a positive image in terms of environmental awareness and social responsibility
Material consulting with BEULCO
We understand that the choice of suitable material has a decisive influence on the quality, durability and functionality of your components. For this reason, we at BEULCO attach great importance to comprehensive material advice to ensure that you make the best possible decision for your requirements.
Our material advice goes beyond the standard offer. We take into account not only the technical requirements, but also your individual needs and expectations. With our expertise, we help you to find the optimum balance between performance, cost and environmental compatibility. We support you in selecting materials that not only meet current requirements, but are also future-proof.
Whether new product or material changeover - the hurdles are similar
An upcoming changeover from leaded to lead-free material in brass production by 2028 (due to the REACH regulation) poses significant challenges for companies. Based on the given text, the following key challenges can be identified:
Market analysis and regulations:
The first challenge is to conduct a comprehensive market analysis and understand the relevant regulations. Companies need to clearly define which markets they want to supply and take into account the specific regulations regarding lead-free materials. This requires careful research and the definition of a clear strategy to meet the legal requirements.
Machinery and manufacturing capabilities:
When selecting a new material, existing machinery facilities must be taken into account. Not every material can be processed on every machine and manufacturing properties, especially in machining, vary considerably. Companies are faced with the task of finding materials that not only meet regulatory requirements but are also compatible with existing production equipment.
Trial productions and findings:
Conducting trial productions is an indispensable phase in the conversion process. Unexpected problems can arise, such as ring chip formation when converting to Cuphin. These challenges must be identified and solved at an early stage in order to avoid negative effects on series production. The findings from the trial productions are of crucial importance and have a significant influence on the subsequent production process.
Decision-making for a new material:
The final decision for a new material is a critical step. All the information gathered, including market analysis, regulatory requirements, machine compatibility and trial runs, must be carefully considered. Choosing a material that not only meets the requirements but is also cost-effective and sustainable requires sound decision-making.
Time required for the entire process:
The entire process from market analysis to decision making for a new material can take considerable time. Months or even years are required to complete all phases of the material changeover. This time commitment can lead to operational challenges and requires strategic planning to ensure a smooth transition.
An upcoming material changeover to lead-free material in brass production is a complex challenge involving various aspects from market analysis to practical trial production.
Example from theory and practice
The conversion of the BEULCO range to Cuphin
The introduction of new materials into industrial manufacturing processes often presents companies with challenging situations. This technical report highlights the experiences of one company during the transition to lead-free material, in particular Cuphin, and analyzes the difference between theoretical expectations and practical implementation.
Challenges and start of the process:
The switch to Cuphin began when the material was still in its "infancy". The company was faced with the challenge of working with a material for which there was only limited experience. There were uncertainties, particularly with regard to hardness, chip breaking behavior, cycle times, speeds and tool design. The process required rapid acquisition of know-how in order to ensure compatibility with the existing production systems.
Theory versus practice:
The theoretical considerations before the start of the changeover process provided a clear framework for the challenges to be expected. However, practice revealed that reality often deviated from the theoretical assumptions. This was particularly evident in the adjustment of speeds and tools, where reworking was often necessary. The discrepancy between theory and practice made it clear that the understanding of the material on paper does not always correspond to the actual requirements.
Learning curve and building expertise:
Despite the initial uncertainties, the company went through a huge learning curve. The practical challenges served as a catalyst for the rapid development of expertise. The intensive involvement with Cuphin led to deep specialization, and the company can now call itself a recognized expert in the processing of this material.
The switch to lead-free material, such as Cuphin in this case, demonstrates the differences between theoretical considerations and practical implementation. The expertise gained and the successfully mastered learning curve illustrate that a successful material changeover is possible despite initial difficulties. This report offers valuable insights into the dynamics of this process and underlines the importance of adaptability and willingness to learn in the modern manufacturing industry.