LG2 Gunmetal Casting | BS 1400 LG2 Bronze Foundry & Cast Parts – Cable Glands India
Cable Glands India manufactures LG2 gunmetal castings (BS 1400 LG2 / BS EN 1982 CC491K / UNS C92200) for valves, pump bodies, marine hardware, pressure fittings, and electrical connectors. LG2 gunmetal — also known as leaded tin bronze or steam bronze — offers an excellent combination of pressure tightness, machinability, corrosion resistance in seawater and steam, and reliable performance across a wide temperature range. We supply castings from 10 grams to 40 kilograms to electrical OEMs, EPC contractors, power utilities, pump manufacturers, and international distributors.
Product Overview
LG2 is a copper-tin-zinc-lead alloy containing approximately 85% copper, 5% tin, 5% zinc, and 5% lead (the traditional “85-5-5-5” red brass/gunmetal). It is one of the most widely specified pressure-tight casting alloys in British and international standards. Its lead content (4–6%) ensures excellent machinability, while tin provides strength and corrosion resistance, and zinc improves fluidity during casting. Cable Glands India produces LG2 gunmetal castings using sand casting, shell mould casting, investment casting, centrifugal casting, and gravity die casting, all from certified LG2 ingots conforming to BS 1400 LG2 / BS EN 1982 CC491K.
Casting Processes We Offer
Sand Casting
Green sand and no-bake (chemically bonded) sand for complex valve bodies, pump casings, and large structural castings. Weight range up to 40 kg. Tolerances CT6–CT7 (ISO 8062). Surface finish Ra 6.3–25 µm.
Shell Mould Casting
Resin-bonded sand shells for valve bodies, meter housings, and fittings requiring better surface and dimensional consistency than green sand. Tolerances CT5–CT6. Medium production volumes.
Lost Wax Investment Casting
Ceramic shell investment process for intricate shapes — valve trim, instrument fittings, hydraulic manifold components. Tolerances CT4–CT5, surface finish Ra 1.6–6.3 µm.
Centrifugal Casting
True and semi-centrifugal casting for cylindrical components — flanges, bearing bushings, ring components. Dense microstructure with minimal porosity. Standard and custom OD/ID configurations.
Gravity Die Casting (Permanent Mould)
Reusable metal dies for medium-to-high production volumes of uniform-shape components. Consistent dimensions and improved surface quality vs. sand casting. Tolerances CT5–CT6.
Pressure Die Casting
For high-volume, thin-wall LG2 components where consistent quality and cycle time are critical. Available for parts up to ~3 kg in weight.
Key Features
- Pressure-tight castings — zero porosity where required by hydrostatic test
- Excellent machinability — free-machining due to lead content
- Outstanding corrosion resistance in seawater, steam, and potable water
- Wide operating temperature range: -200 °C to +250 °C
- Good electrical and thermal conductivity
- Non-sparking properties for hazardous environments
- Weight range: 10 g to 40 kg
- Full in-house machining and surface treatment capability
- EN 10204 3.1 material test certificates supplied with each batch
Technical Specifications – LG2 Gunmetal (BS EN 1982 CC491K)
| Parameter | Specification |
|---|---|
| Copper (Cu) | 83.0 – 87.0% |
| Tin (Sn) | 4.0 – 6.0% |
| Zinc (Zn) | 4.0 – 6.0% |
| Lead (Pb) | 4.0 – 6.0% |
| Nickel (Ni) | 2.0% max |
| 0.2% Proof Stress | 100 MPa min |
| Tensile Strength | 230 MPa min |
| Elongation | 13% min |
| Brinell Hardness | 60 – 80 HB |
| Density | 8.7 g/cm³ |
| Melting Range | 854 – 1000 °C |
| Thermal Conductivity | 72 W/m·K |
| Hydrostatic Pressure | Up to 160 bar (casting quality dependent) |
| Weight Range | 10 g – 40 kg |
| Max Length | 1,000 mm |
LG2 Gunmetal International Standard Equivalents
| Standard | Grade Designation | Notes |
|---|---|---|
