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Tombac

Tombac is a reddish alloy primarily composed of copper and zinc, often with small amounts of tin or arsenic, valued for its gold-like appearance and affordability.^[1] It typically consists of 70-92% copper and 8-30% zinc, resulting in a low-zinc brass that exhibits a warm, red hue and good machinability.^[2] This composition allows tombac to serve as a cost-effective substitute for gold in various applications. Originating from the Malay word tĕmbaga meaning "copper," the term entered European languages via Dutch as tombak around 1602, reflecting its historical trade connections in Southeast Asia.^[1] Synonyms include tombak, tambac, and Mannheim gold, and it is sometimes referred to as "Dutch metal" or "rich low brass" in metallurgical contexts.^[2] Unlike higher-zinc brasses, tombac's lower zinc content (often around 15%) minimizes corrosion while maintaining ductility, making it suitable for casting and forming.^[3] Tombac has been widely used for inexpensive jewelry, buttons, and gilding due to its luster and resistance to tarnish when properly alloyed.^[1] In decorative arts and manufacturing, it appears in items requiring a metallic sheen without the expense of precious metals, and its arsenic addition historically provided enhanced depth and shine.^[2] While less common today, tombac remains notable in historical metallurgy for bridging utilitarian and ornamental metalworking traditions.^[3]

History and Etymology

Etymology

The term "tombac" originates from the Malay word tembaga, meaning "copper," which itself derives from the Prakrit tamraka ("copper"), ultimately tracing back to the Sanskrit tāmra ("dark coppery red").^[4]^[5] This linguistic root reflects the alloy's copper-dominant composition, emphasizing its reddish hue reminiscent of copper.^[6] The word entered European languages through colonial trade routes in the East Indies during the 16th century. Portuguese traders adopted it as tambaca around that time, likely during interactions with Malay and Javanese communities where tembaga (a term of Javanese origin borrowed into Malay) denoted copper or brass-like alloys.^[1]^[5] From Portuguese, it passed to Dutch as tombak and then to French as tombac by 1595–1605, entering English usage shortly thereafter in trade descriptions of East Indian metals.^[4]^[7] Related terms appear in other languages influenced by the same Austronesian and Indo-Aryan pathways. In Tagalog, tumbaga refers to a copper-gold alloy, borrowed directly from Malay tembaga.^[8] Javanese tembaga shares this Sanskrit-derived root, highlighting the term's diffusion across Southeast Asian cultures through maritime exchange.^[5] The first recorded use of "tombac" in English dates to 1602, appearing in trade contexts describing imported alloys from the East Indies, as noted in early dictionaries and mercantile records.^[1] By the mid-17th century, variant spellings like "tombak" emerged in English translations of European texts, solidifying its place in metallurgical nomenclature.^[7]

Historical Development

Tombac originated in East India around the 16th century or earlier as a copper-zinc alloy employed for crafting gongs, bells, and ornaments due to its resonant qualities and malleability.^[9] The alloy's name derives from the Malay term tembaga, meaning copper, underscoring its Southeast Asian roots.^[4] In these regions, particularly Indonesia and the Malay Peninsula, tombac was integral to traditional metalworking.^[10] Introduced to Europe via Dutch and British trade routes through the East Indies in the 17th century, tombac quickly gained favor for its gold-like appearance and affordability, leading to its widespread use in imitation goldware such as jewelry and decorative objects.^[11] European artisans adapted the alloy for luxury imitations, capitalizing on its workability to mimic precious metals amid expanding colonial commerce. By the 18th century, tombac had become common in buttons and decorative hardware across Europe and colonial America, where its pale yellow-white hue and ease of casting made it ideal for clothing fasteners and furnishings excavated at sites like Mount Vernon and Colonial Williamsburg.^[12]^[13]^[14] In the 20th century, material shortages during World War II prompted the use of tombac in various applications, including pattern coins like the German 10 pfennig of 1941, as a cost-effective alternative to scarcer metals.^[15] This wartime adaptation highlighted tombac's versatility under resource constraints, extending to military badges and components where its corrosion resistance proved advantageous.^[16] Toward the late 20th century, tombac evolved into silicon tombac by incorporating approximately 4% silicon, improving castability, strength, and resistance to dezincification for industrial applications such as sand and die casting.^[17] Known under trademarks like Tombasil, this variant emerged in the mid-20th century and gained prominence in the 1970s–1990s for high-performance components in engineering and marine environments.^[18]

