Much has been written about last December’s release of the Ford F-150, the automaker’s first truck to be produced with aluminum hoods, cabs, beds and body panels. According to Ford, the result is a 700-lb. lighter truck requiring a smaller engine resulting in improved fueled economy. The move by Ford is prompted by a US standards mandate requiring automakers to increase corporate average fuel economy to 54.5 miles per gallon by 2025, up from 35.5 mpg in 2016. The automaker expects the F-150 to improve fuel efficiency by 5-20{41f8e085fc68038a2da2699f98ad8aea8b7e87e25f742017f6f76a0b55118d3c}.
Aluminum has long been used in wheels and transmission casings and is the primary component in powertrain and wheel applications, but not in the body. Steel was the metal of choice; it was more cost efficient (about ½ the cost of aluminum) and easily molded in to shape even though it is both heavier and more corrosive than aluminum. In 1993, Ford started testing the use of an aluminum-body car with its Mercury Sable AIV (Aluminum Intensive Vehicle) and later, in 2003, with its Jaguar XJ. They discovered new welding technology, stamping processes and have added structural adhesive beads to improve strength, durability and crash performance, and reduce noise. Now able to meet tight specifications and be molded into intricate shapes, aluminum is increasingly found in hoods, trunks, doors and bumpers, along with complete vehicle structures, according to The Aluminum Association.
In addition, compared with steel, aluminum delivers a reduced carbon footprint and because it is infinitely recyclable, it has become more cost-efficient without sacrificing safety and performance. Without recycling, the price of aluminum could add about $750 to the cost of each truck, but much of that is recouped by selling the scrap from production back to the supplier. This innovative closed loop supply chain is the kind of recycling relationship that Novelis has established with Ford. Ford purchases large aluminum rolls from Novelis, 30-40{41f8e085fc68038a2da2699f98ad8aea8b7e87e25f742017f6f76a0b55118d3c} of which winds up as scrap because of the large holes, such as windows, that are stamped out of it. The very trucks that deliver aluminum to Ford, drive away with thousands of pounds of shredded scrap every day. It is then recycled, returning it to aluminum rolls that are sold back to Ford at a lower cost than virgin aluminum.
Ford is not the only automaker taking notice of aluminum’s many benefits; it’s been reported that GM has been adding more aluminum to its cars through improved spot welding processes. As a result, demand for the metal is at an all-time high. According to a recent article in the Wall Street Journal, “Alcoa Inc. and Novelis, the top two U.S. aluminum sheet producers, invested about $1 billion last year in U.S. factories producing metal for autos.” Rusal, one of the world’s largest aluminum companies, expects car-maker consumption to rise 65 percent to 23 million metric tons by 2020.
Whether or not you drive an F150, the use of aluminum has become a megatrend in the transportation industry. Demand from automotive and aerospace means a huge percentage of aluminum production is being dedicated to transportation, limiting capacity for other industries. “Lead times are little longer and prices are creeping up,” according to Joe Cannata, Aluminum Product Manager at Admiral Metals, “While we don’t anticipate any major changes through year end, we are fortunate to have planned in advance for the increased demand.”
We reported in a 2012 newsletter: aluminum seems to have an endless number of applications. Its cost-, time- and energy- efficient qualities tell us that it is the go-to metal today and will remain so for the foreseeable future. Three years later, the same holds true. Just this week, the ever-innovative Tesla Motors launched its Powerwall, a solar powered battery bank designed for homes, businesses, and utilities. Solar panels may very well be our next aluminum-intensive megatrend.
Sources: aluminum.org, autonews.com, Bloomberg.com, Car and Driver, Fortune, marketrealist.com, The Wall Street Journal
SIDEBAR
Quick facts about aluminum
Once, more precious than gold and silver
Before the discovery of the Bayer and Hall–Héroult processes, aluminum was more expensive than gold or silver.
Aluminum helped pioneer flight
The Wright brothers used aluminum to build a biplane engine light enough with the needed horsepower.
