Brass, a versatile and widely used metal, poses challenges when cutting due to its unique properties. However, waterjet technology has revolutionized the way of cutting brass, making the process simpler and more effective.

In this article, we will delve into the world of waterjet cutting brass, exploring how it works, the types of brass that you can cut, its applications, advantages, and essential safety precautions.

Can A Waterjet Cut Brass?

Yes, you can cut brass using waterjet technology. While brass can be a challenging material to work with and cut, waterjet technologies have made brass cutting a simple process.

Unlike standard lasers that require repeated exposure to the material, waterjet cutting reduces the risk by using a high-pressure stream of water mixed with an abrasive substance.

This method prevents clogging, a common issue with conventional cutting tools when working with brass. Waterjet cutting is undoubtedly the best method to achieve precise and efficient results when cutting brass.

How Does Waterjet Cutting Brass Work?

Waterjet cutting, a manufacturing erosion process, has become a highly effective and adaptable machining technique in various industries worldwide. But how does waterjet cutting actually work for brass materials? Here is the waterjet cutting process, step by step:

Extreme Pressure and Water Propulsion

Waterjet cutting begins with filling a mixing chamber with water that has been subjected to extreme pressure.

This pressurized water is then propelled through a nozzle made of ruby or diamond. The result is a high-velocity stream of water that is directed toward the target material – in this case, brass.

Introduction of Garnet Sand

To enhance the cutting capability of the waterjet, the pressure creates a vacuum, which pulls garnet sand into the stream.

The garnet sand is introduced into the water jet stream. It travels along with the high-velocity water toward the brass material to be cut.

Erosion and Cutting

As the waterjet stream, now carrying the garnet sand, comes into contact with the brass material, erosion begins to occur.

The sand particles in the stream hit the brass surface at an incredibly high speed, causing the material to erode rapidly. This erosion is so fast that it is considered cutting.

What Types Of Brass Can Be Cut With A Waterjet

Brass is a versatile metal and various industries commonly uses it due to its excellent properties, such as corrosion resistance, machinability, and aesthetic appeal.

Waterjet cutting provides precise and accurate cuts, making it suitable for various types of brass. Here are the different types of brass that waterjet can cut:

1. Red Brass (CuZn15)

Red brass, or gunmetal or 85-5-5-5, comprises approximately 85% copper and 15% zinc. It also contains trace amounts of tin, lead, and iron, resulting in its reddish hue. Red brass is highly corrosion-resistant, making it a popular choice for plumbing applications.

It is also suitable for casting and has good machinability and moderate strength. With the right techniques, it is possible to braze, weld, and solder the red brass.

Waterjet cutting is an excellent method for cutting red brass due to its corrosion resistance and machinability. Its common uses are in valves, plumbing fittings, and pumps because of its resistance to corrosion and an attractive reddish appearance.

2. Yellow Brass (CuZn33)

Yellow brass, also called cartridge brass, has a composition of about 67% copper and 33% zinc. Its vibrant yellow color makes it a popular choice for ornamental uses. Yellow brass is highly formable and has excellent cold-working characteristics.

It has average strength and decent corrosion resistance. Like red brass, yellow brass can be soldered, brazed, and welded with the right procedures.

Waterjet cutting is suitable for yellow brass due to its high cold workability, resistance to corrosion, and compatibility with various joining methods. It finds applications in plumbing fittings, musical instruments, and decorative hardware.

3. Naval Brass (CuZn40Sn1)

Naval brass has approximately 60% copper, 39% zinc, and 1% tin. It is more resistant to dezincification, making it ideal for maritime applications. It is possible to heat-work or cold-work the naval brass and also it has high strength and wear resistance.

Waterjet cutting is suitable for cutting naval brass. The common uses of naval brass are in bearings, bushings, ship propellers, and marine hardware, due to its ability to withstand the severe marine environment.

4. Leaded Brass (CuZn39Pb3)

Leaded brass alloys contain a small amount of lead (often 1-3%) to enhance their machinability. They are suitable for applications which require high-speed machining and complex forms.

Leaded brasses have strong corrosion resistance, can be cold-worked, and are readily available. However, they are less ductile than non-leaded brasses.

Waterjet cutting is beneficial for leaded brass. Due to its good machinability, its corrosion resistance and pleasing appearance, it is commonly used in plumbing fittings, valves, and ornamental hardware.

5. High-Zinc Beta Brass (CuZn15)

High-zinc beta brasses contain approximately 15% copper and 85% zinc. They are commonly used for die casting due to their low melting point and high fluidity.

These brasses have high wear resistance and can be heat treated for additional strength. However, they are more prone to stress corrosion cracking than other brass types.

