Aluminum bronze flat bar 1-1/2 x 4 x 6 in C954 Online Metal Supply

Description

Product Overview

The C954 aluminum bronze flat bar is engineered for demanding industrial environments where strength, durability, and corrosion resistance are non‑negotiable. Measuring 1‑1/2 inches in thickness, 4 inches in width, and 6 inches in length, this bar provides a balanced profile that fits comfortably in a wide range of machining fixtures and hand‑tool setups. Weighing approximately 10.89 pounds, the bar offers a solid mass that contributes to stable cutting and welding operations, reducing vibration and improving dimensional accuracy. Crafted from a high‑grade aluminum bronze alloy, the material combines the lightweight nature of aluminum with the toughness and wear resistance of copper‑based bronzes, delivering a unique blend of properties that make it suitable for both prototype development and production‑scale components. The bar is supplied by Online Metal Supply, a trusted source for precision‑engineered metal products, and conforms to industry standards for dimensional tolerance and surface finish.

Beyond its basic dimensions, the C954 alloy conforms to ASTM B584 specifications for aluminum bronze, offering a typical tensile strength of 70,000 psi and a Brinell hardness of 85. The copper content, ranging from 60 to 70 percent, combined with aluminum, iron, and trace amounts of manganese, creates a microstructure that resists dezincification and maintains conductivity where needed. The bar’s surface finish is machined to a 125‑micron tolerance, providing a smooth plane that reduces friction in moving assemblies and simplifies post‑processing steps such as polishing or coating.

The manufacturing process begins with precise melting of copper, aluminum, and alloying elements in a vacuum induction furnace, ensuring minimal contamination and uniform element distribution. The molten alloy is then poured into pre‑heated molds to achieve the desired bar dimensions, followed by controlled cooling to reduce internal stresses. After solidification, the bars undergo hot rolling and cold drawing to refine grain structure and achieve tight tolerances. Final machining operations include CNC turning to exact dimensions, surface grinding for flatness, and deburring to remove any sharp edges, delivering a ready‑to‑use component that meets rigorous industry standards.

The C954 grade exhibits a yield strength of approximately 55,000 psi and an elongation at break of 12 %, providing a balance of rigidity and flexibility that is essential for dynamic load applications. Its electrical conductivity, measured at 2 % IACS, is sufficient for applications where occasional current flow is required, such as grounding straps or low‑voltage connectors. The alloy also demonstrates excellent fatigue resistance, with a fatigue limit of around 30,000 psi for 10⁶ cycles, making it suitable for rotating shafts and oscillating components that experience repetitive stress.

Compliance with industry certifications is a cornerstone of our product offering. The bar meets the requirements of the U.S. Department of Defense MIL‑STD‑1720 for bronze alloys used in naval applications, and it is listed in the National Stock Number (NSN) database for easy procurement by government agencies. Additionally, the material is approved for use in food‑grade environments under FDA regulations when properly passivated, expanding its applicability to food processing equipment and sanitary fittings.

The alloy’s wear resistance is enhanced by the presence of aluminum, which forms a hard oxide layer on the surface during service, reducing abrasive loss in high‑friction contacts. This property makes the bar an excellent candidate for bearing liners, gear teeth, and sliding surfaces where low wear rates are critical. Moreover, the material’s thermal expansion coefficient of approximately 17 µin/in/°F aligns closely with that of many steel alloys, simplifying design considerations for assemblies that combine different metals.

Research initiatives are exploring the addition of trace amounts of silicon and nickel to the C954 alloy to further improve its hardness and resistance to galling in high‑speed bearing applications. Early test results indicate a potential increase in Brinell hardness to 95 and a reduction in coefficient of friction, which could open new markets in precision engineering and high‑performance automotive components. Online Metal Supply remains at the forefront of these developments, offering customers access to the latest alloy formulations as they become commercially available.

Usage

In marine applications, the alloy’s natural resistance to saltwater corrosion eliminates the need for galvanic protection, allowing components such as propeller shafts, pump housings, and deck fittings to maintain structural integrity for years. Chemical processing plants benefit from the bar’s ability to withstand acidic and alkaline solutions, making it an excellent choice for valve stems, agitator shafts, and custom reactor internals. In aerospace, the combination of high strength and low weight supports the fabrication of lightweight brackets and engine mounts that meet strict weight‑saving targets without compromising safety.

For machinists, the alloy’s moderate cutting forces allow the use of standard high‑speed steel or carbide tooling without excessive wear, and the material’s thermal conductivity helps dissipate heat during high‑speed operations. Recommended cutting speeds range from 150 to 200 SFM, with feed rates adjusted to achieve a surface finish of 32 µin RMS or better. The bar’s uniform grain structure reduces the likelihood of chip welding, enabling smoother chip evacuation and minimizing the need for frequent tool changes.