Composition and Variants

Chemical Composition

Tombac is classified as a high-copper brass alloy, primarily composed of 65–95% copper (Cu) and 5–35% zinc (Zn).^[19]^[20] This composition places it within the alpha-phase brass family, where the elevated copper proportion dominates the alloy's structure.^[21] Common formulations include specific ratios tailored to applications; for instance, coinage tombac often features 88% Cu and 12% Zn, as utilized in wartime Canadian nickels.^[22] For general decorative and industrial uses, ratios such as 85% Cu and 15% Zn (corresponding to CuZn15 or C23000) or 84–86% Cu and 14–16% Zn (CuZn15 variants) are prevalent.^[19]^[23] Additives are incorporated in limited quantities to modify characteristics, with up to 1–2% tin (Sn) or lead (Pb) appearing in certain red brass variants akin to tombac for enhanced workability and appearance.^[3] Small amounts of arsenic (As) may also be added in some brass formulations to improve corrosion resistance without altering the primary hue, though less commonly specified for tombac. Rare variants, such as silicon tombac (CuZn16Si4), include up to 4% silicon (Si) alongside 16% Zn and the balance Cu, expanding the alloy's utility in casting applications.^[20] In comparison to standard brasses, which generally contain 60–70% Cu and higher zinc levels for a yellowish tone, tombac's elevated copper content imparts a distinctive redder hue.^[19]^[3] This differentiation arises directly from the Cu-Zn ratio, with zinc percentages above 20–28% shifting the color toward conventional yellow brasses.^[19]

Common Types and Variants

Tombac alloys are primarily categorized by their copper-zinc ratios, with standard formulations defined under international specifications such as EN, DIN, and UNS. The most prevalent types include CuZn10 and CuZn15, which offer a balance of ductility and golden coloration suitable for forming processes.^[19] CuZn10 consists of approximately 90% copper and 10% zinc, corresponding to EN designation CW501L (DIN 2.0230) and UNS C22000. This variant exhibits a rich gold-like hue and high electrical conductivity, making it ideal for applications requiring precise stamping and embossing.^[19]^[24] CuZn15, with about 85% copper and 15% zinc, aligns with EN CW502L (DIN 2.0240) and UNS C23000, providing enhanced strength over CuZn10 while maintaining excellent cold formability for bending and coining.^[19]^[25] A rich low brass variant, CuZn20, features approximately 80% copper and 20% zinc (Cu 78.5–81.5%, Zn remainder) under EN CW503L (DIN 2.0250) and UNS C24000, prized for its deep drawing capabilities in decorative items.^[26]^[27] Silicon tombac, designated CuZn16Si4 or CC761S (DIN EN 1982 2.0490, UNS C87800), incorporates 2–4% silicon alongside roughly 80% copper and 16% zinc, improving castability for high-pressure die casting as a steel substitute in demanding components.^[28]^[29] Traditional variants include designations such as Ms80 (78–81% Cu, light red tombac), Ms85 (84–86% Cu, gold tombac), and Ms90 (89–91% Cu, red tombac). Specialized variants include arsenic-added tombac, with small amounts of arsenic added to high-copper formulations to enhance shine and color depth for jewelry.^[2] Leaded tombac variants, such as those akin to UNS C31400 with 1.3–2.5% lead in an 87.5–90% copper, 9–11% zinc matrix, improve machinability for industrial fittings under ASTM B36 standards.^[3]

Properties

Physical Properties

Tombac displays a characteristic reddish-gold color attributable to its high copper content, which imparts a warmer tone compared to standard brasses; this hue shifts toward golden yellow with increasing zinc proportions. The alloy can be polished to achieve a high luster that closely mimics gold, enhancing its aesthetic appeal in decorative uses. In certain formulations, small additions of arsenic further deepen the color and improve the shine, providing greater visual depth.^[30]^[31]^[2] The density of tombac ranges from 8.7 to 8.9 g/cm³, influenced by the zinc content, with higher zinc levels slightly reducing the value. For instance, CuZn10 tombac has a density of 8.8 g/cm³, while CuZn15 measures 8.75 g/cm³. Its melting point falls between 950 and 1080°C, lower than pure copper's due to the alloying effect of zinc, which depresses the melting temperature; specific variants exhibit ranges such as 1040–1050°C for CuZn10 and 1020–1030°C for CuZn15.^[23]^[32] Tombac offers electrical conductivity of 30–37% IACS, adequate for non-critical electrical components where cost and formability are prioritized over maximal conductance. It exhibits good corrosion resistance in neutral environments, resisting dezincification in many aggressive media, though it is prone to stress corrosion cracking in ammonia atmospheres unless properly stress-relieved; silicon tombac variants show particular vulnerability to ammonia exposure.^[23]^[32]^[33]