Waterjet cutting is suitable for high-zinc beta brasses due to their affordability, excellent casting properties, and wear resistance. They find applications in the creation of die-cast parts such as fasteners, hinges, and locks.

6. Alpha-Beta Brass (CuZn40)

Alpha-beta brasses, or duplex brasses, contain approximately 60% copper and 40% zinc. They have excellent cold and hot working characteristics, making them suitable for forging, pressing, and machining applications.

Heat treatment can achieve different strength and ductility levels, and small quantities of lead can be added to enhance machinability.

Waterjet cutting is beneficial for alpha-beta brasses although it has high strength, versatile workability, and corrosion resistance. They are commonly used in valves, gears, and fittings that require strength and longevity.

7. Alpha Brass (CuZn)

Alpha brasses are single-phase alloys containing 35-45% zinc and 55-65% copper. They have a face-centered cubic (FCC) crystal structure. Alpha brasses are popular for their exceptional cold workability and strong corrosion resistance.

They are often used for shaping and drawing applications. Cold working can harden these alloys, and adding small amounts of silicon, iron, and aluminum can enhance their mechanical properties.

Waterjet cutting suits alpha brasses due to its outstanding cold workability, corrosion resistance, and appealing look. They are often used for architectural and aesthetic purposes due to their vivid color and ability to maintain a polished surface.

Applications Of Waterjet Cutting Brass

Brass, a combination of copper and zinc, is widely used in various industries due to its unique properties. The following are the applications of brass, cut with waterjet:

Strumenti musicali

Throughout history, a variety of musical instruments have been crafted from brass. Trombones, tubas, trumpets, French horns, and other wind instruments are all made using brass.

However, the precision and accuracy of waterjet cutting make it an ideal method for shaping the intricate components of these instruments.

Furthermore, brass inner parts are common in electronic instruments like electric guitars and violins. This makes waterjet cutting a valuable technique in their production as well.

Mechanical Components

Brass components are often found in mechanical systems. This is because brass displays less friction in situations requiring metal-on-metal contact. Brass gears, axle boxes from locomotives, marine engines, and other components are frequently used in machinery.

The ability of waterjet cutting to produce precise and intricate shapes makes it an excellent choice for manufacturing these components.

Plumbing And Electrical Systems

Plumbing and electrical systems, two of the most frequently utilized systems in a house, often include brass as a component. The use of brass alloys in several parts of electrical switches and sockets, can benefit from the material’s electrical conductivity.

Brass is also commonly used in plumbing applications such as valves and various pipe fittings, including plugs, elbows, and couplings. However, waterjet cutting enables precise shaping of these components. This ensures a perfect fit and optimal performance in plumbing and electrical systems.

Architectural Purposes

Brass is a widely used alloy for architectural applications because of its natural durability and resistance to corrosion. The use of brass in hinges, trimmings, and architectural fascia, can add a touch of elegance to buildings and structures.

Worldwide restoration and renovation projects involving historic structures have also made use of certain brass alloys, as waterjet cutting can accurately replicate intricate designs and patterns found in these structures.

Decorative Purposes

We often employ a lot of brass-alloy-based décor products to beautify our houses. The use of brass for aesthetic reasons in antique candle holders is superb. Another excellent example of ornamental brass is sculptures and accessories made of brass.

Waterjet cutting allows for intricate detailing and precise shaping, enhancing the visual appeal of these decorative items.

Advantages Of Waterjet Cutting Brass

Waterjet cutting brass offers several advantages. These advantages make waterjet cutting a preferred choice for many applications that require efficient and precise metal cutting. Here are the advantages of waterjet cutting brass:

Quick Setup

One of the major advantages of waterjet cutting brass is its efficiency. The setup process is quick and easy, saving valuable time. Unlike other cutting technologies, waterjet cutting does not require the drilling of beginning holes in the metal before slicing.

The waterjet pierces the metal as it works, making it immediately ready for use without any additional steps. Moreover, unlike other methods that require changing gases or optics when cutting different materials, waterjet cutting eliminates the need for such adjustments.

Versatilità

One of the key advantages of waterjet cutting is its flexibility. It has no restrictions on cutting in two axes, allowing it to cut any shape or form. Waterjets can cut a wide range of metals, including aluminum, copper, tin, stainless steel, titanium, and brass.

It can even handle materials up to 10 inches thick and 1/16 inch thick. Unlike laser cutters, waterjets can cut reflective materials like brass and aluminum.

No Heat Damage: Cold-Cutting Method

Waterjet cutting stands out due to its cold-cutting method. Unlike techniques that produce heat, such as torches, lasers, and plasma cutters, waterjets do not create heat-affected zones (HAZs) during the cutting process.