| BS 1400 (UK) | LG2 | Legacy British standard |
| BS EN 1982 (Europe) | CC491K | Current European standard |
| UNS / ASTM B505 | C92200 | Navy M bronze equivalent |
| DIN 1705 (Germany) | GBz10Pb (approx.) | Leaded tin bronze |
| JIS H5111 (Japan) | CAC402B | Closest JIS equivalent |
| IS 318 (India) | Grade LB2 | Leaded gun metal |
| ISO 1338 | CuSn5Zn5Pb5 | ISO designation |
Product Types and Variants
- Valve Bodies — gate, globe, ball, check, and butterfly valves for water, steam, and gas service
- Pump Bodies and Casings — centrifugal, gear, and reciprocating pump casings
- Flanged Fittings — elbows, tees, reducers, unions in BS, ANSI, DIN flange standards
- Plumbing and Pipe Fittings — compression fittings, threaded couplings, adapters
- Marine Hardware — seacocks, throughhull fittings, propeller shaft components, deadlights
- Meter Bodies and Housings — water meters, flow meter bodies, pressure gauge bodies
- Electrical Connector Housings — cable gland bodies, conduit fittings, earth clamps
- Bearing Bushings — centrifugal cast sleeves and bushings
- Custom Castings — engineered to customer drawings or 3D model
Industry Applications
- Plumbing and Water Infrastructure — water main fittings, valve bodies for municipal and industrial water systems
- Oil and Gas — wellhead components, manifold valves, meter bodies, non-sparking fittings
- Marine and Offshore — seacocks, sea strainers, throughhull fittings, pump bodies, shaft seals
- Power Generation — steam valve bodies, condenser fittings, feedwater fittings
- Electrical Industry — cable gland bodies, conduit unions, earthing fittings
- HVAC and Refrigeration — refrigerant valve bodies, pressure control valves
- Fire Protection — hose couplings, deluge valve bodies, sprinkler fittings
- Shipbuilding — hull fittings, deck hardware, sea chest components
Manufacturing Process
LG2 ingots (certified to BS EN 1982 CC491K) are charged into induction furnaces and melted at controlled temperature. Metal is degassed and poured into prepared moulds at the correct pouring temperature to ensure complete filling, directional solidification, and minimum porosity. After cooling, castings are fettled (runners, risers, and flash removed), heat treated if required (stress relief or solution anneal), and machined to drawing dimensions on CNC lathes and machining centres. Each batch is tested for chemical composition using an optical emission spectrometer, and dimensional inspection is carried out. Pressure tests (hydrostatic or pneumatic) are performed where specified. Full traceability from heat number to finished casting is maintained.
Quality Standards and Certifications
- ISO 9001:2015 Quality Management System
- Material conformance to BS 1400 LG2 / BS EN 1982 CC491K
- EN 10204 3.1 Mill Test Certificates with every batch
- Hydrostatic/pneumatic pressure testing available
- Non-destructive testing: dye penetrant, ultrasonic, radiographic (on request)
- Dimensional inspection and CMM reporting on request
- PPAP Level 1–3 documentation available for OEM customers
Why Choose Cable Glands India for LG2 Gunmetal Castings?
- Proven Alloy Expertise: LG2 is our most commonly cast alloy. We have deep process knowledge for producing pressure-tight, leakage-free castings.
- Pressure Testing: Hydrostatic test capability to verify casting integrity before dispatch.
- Valve Body Specialisation: Decades of experience casting gate valve, globe valve, and ball valve bodies for water, steam, and gas service.
- Full Machining In-House: Thread cutting, boring, facing, and precision machining to BS, ASME, ISO thread standards.
- Competitive Pricing: India-based manufacturing at 20–40% lower cost than European or North American sources.
- Fast Delivery: Standard orders 3–5 weeks casting only; 5–8 weeks fully machined.