Mechanical Properties

Tombac, particularly in its standard CuZn15 variant, possesses tensile strength ranging from 300 to 500 MPa, which varies with temper; cold-worked conditions yield higher values up to 550 MPa or more.^[34]^[32] In annealed form, it exhibits high ductility with elongation of 40–60%, enabling extensive deformation during forming operations without cracking.^[35]^[36] Hardness in soft tempers measures 60–100 HV (Vickers), providing a balance of formability and resistance to surface deformation.^[36] Leaded variants improve machinability, reducing cutting forces and enhancing surface finish in turning and milling processes.^[37] Silicon tombac demonstrates excellent bearing properties, characterized by a low friction coefficient suitable for sliding contacts and reduced wear in lubricated environments.^[38] Its fatigue resistance is moderate, typically 100–200 MPa endurance limit, making it appropriate for low-cycle decorative applications but limiting use in high-stress structural roles.^[37]

Production and Processing

Manufacturing Methods

Tombac, a copper-zinc alloy, is primarily produced through a multi-stage process beginning with melting and alloying of raw materials. Copper and zinc are melted together in induction furnaces, which provide efficient and controlled heating, typically reaching temperatures around 900–1000°C to achieve a homogeneous liquid alloy.^[39]^[28] To minimize oxidation and zinc evaporation—common issues due to zinc's volatility—an inert atmosphere, such as argon or nitrogen, is maintained during melting.^[40] Additives like lead, tin, or silicon for specific variants are stirred into the melt to refine properties, with the mixture deoxidized using phosphorus or other agents before pouring.^[41] Following alloying, the molten tombac is cast into basic shapes. For standard tombac, continuous casting or sand casting is employed to form ingots or billets, allowing for efficient production of large volumes with controlled solidification to reduce defects like porosity.^[42] In the case of silicon tombac, a high-strength variant, high-pressure die casting is the preferred method, where the alloy is injected into steel molds under pressures up to 1500 bar, enabling complex geometries and thin walls with high dimensional accuracy.^[28] This process, conducted at approximately 1000°C followed by rapid cooling, results in a fine-grained structure that enhances mechanical performance.^[28] The cast forms are then shaped through forming processes to produce sheets, strips, or foils. Hot rolling is typically performed at 600–800°C, where ingots are passed through a series of rollers to reduce thickness and improve uniformity, often followed by surface scalping to remove oxides.^[43] For precision applications, cold rolling follows, progressively reducing the material to thicknesses as fine as 0.01 mm while increasing hardness through work hardening.^[44] Specialized foil production for decorative uses, such as in C22000 (90% Cu, 10% Zn) or C23000 (85% Cu, 15% Zn) grades, involves multi-pass rolling mills with intermediate annealing to maintain ductility and achieve gold-like finishes suitable for leaf or stamping.^[45] Quality control is integral throughout manufacturing to ensure alloy integrity. Spectrographic analysis, often via optical emission spectroscopy (OES), verifies the chemical composition against standards like CuZn10 or CuZn15, detecting trace elements to within 0.01%.^[46] Non-destructive testing methods, including ultrasonic inspection and X-ray radiography, identify internal defects such as cracks or inclusions in cast and rolled products without compromising the material.^[47] These measures confirm compliance with specifications, minimizing variability in final components.

Tempers and Heat Treatments

Tombac, a copper-rich brass alloy typically containing 10-20% zinc, undergoes heat treatments to modify its microstructure, primarily within the alpha phase, enhancing formability, ductility, or strength as required for specific applications. Full annealing is performed at temperatures between 427°C and 732°C to achieve softness and maximum ductility, particularly after cold working processes that induce strain hardening.^[48] This treatment promotes recrystallization, transforming the deformed microstructure into equiaxed, twinned alpha grains, which restores formability without forming the brittle beta phase that can occur in higher-zinc brasses.^[49] Standard temper designations for tombac, aligned with ASTM B601, include O-temper for annealed conditions offering maximum ductility, such as O60 (soft anneal), and H-temper for cold-worked states providing balanced strength and formability, like H04 (hard).^[50] These tempers are achieved by controlling the extent of cold reduction after annealing; for instance, O-temper tombac exhibits high elongation suitable for deep drawing operations, while H-temper variants offer increased yield strength for stamping electrical components.^[48] The resulting mechanical improvements, such as enhanced ductility in soft tempers, directly support its use in fabrication processes.^[49] Stress relieving involves a low-temperature anneal at 200-300°C to alleviate internal stresses from machining or forming without significantly altering hardness or promoting recrystallization.^[51] This process is crucial for tombac exposed to environments prone to stress corrosion cracking, ensuring dimensional stability while maintaining the alpha-phase microstructure and avoiding beta-phase formation that could lead to brittleness.^[49]