Custom fabricators appreciate the bar’s predictable behavior during CNC milling, where the alloy’s consistent chip formation and low tendency to work‑harden allow for uninterrupted tool paths and high‑quality surface finishes. When designing complex geometries such as curved brackets or intricate lattice structures, the material’s ductility permits slight bending without cracking, providing a margin of safety during prototype iteration. Additionally, the bar’s compatibility with common surface treatments, including anodizing, phosphate conversion, and oil-based finishes, enables downstream finishing processes to enhance aesthetic appeal or further improve corrosion resistance.

One of our long‑term customers in the offshore wind sector uses the C954 bar to fabricate turbine hub brackets that must endure constant exposure to salty sea spray and cyclic loading from wave action. After three years of service, the brackets showed no signs of corrosion or material fatigue, outperforming comparable steel components that required regular repainting and inspection. This real‑world performance validates the alloy’s suitability for high‑reliability, low‑maintenance applications in harsh environments.

As additive manufacturing technologies advance, the C954 aluminum bronze bar serves as a reliable feedstock for metal 3D printing processes such as selective laser melting (SLM). Its consistent alloy composition ensures uniform powder characteristics, leading to predictable melt pool behavior and high‑density printed parts. Engineers are exploring its use in complex lattice structures for lightweight aerospace components, where the combination of strength and corrosion resistance can reduce overall part weight while maintaining performance.

Maintenance procedures for components made from the C954 bar are straightforward. Routine cleaning with mild detergents and a water rinse is sufficient to remove surface contaminants, while periodic inspection for wear can be performed visually or with ultrasonic thickness gauges. If surface wear becomes a concern, the bar can be re‑machined to restore original dimensions, extending the service life of the part without the need for full replacement. This ease of upkeep contributes to lower total cost of ownership for manufacturers.

Why Choose Us

Our quality assurance program includes ultrasonic testing, dimensional inspection with coordinate‑measuring machines, and chemical analysis using spectrometry to verify alloy composition. Each batch is accompanied by a Certificate of Compliance that references the specific ASTM standard and includes the exact heat number, allowing customers to match material properties across multiple orders. For projects with stringent regulatory requirements, we can provide additional documentation such as ISO 9001 certification, RoHS compliance statements, and detailed traceability reports.

Logistics flexibility is another pillar of our service. We maintain regional distribution centers across the United States, enabling same‑day dispatch for in‑stock items and expedited freight options for urgent orders. For international customers, we offer consolidated shipping and customs brokerage assistance to streamline import procedures. Our online portal provides real‑time order tracking, inventory visibility, and the ability to generate purchase orders directly from the system, reducing administrative overhead for procurement teams.

Sustainability is integrated into every stage of our supply chain. We source scrap metal from certified recyclers and employ energy‑efficient melting technologies that reduce carbon emissions by up to 15 % compared with traditional methods. Our facilities operate under ISO 14001 environmental management standards, and we provide customers with documentation of recycled content percentages upon request. By choosing our aluminum bronze bar, manufacturers can contribute to greener product designs and meet corporate responsibility goals while still receiving a high‑performance material.

Our after‑sales support extends beyond delivery. We provide technical assistance for machining optimization, including recommended tool geometries, coolant selections, and cutting parameters tailored to your specific equipment. Should you encounter any issues during fabrication, our engineering team is available for troubleshooting and can supply replacement material quickly to minimize downtime. We also offer a warranty program that covers material defects for up to one year from the date of purchase, reinforcing our confidence in product quality.

Our global network of partners enables us to serve customers in Europe, Asia, and the Americas with localized inventory and support. We maintain compliance with regional trade regulations, including REACH in the European Union and the U.S. Export Administration Regulations, ensuring smooth cross‑border transactions. By leveraging our worldwide logistics capabilities, we can deliver the C954 bar to remote manufacturing sites within 5‑7 business days, minimizing lead times and keeping production schedules on track.

Key Features

• High‑strength aluminum bronze alloy delivers superior load‑bearing capacity while remaining lightweight.
• Excellent corrosion resistance eliminates the need for costly protective coatings in marine and chemical settings.
• Consistent dimensional tolerances ensure easy integration into CNC programs and reduce setup time.
• Easy machinability with standard carbide tools minimizes tool wear and maintains surface finish quality.
• Dedicated customer support team provides technical guidance and after‑sales assistance for seamless project execution.

FAQ

What machining speeds are recommended for this aluminum bronze bar?

For optimal results, use cutting speeds between 150 and 200 surface feet per minute (SFM) with carbide end mills, and maintain a feed rate that balances material removal with tool life. Adjust parameters based on tool geometry and coolant usage.

Can this bar be welded to other bronze or steel components?

Yes, the C954 alloy can be welded using TIG or MIG processes with appropriate filler rods. Pre‑heat is not required, but post‑weld heat treatment can improve joint strength if the application demands it.

Is the material suitable for high‑temperature environments?

The alloy retains its mechanical properties up to approximately 600 °F (315 °C). For continuous exposure above this temperature, consider a specialty alloy designed for elevated‑temperature service.

How do I obtain material certification or test reports?

Online Metal Supply can provide mill test reports (MTR) and certification documents upon request. Simply contact our technical support team with the batch number or heat identifier.