Multilingual Equivalent Terms
| Language | Terms (3–4) |
|---|---|
| Spanish (ES) | Fundición de metal de cañón LG2, Fundición de bronce-latón LG2, Colada de gunmetal BS 1400, Piezas fundidas de bronce al plomo |
| Russian (RU) | Литьё из пушечного металла LG2, Литьё из оловянно-свинцовой бронзы, Пушечный металл BS 1400 литьё, Бронзово-свинцовые отливки |
| French (FR) | Moulage en bronze gunmetal LG2, Fonderie bronze BS 1400 LG2, Pièces coulées en gunmétal, Bronze rouge fondé LG2 |
| Portuguese (PT) | Fundição em metal de canhão LG2, Fundição em bronze gunmetal BS 1400, Peças fundidas de bronze LG2, Liga de bronze-chumbo fundida |
| Italian (IT) | Fusione in gunmetal LG2, Fonderia bronzo BS 1400 LG2, Getti in bronzo gunmetal, Bronzo al piombo fuso LG2 |
Frequently Asked Questions (FAQ)
What is LG2 gunmetal?
LG2 is a leaded tin-zinc bronze (gunmetal) conforming to BS 1400 LG2 and BS EN 1982 CC491K. It contains approximately 85% copper, 5% tin, 5% zinc, and 5% lead. The alloy combines pressure tightness, excellent machinability, and corrosion resistance in seawater, steam, and potable water, making it the most widely used valve and fitting bronze worldwide.
What is the difference between LG2 and phosphor bronze?
LG2 contains lead and zinc in addition to tin, which makes it more machinable and pressure-tight (less porosity due to better fluidity). Phosphor bronze (PB1, PB2) contains phosphorus instead of lead, giving it higher strength, better fatigue resistance, and anti-friction properties. Phosphor bronze is preferred for bearings and gears; LG2 is preferred for valve bodies, pump casings, and pressure fittings.
Is LG2 gunmetal suitable for potable water applications?
Traditional LG2 contains 4–6% lead which may not comply with current drinking water regulations (e.g., NSF/ANSI 61, UK WRAS, EU Directive 98/83/EC). For potable water, specify lead-free alternatives (CW510L, C89835). Our technical team can advise on regulatory compliance for specific applications.
What casting process do you recommend for LG2 valve bodies?
Sand casting is standard for complex valve bodies in low-to-medium volumes. Shell mould casting or gravity die casting is preferred for higher volumes or tighter dimensional requirements. Investment casting suits small, intricate valve trim components.
Do you cast to BS EN 1982 or the legacy BS 1400 standard?
We can cast to either standard. BS 1400 LG2 and BS EN 1982 CC491K are compositionally equivalent. We provide material test certificates quoting both designations where required.
What pressure testing do you offer?
We perform hydrostatic pressure tests per customer specification (typically 1.5× working pressure) and pneumatic (air under water) tests for small castings. Test pressure, duration, and acceptance criteria are agreed at the time of order.
Can you machine LG2 castings to finished valve body dimensions?
Yes. We machine valve bodies to all common standards including BSP, NPT, BSPP, metric, and ANSI/ASME flange face dimensions. CNC machining to drawing tolerances with inspection reports supplied.
What is the lead time for LG2 gunmetal castings?
Standard castings: 3–5 weeks. Machined castings: 5–8 weeks. Express service available for urgent requirements; contact our team for availability.
Do you supply LG2 castings for export?
Yes. We regularly export LG2 castings to the UK, EU, Middle East, Southeast Asia, and Africa. We provide all export documentation including commercial invoice, packing list, certificate of origin, and EN 10204 3.1 MTC.
Can you match an existing casting from a sample or broken part?
Yes. We can reverse-engineer from a physical sample using 3D scanning, or from dimensional drawings prepared from the sample. Spectrometer analysis of the sample material confirms the alloy grade. Contact us with the sample details.
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Request a Quote
To receive a quotation for LG2 gunmetal castings, contact Cable Glands India with your drawing, alloy specification, quantity, and delivery requirement. Our technical and commercial team will respond within 24 hours.
Email: sales@cableglandsindia.com | Phone: +91 22 4344 9300