HAZs are areas where the material’s microstructure and characteristics usually alters by the heat generated during cutting. These changes in the metal can negatively impact its strength. With waterjet cutting, parts emerge with a smooth, crisp edge and no heat damage.

Multi-axis Cutting

Waterjet cutting is a multi-axis cutting technology and offers various cut forms. A good waterjet cutter can cut in five distinct axes, making it ideal for creating complex parts, including tiny engine components.

The advantages of 5-axis waterjet cutting over traditional 3-axis technologies include increased versatility, cutting speed, and reduced manual labor.

High Accuracy and Precision

Waterjet cutting provides a higher degree of precision compared to conventional cutting techniques. Its ability to precisely adjust the angle at which the jet strikes the material allows for more elaborate patterns without compromising accuracy or speed.

In fact, waterjet cutting can be up to four times more precise than a plasma cutter. Additionally, waterjets can maintain precise tolerances, which is crucial for many applications.

Rispettoso dell'ambiente

Waterjet metal cutting is environmentally friendly in comparison with other cutting methods. It produces no toxic waste or emissions during the cutting process.

Additionally, the thin kerf of waterjet cutting results in less material wastage. This allows for the cutting of more components per sheet or the recycling of more material.

Tips And Precautions For Waterjet Cutting Brass

Waterjet cutting is an industrial cutting device that requires specific safety measures to ensure your safety throughout the cutting procedure. Below are some tips and precautions you should take while using a waterjet cutter:

Sufficient Equipment

Investing in high-quality equipment is essential when using a waterjet cutter. Even when you follow all safety procedures, using a subpar machine can still result in injury. This investment will prioritize your safety and lead to long-term financial savings.

Company Policies

Before using equipment or joining the workforce, check if your company has an appropriate safety policy in place.

Ensure that the workplace has received approval from the Salute e sicurezza sul lavoro (WHS) rules. Prioritizing safety at a company-wide level is crucial for a secure working environment.

Drunken State

Under no circumstances should you operate a waterjet cutter or any other heavy industrial machinery while intoxicated or under the influence of drugs, including sedatives. Impairment can lead to serious accidents and jeopardize the safety of yourself and others.

User Guide

Each waterjet cutter has its own set of safety measures. It is vital to thoroughly read the user handbook before using the waterjet cutter for the first time.

Familiarize yourself with the specific safety PPE equipment required for your machine, as it may differ from other models. Following the manufacturer’s instructions will help ensure safe operation.

Safety Equipment

Waterjet cutting requires specialized safety equipment. Make sure to wear water jet cutting safety pressure protection gear to protect yourself from potential hazards. Safety goggles with ISO approval are necessary to prevent eye injuries.

You should wear proper ear protection to avoid damaging your ears. Consider wearing Kevlar-reinforced cut-resistant safety gloves for suitable hand protection.

Extra Security

Besides the essential safety equipment, consider using additional security measures such as helmets, shin and knee guards, and knee pads.

However, it is important to note that you should never approach the waterjet stream, even with these extra precautions. The force of the water jet can cause severe injuries.

Conclusione

Waterjet cutting brass is a game-changer when it comes to precision metal cutting. Its ability to cut through different types of brass, such as red brass, yellow brass, naval brass, leaded brass, and more, opens up a world of possibilities in various industries.

From musical instruments to mechanical components, plumbing, and electrical systems to architectural and decorative purposes, waterjet cutting offers unmatched accuracy and versatility.

FAQ for Waterjet Cutting Brass

Is Waterjet Cutting More Expensive Than Traditional Methods Of Cutting?

Quite the opposite. Waterjet cutting can actually reduce costs because it removes the need for additional tools and dies that you would need with methods such as laser or die cutting.

Can You Use Waterjet Cutting For Intricate Designs And Patterns In Brass?

Yes, waterjet cutting is highly precise and you can use it to create intricate designs and patterns in brass. The ability to adjust the angle of the waterjet stream allows for complex shapes and detailed cuts.

Can You Cut Glass Using A Water Jet?

Absolutely! Many users across various sectors have discovered the remarkable flexibility and cost-effectiveness of using waterjet technology to cut glass materials. Waterjet technology is the go-to method for cutting intricate stained glass designs, creating holes in glass, or effortlessly cutting through laminated ballistic glass.

What Is The Maximum Waterjet Pressure?

Intensifier systems can provide up to an impressive 100,000 psi, while direct drive pumps have a maximum pressure of 60,000 psi.

However, it’s important to consider that intensifiers, with their higher maximum pressures, come with some drawbacks. These include increased failure rates, the need for coolant, and a louder operation. Thanks a lot for reading till the end.