Applications

Decorative Applications

Tombac, prized for its red-gold color and lustrous appearance, finds extensive use in decorative applications where a gold-like aesthetic is desired without the expense of precious metals. This alloy's high copper content imparts a warm, golden tone suitable for ornamental purposes.^[2] In jewelry and ornaments, tombac serves as an affordable imitation of gold, often containing small amounts of arsenic, which lightens and yellows its hue for a more authentic golden sheen. It has been employed in inexpensive pieces such as necklaces and accessories, with examples including 20th-century items in museum collections. During the 18th century, tombac was particularly popular for buttons on clothing like coats and waistcoats, valued for its malleability in casting and engraving; archaeological finds from sites like George Washington's Mount Vernon include flat disc tombac coat buttons dated 1760–1800, and similar hand-engraved examples appear in cultural trust collections. These buttons, typically composed of 80–88% copper and 12–20% zinc, provided a shiny, durable alternative to costlier materials.^[52]^[2]^[53]^[54] Tombac is also utilized in gilding and foils, where thin sheets or leaves are applied as overlays to mimic gold on furniture, artwork, and architectural elements. Produced as foil, it enables cheap gilding techniques, offering a reflective surface for decorative enhancement without genuine gold. This application leverages tombac's workability, allowing it to be beaten into fine layers for intricate designs.^[55] Historically, tombac featured in numismatics for low-denomination coins, providing a cost-effective material with visual appeal during economic constraints. In post-World War II Germany, it was used as a covering on iron for 5 and 10 pfennig coins issued by the Bank of German States in 1949, reflecting efforts in currency stabilization and resource efficiency. Earlier, during the Weimar Republic's hyperinflation in 1923, tombac appeared in emergency notgeld like gold-plated pieces from Westphalia, imitating higher-value currency.^[56]^[57] For interior decorative items, tombac's malleability and inherent shine make it ideal for hardware such as knobs and fittings, as well as kitchen utensils like handles and ornaments, where its golden finish adds aesthetic value. In modern artistic metalwork, tombac foils are etched or heated to develop patinas and textures, enabling contemporary creations in sculpture and mixed-media pieces that highlight its color transformations.^[2]

Industrial and Other Applications

In the ammunition sector, tombac serves as a cladding material for steel bullet jackets, particularly during World War II-era production, where its corrosion resistance and formability facilitated reliable performance in harsh conditions.^[11] This application leveraged the alloy's ability to protect underlying steel from oxidation while maintaining structural integrity during manufacturing and use.^[58] For electrical and appliance components, the CuZn15 variant of tombac is widely used in connectors and deep-drawn parts due to its balanced electrical conductivity, ductility, and resistance to stress corrosion cracking.^[59] These properties make it suitable for high-volume production of terminals and lead frames in industrial electrical systems.^[25] Silicon tombac finds application in bearings and machinery, particularly for friction bearings and die-cast components that replace steel parts, benefiting from its high strength, elongation, and corrosion resistance up to 200°C.^[38] In machine and plant engineering, it provides excellent friction-bearing properties, especially in same-material pairings, enabling durable operation in automotive and electrical industries.^[60] Additional industrial uses include stamping for automotive trim components, where tombac's malleability supports precise forming in high-volume assembly lines.^[61] Silicon tombac also acts as a substitute for investment casting in high-volume production of complex parts, offering cost-efficient die-casting with superior mechanical properties compared to traditional steel alternatives.^[62] Overall, tombac's industrial advantages stem from its cost-effectiveness in processing, full recyclability as a copper-based alloy, and improved machinability in lead-added variants, which reduce cutting forces and enhance chip formation during fabrication. In recent years, lead-free variants have gained prominence to comply with environmental regulations such as the EU RoHS directive.^[63] These attributes contribute to its adoption in defense, engineering, and manufacturing contexts, promoting sustainable and efficient material use.^[64]

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... imitation, diamonds modern brilliant cut, diamonds old brilliant cut, diamonds ... An alloy consisting of copper and zinc (being various forms of brass) used for ...Missing: decorative applications
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Tombac Brass - C22000 CuZn10 Round Bar & Sheet - Alibaba
Traditional Tombac. A copper-rich alloy (typically 85–90% Cu, 10–15% Zn) prized for its warm golden appearance and excellent workability. ... High-Strength Tombac.
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Investment Casting Showdown Brass Compared to Bronze
Aug 7, 2025 · For example, silicon tombac includes about 80% copper, 16% zinc, and 4% silicon, making it a strong alternative to steel parts. Red brass (C230) ...
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Comparative study on the machinability of lead-free brass
Apr 15, 2017 · The addition of lead is considered as resulting in an enhanced machinability through improving the chip breaking, lowering the cutting forces, ...Missing: tombac | Show results with:tombac
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[PDF] The Copper Book - Nordic Copper
base metal in cutlery, kitchenware, etc. However, it is mostly used on account of its deeper qualities, good strength and great corrosion resistance. Bronze.