Development of Lead-Free Copper alloy Manufacturing System Based on Life Cycle Assessment

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The method for removing Pb from bronze containing Pb was examined by the compound-separation method. NaF is added to molten bronze, followed by adding the Ca-Si compound. Therefore, the reaction of ca with Pb is promoted without the reaction of Ca with Sn. Using this method, 82% of Pb can be removed from bronze containing 5.5 mass% Pb.The inventory analysis of both the former Pb-free copper alloy manufacturing system that uses virgin materials and the new one that uses copper alloy scrap containing Pb, which is removed in the production process, was carried out. The results show that the shift from the former manufacturing system to the new one reduces environmental impacts such as global warming, acidification, energy consumption and resource consumption significantly. Thus in the LCA perspective, the new manufacturing system that uses a recycled copper alloy scrap is superior to the former one that uses virgin materials.The effect of molybdenum disulfide on machinability of bronze was examined. The result shows the cutting forces and chip-disposability can be greatly improved by the addition of molybdenum disulfide.