The lifespan of an aluminum can
A can recycled today can be back in the marketplace in 60 days.
Strength
Four six-packs of cans are able to support the weight of a 2-ton vehicle!
Staying Power
Nearly 75 percent of all aluminum ever produced is still in use today.
Recycling efforts can be improved
Every three months, Americans throw away enough scrap aluminum to rebuild the entire U.S. commercial airplane fleet equaling 16 million barrels of oil.
Source: The Aluminum Association www.aluminum.org
Brass and bronze are two of the most widely used copper alloys in precision manufacturing — and while they're often mentioned in the same breath, they perform very differently in the field. Choosing the right alloy for a given application isn't just about cost or availability; it's about matching the material's properties to the demands of the job.
This guide covers the key differences between brass and bronze, highlights the grades we rely on most at Admiral Metals — including C360's industry-leading machinability, C954's outstanding corrosion resistance, and the growing shift from C360 to C2745 for lead-free applications — and gives you a practical framework for making the right call.
The Fundamental Difference
Both are copper alloys, but the alloying elements define everything:
Brass
Bright golden appearance, excellent machinability, and strong corrosion resistance in everyday environments. The go-to choice for high-volume precision machining.
Bronze
Harder, stronger, and superior in harsh or submerged environments. The specialist alloy for marine, industrial, and heavy-load applications.
Zinc (brass) favors cost, machinability, and electrical conductivity. Tin, aluminum, or silicon (bronze) favors strength, wear resistance, and corrosion performance under demanding conditions.
Key Property Comparison
| Property | Brass | Bronze |
|---|---|---|
| Machinability | ||
| Corrosion Resistance | ||
| Hardness / Wear | ||
| Material Cost | ||
| RoHS / Lead-Free | C360: contains lead · C2745: fully compliant | C954: compliant |
Brass Grades: What You Need to Know
C360 — Free-Cutting Brass: The Machinability Benchmark
C360 — Alloy 360 / Free-Cutting Brass
- Machinability rated at ~100% — the universal benchmark against which all other copper alloys are measured
- Contains ~3% lead, which acts as a built-in chip-breaker and internal lubricant during cutting operations
- Produces short, manageable chips — critical for screw machines and high-speed CNC turning centers
- Dramatically extends tool life and enables faster cycle times versus other copper alloys
- Delivers excellent surface finish with minimal secondary operations required
- Ideal for fittings, valves, fasteners, gears, and general-purpose machined components
- Limitation: Not RoHS compliant — restricted in potable water plumbing, EU-exported products, and medical applications
The lead particles in C360 don't dissolve into the copper matrix — they remain as tiny dispersed inclusions that act as a chip-breaker and internal lubricant at the cutting edge. The result: short, manageable chips instead of the long stringy swarf that plagues other alloys, dramatically reduced tool wear, faster cycle times, and a superior surface finish right off the machine. For high-volume screw machine work or CNC turning, no other copper alloy delivers this combination of speed, finish quality, and cost efficiency.
C2745 — Lead-Free Eco Brass: The Modern Alternative
The traditional choice
~3% lead content · Machinability ~100% · Not RoHS or NSF 61 compliant · Restricted in potable water and EU applications
The lead-free standard
<0.09% lead · Machinability ~70–80% of C360 · Fully RoHS, NSF 61 & California AB 1953 compliant · Drop-in replacement for most machined parts
As regulations around lead in plumbing and potable water systems have tightened — particularly under NSF/ANSI 61, the EU's RoHS directive, and California's AB 1953 (Prop 65 "Lead-Free" standard) — the industry has been steadily migrating away from C360 for these applications. C2745 is the primary engineered replacement: it retains excellent machinability (~70–80% of C360), fits the same stock forms and tolerances, and requires no significant design changes in most cases.
