The value of the element lead in brass alloys lies in the fact that it has a low melting point, 620ºF, and that it is virtually insoluble in solid copper, (less than 50 parts per million). These reasons explain the longtime use of lead in the creation of castings. For example, red brasses are wide freezing range alloys, which means that as they solidify, countless microscopic strutures called dendrites are formed. These dendrites then tend to lock into one another, leaving voids known as microporosity during solidification.

The role of lead in a brass casting is to fill these microvoids and make the entire casting pressure tight. Also, the distribution of lead into a copper matrix adds to its machinability. A.R. Singh was determined to find an applicable method to replace the lead in his castings with a non-toxic element.

Bismuth, with a melting point of 520ºF and located next to lead on the periodic table, exhibits similar properties and was an excellent choice as a lead replacement. The distinguishing factor between the two is that lead is soft and malleable, whereas bismuth is hard and brittle. In his research, Mr. Singh concluded that the introduction of a proprietary additive in a unique manner helps distribute bismuth uniformly throughout the alloy structure. This special feature virtually eliminates the problems associated with the embrittlement of bismuth and is essential for Federalloy alloys to exhibit excellent pressure tightness and comparable mechanical properties as are in leaded brass castings.