Continuously Cast Mg Brass

Abstract

A quantity of continuously cast Mg brass is made by the step of melting a charge of Mg brass and then continuously casting a rod of the Mg brass through a casting die. The casting die has been previously treated by continuously casting a melt of copper or brass through it to clean out Mg deposits formed by an earlier continuous casting of Mg brass which formed the Mg deposits. The quantity of continuously cast Mg brass may be in the form of EDM wire. These methods may be used to purify scrap or used brass, by removing metal oxides to improve the material quality, thus reducing the need to use premium priced virgin copper and zinc.

1 . A quantity of continuously cast Mg brass wire for electric discharge machining wherein:
 a) said Mg brass wire comprises:
 i) zinc at a first zinc concentration in the range of 5 wt % to 50 wt %; 
 ii) magnesium at a first magnesium concentration in the range of 0.02 wt % to 5 wt %; and 
 iii) balance copper and inevitable impurities; 
   b) said Mg brass wire has a tensile strength of at least about 900 MPa; and   c) said Mg brass wire has a diameter in the range of 0.1 mm to 0.4 mm.   
     
     
         2 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said first magnesium concentration is in the range of 0.02 wt % to 0.09 wt %. 
     
     
         3 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said Mg brass wire has an electrical conductivity of at least about 27.6% International Annealed Copper Standard (IACS). 
     
     
         4 . The quantity of continuously cast Mg brass wire of  claim 3  wherein said Mg brass wire has an electrical conductivity in the range of 27% IACS to 33% IACS. 
     
     
         5 . The quantity of continuously cast Mg brass wire of  claim 1 , further comprising copper at a first copper concentration in the range of 60 wt % to 65 wt %. 
     
     
         6 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said Mg brass wire has a tensile strength in the range of 900 MPa to 1400 MPa. 
     
     
         7 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said inevitable impurities include an oxygen content of less than 0.025 wt %. 
     
     
         8 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said Mg brass wire is a continuously cast quantity of between about 1000 lb to about 20,000 lb size. 
     
     
         9 . The quantity of continuously cast Mg brass wire of  claim 1 , wherein said Mg brass wire has a coating comprising copper, zinc or alloys thereof. 
     
     
         10 . The quantity of continuously cast Mg brass wire of  claim 1 , wherein said first zinc concentration is in the range of 30 wt % to 40 wt %. 
     
     
         11 . A quantity of continuously cast Mg brass wire for electric discharge machining wherein:
 a) said Mg brass wire comprises:
 i) zinc at a first zinc concentration in the range of 5 wt % to 50 wt %; 
 ii) magnesium at a first magnesium concentration in the range of 0.02 wt % to 0.09 wt %; and 
 iii) balance copper and inevitable impurities; and 
   b) said Mg brass wire has a tensile strength of at least about 350 MPa;   c) said Mg brass wire has a diameter in the range of 0.1 mm to 0.4 mm.   
     
     
         12 . The quantity of continuously cast Mg brass wire of  claim 11  wherein said Mg brass wire has an electrical conductivity of at least about 27.6% International Annealed Copper Standard (IACS). 
     
     
         13 . The quantity of continuously cast Mg brass wire of  claim 12  wherein said Mg brass wire has an electrical conductivity in the range of 27 IACS to 33 IACS. 
     
     
         14 . The quantity of continuously cast Mg brass wire of  claim 11  wherein said Mg brass wire has a tensile strength in the range of 350 MPa to 1400 MPa. 
     
     
         15 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said inevitable impurities include an oxygen content of less than 0.025 wt %. 
     
     
         16 . The quantity of continuously cast Mg brass wire of  claim 1  wherein said Mg brass wire is a continuously cast quantity of between about 1000 lb to about 20,000 lb size. 
     
     
         17 . The quantity of continuously cast Mg brass wire of  claim 1 , wherein said Mg brass wire has a coating comprising copper, zinc or alloys thereof. 
     
     
         18 . The quantity of continuously cast Mg brass wire of  claim 1 , wherein said first zinc concentration is in the range of 30 wt % to 40 wt %.