Other Key Brass Grades
C464
- Tin addition significantly improves seawater corrosion resistance over standard brass
- Common in marine hardware, propeller shafts, and condenser tubes
- Good combination of strength and formability
C260
- Exceptional cold-working and deep-draw capability
- Used for ammunition casings, radiator cores, springs, and stampings
- Good corrosion resistance; moderate machinability
Bronze Grades: Strength Where It Counts
C954 — Aluminum Bronze: The Corrosion Resistance Leader
C954 — Alloy 954 / Aluminum Bronze
- Outstanding corrosion resistance — resists seawater, mild acids, and high-temperature oxidation
- Aluminum content (~9–11%) forms a tenacious, self-healing oxide layer similar in principle to stainless steel
- High tensile strength (~85 ksi) combined with excellent wear and erosion resistance
- Preferred for pump impellers, propellers, marine shafting, valves, and chemical plant components
- Inherently corrosion-resistant throughout its cross-section — not dependent on coatings or plating
- Lead-free and fully compliant with environmental regulations
- Well-suited for heavy structural and flow-exposed parts where coating integrity cannot be guaranteed
The aluminum content in C954 creates a dense, tightly adhering aluminum oxide surface layer that reforms instantly if the surface is scratched or abraded — providing robust, self-repairing protection in saltwater, mild acids, and oxidizing atmospheres. Unlike many alloys that rely on surface coatings for corrosion protection, C954 is corrosion-resistant throughout its entire cross-section. This makes it the material of choice for pump components, propeller hubs, marine shafting, and any application where coating integrity cannot be reliably maintained.
Other Key Bronze Grades
C932
- The workhorse bearing bronze — conformable, low friction, embeds contaminants
- Excellent for bushings, washers, and thrust bearings under moderate loads
- Available in oil-impregnated form for self-lubricating applications
C510 / C544
- Phosphorus addition increases hardness and significantly improves fatigue resistance
- Excellent for springs, electrical contacts, and fine wire mesh
- Good corrosion resistance in both fresh and salt water
C651 / C655
- Outstanding weldability — preferred for architectural and artistic fabrication
- Good strength and corrosion resistance
- Used in marine fasteners, bolts, and sculpture
C863
- Very high strength — among the strongest of all copper alloys
- Used for heavy-duty gears, wear plates, and structural hardware
- Good resistance to dezincification in seawater
When to Use Each: A Practical Guide
Choose Brass When…
- High-volume precision machining is the priority (C360 or C2745)
- Electrical or thermal conductivity matters for the design
- Aesthetic / decorative finish is important (warm golden color)
- Cost is a primary constraint on the project
- Mild corrosion environments — air, fresh water, indoor service
- Lead-free compliance is required → specify C2745 or C464
- Plumbing fittings, HVAC components, instrumentation
- Locks, gears, ammunition casings, musical instruments
Choose Bronze When…
- Marine or submerged saltwater exposure is a factor (C954, C464)
- High wear, bearing, or bushing performance is required (C932, C954)
- Elevated temperature or chemical plant service conditions apply
- Heavy structural parts require high tensile strength
- Pump impellers, propellers, shafts, valves in aggressive media
- Springs and electrical contacts needing fatigue resistance (C510)
- Welded assemblies and architectural or artistic work (C655)
- Inherent corrosion resistance is needed throughout the cross-section
Quick Grade Reference
The Bottom Line
Brass and bronze aren't interchangeable — they're complementary. Brass wins on machinability, cost, and everyday corrosion resistance, making it the default choice for precision machined parts in benign environments. Bronze wins in demanding conditions: marine exposure, heavy loads, bearing surfaces, and anywhere a coating simply can't be relied upon.
Within each family, grade selection matters just as much as alloy family. C360 remains the machining benchmark, but C2745 is becoming the responsible default for any application touching potable water or destined for regulated markets. And when corrosion or wear is the design driver, C954 aluminum bronze is in a class of its own among copper alloys.
Not sure which grade is right for your next job? Our team has been matching customers to the right material since 1950 — give us a call or request a quote online.
Ready to Order or Need a Recommendation?
Admiral Metals stocks a full range of brass and bronze alloys in rod, bar, tube, and plate — cut to your exact requirements.