 The Clarinet BBoard
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Author: Lindsey Ondrey
Date: 2002-02-03 05:10
Ok, so the conversation came up this evening while I was cleaning my clarinet while my fiancee and some of his friends were sitting around about how an instrument is made and what all its made of (He is a mechanical engineering major and is facinated by those things). We got in this big debate trying to figure out how they make the keys for the different clarinets and what they're made of. I know my Buffet's keys are silver plated, but what is it over? Does anyone know of somewhere on the web where it goes into length about how they make the keys for the different clarinet manufacturers (I know people like Buffet vs. Selmer do it slightly different), etc.? It has me puzzled now as well.
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Author: Bob
Date: 2002-02-03 17:03
Lindsey: historically the keys are made from a nickel-silver alloy which is a copper-base alloy containing anywhere from 17% to 32% Zinc and 30% Nickel. The cast alloy is fabricated into wire which is then "power forged" (drop forged in a closed die the approximate shape of the key) after which it is "cleaned up" and machined as necessary. In prior years the nickel-silver keys were used as-is without plating,however, these days they are usually electroplated with nickel or silver after being given a "flash coat" of electro-copper. This is only a "rough sketch" of the manufacturing process. It is possible that some manufacturers might make the keys from other alloys and/or by a die casting process either of which would probably result in keys that presented some problems as regards repairs and possibly even "action".
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Author: willie
Date: 2002-02-03 18:13
I'd like to add too that there have been and still are some cheaper clarinets out there that have keys cast from a cheaper alloy of mostly zinc called zamack. These should be avoided as you can't tweak them as the just snap off. If you try to solder them they just melt into a glob. Most of the current "cheapos" I've seen like this are from China or India, but there have been some made in this country also. One I have is a no name wooden horn that just says Chicago, USA, and appears to be from the 30s. It has the most beautiful wood but some of the keys are broken and can't be fixed.
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Author: Bob
Date: 2002-02-03 23:21
Willie: yer right....Zamak was a popular Zinc diecasting alloy and although some of the newer ones have more ductility Zn diecastings in clarinet key cross section just don't have enough ductility for adjustment without breaking. And you can't tell them from Nickel silver since both are not attracted by a magnet. I certainly wouldn't recommend a horn with Zinc die cast keys to anyone....a real bummer.
Oh, some might think these are investment cast but that's a completely different process and I don't know if anyone is making investment cast woodwind keys. Using this process vis a vis closed die forging and using some appropriate alloy such as nickel silver or stainless steel would present possibilities. Somewhere someone is probably experimenting with it as tooling costs for closed die forging and zinc die cast dies is becoming more prohibitive.
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Author: Ken Shaw
Date: 2002-02-04 18:47
Prior to the introduction of the R-13, Buffet keys were made of unplated "German silver" (which contains no silver).
Kalmen Opperman has told me that on the older Buffets (with the triangle-shaped guide for the uper two trill keys), the keys were not forged. Instead, the various parts of the keys were rough-cut and then filed by hand into the final shape and soldered together.
Best regards.
Ken Shaw
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Author: Gordon (NZ)
Date: 2002-02-05 11:42
As I understand it drop-forged parts are stronger than cut parts of the same shape and metal.
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Author: Bob
Date: 2002-02-09 15:37
Gordon: I think that's generally true and in the case of clarinet keys I'd say you could take that statement to the bank. "Cut" machined clarinet keys would have to be a very difficult machining job using traditional methods(especially those back in the era you mention). Today NC machines could be used but I would think the costs would exceed drop or press forging....even with the tooling cost of forging dies. The main advantage of forged keys is that they are stronger at the abrupt changes of cross section vis a vis machined keys.
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Author: Gordon (NZ)
Date: 2002-02-09 15:58
Bob: That is why I was surprised to read "The part of the key that connects the cup to the hinge and or touch-piece is electro-eroded on a specialty EDM machine..." on the Chadash site. I presume electro-erosion is similar to cutting, with no reduction of the stress raisers achieved by forging. It surely shouldn't be a thing to boast about, even if it is modern?
http://www.chadash-clarinet.com/metal.htm
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