Bronze

I

Introduction

Bronze, metal compound containing copper and other elements. The term bronze was originally applied to an alloy of copper containing tin, but the term is now used to describe a variety of copper-rich material, including aluminum bronze, manganese bronze, and silicon bronze.

Bronze was developed about 3500 BC by the ancient Sumerians in the Tigris-Euphrates Valley. Historians are unsure how this alloy was discovered, but believe that bronze may have first been made accidentally when rocks rich in ores of copper and tin were used to build campfire rings (enclosures for preventing fires from spreading). As fire heated these stones, the metals may have mixed, forming bronze. This theory is supported by the fact that bronze was not developed in North America, where natural tin and copper ores are rarely found in the same rocks.

Around 3000 BC, bronze-making spread to Persia, where bronze objects such as ornaments, weapons, and chariot fittings have been found. Bronzes appeared in both Egypt and China around 2000 BC. The earliest bronze castings (objects made by pouring liquid metal into molds) were made in sand; later, clay and stone molds were used. Zinc, lead, and silver were added to bronze alloys by Greek and Roman metalworkers for use in tools, weapons, coins, and art objects. During the Renaissance, a series of cultural movements that occurred in Europe in the 14th, 15th, and 16th centuries, bronze was used to make guns, and artists such as Michelangelo and Benvenuto Cellini used bronze for sculpting. See also Metalwork; Founding.

Today, bronze is used for making products ranging from household items such as doorknobs, drawer handles, and clocks to industrial products such as engine parts, bearings, and wire.

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II

Types

Tin bronzes, the original bronzes, are alloys of copper and tin. They may contain from 5 to 22 percent tin. When a tin bronze contains at least 10 percent tin, the alloy is hard and has a low melting point. Leaded tin bronzes, used for casting, contain 5 to 10 percent tin, 1.5 to 25 percent lead, and 0 to 4.5 percent zinc. Manganese bronze contains 39 percent zinc, 1 percent tin, and 0.5 to 4 percent manganese. Aluminum bronze contains 5 to 10 percent aluminum. Silicon bronze contains 1.5 to 3 percent silicon.

Bronze is made by heating and mixing the molten metal constituents. When the molten mixture is poured into a mold and begins to harden, the bronze expands and fills the entire mold. Once the bronze has cooled, it shrinks slightly and can easily be removed from the mold.

III

Characteristics and Uses

Bronze is stronger and harder than any other common metal alloy except steel. It does not easily break under stress, is corrosion resistant, and is easy to form into finished shapes by molding, casting, or machining (See also Engineering).

The strongest bronze alloys contain tin and a small amount of lead. Tin, silicon, or aluminum is often added to bronze to improve its corrosion resistance. As bronze weathers, a brown or green film forms on the surface. This film inhibits corrosion. For example, many bronze statues erected hundreds of years ago show little sign of corrosion. Bronzes have a low melting point, a characteristic that makes them useful for brazing—that is, for joining two pieces of metal. When used as brazing material, bronze is heated above 430°C (800°F), but not above the melting point of the metals being joined. The molten bronze fuses to the other metals, forming a solid joint after cooling.

Lead is often added to make bronze easier to machine. Silicon bronze is machined into piston rings and screening, and because of its resistance to chemical corrosion it is also used to make chemical containers. Manganese bronze is used for valve stems and welding rods. Aluminum bronzes are used in engine parts and in marine hardware.

Bronze containing 10 percent or more tin is most often rolled or drawn into wires, sheets, and pipes. Tin bronze, in a powdered form, is sintered (heated without being melted), pressed into a solid mass, saturated with oil, and used to make self-lubricating bearings.