Cu-Based Alloy Powder

Abstract

A Cu-based alloy powder is provided that is suitable for a process involving rapid-melting and rapid-solidification and can produce a shaped article having superior properties. The powder is made of a Cu-based alloy. The Cu-based alloy includes 0.1 to 5.0 mass % of at least one element M selected from V, Fe, Zr, Nb, Hf, and Ta. The balance in the alloy is Cu and inevitable impurities. The powder has a ratio D50/TD of a mean particle diameter D50 (μm) to a tap density TD (Mg/m.sup.3) in a range of 0.2×10.sup.−5.Math.m.sup.4/Mg to 20×10.sup.−5.Math.m.sup.4/Mg.

Claims

1. A powder made of a Cu-based alloy comprising 0.1 to 5.0 mass % of at least one element M selected from the group consisting of V, Fe, Zr, Nb, Hf, and Ta, the balance being Cu and inevitable impurities, wherein the powder has a ratio D50/TD of a mean particle diameter D50 (μm) to a tap density TD (Mg/m.sup.3) in a range of 0.2×10.sup.−5.Math.m.sup.4/Mg to 20×10.sup.−5.Math.m.sup.4/Mg.

2. The powder according to claim 1, wherein the Cu-based alloy comprises 0.1 to 2.0 mass % of Zr.

3. A shaped article produced from a powder made of a Cu-based alloy, wherein: the Cu-based alloy comprises 0.1 to 5.0 mass % of at least one element M selected from the group consisting of V, Fe, Zr, Nb, Hf, and Ta, the balance being Cu and inevitable impurities, the powder has a ratio D50/TD of a mean particle diameter D50 (μm) to a tap density TD (Mg/m.sup.3) in a range of 0.2×10.sup.−5.Math.m.sup.4/Mg to 20 ×10.sup.−5.Math.m.sup.4/Mg, the shaped article comprises a matrix phase comprising Cu as a main component and a precipitate formed in the matrix phase, and the precipitate is composed of an element M single phase and/or a compound Cu.sub.XM.sub.Y, where X and Y each represent a natural number and a ratio X/Y of X to Y is 1.0 to 5.0.

4. The shaped article according to claim 3, wherein the precipitate has a size of 0.01 to 20 μm.

Description

EXAMPLES

[0065] The following examples will demonstrate the advantageous effects of the present invention, although the invention should not be construed as being limited to the description of the examples.

[0066] [Production of Powder] [0067] In each example, a material having a predetermined composition was heated to melt in an alumina crucible by high-frequency induction heating under vacuum. The molten metal was dropped through a nozzle with a diameter of 5 mm at the bottom of the crucible. Argon gas or nitrogen gas was sprayed to the molten metal to form a Cu-based alloy powder. Tables 1 to 3 show the details of the compositions of powders.

[0068] [Forming] [0069] Each of the powders was used as raw material for an additive manufacturing process using a three-dimensional additive manufacturing system (EOS-M280) to produce an unheated shaped article. Tables 1 to 3 show energy densities E.D. in the additive manufacturing process. The shaped articles were each a cube with a side of 10 mm.

[0070] [Heat Treatment] [0071] Unheated shaped articles were subjected to a heat treatment (aging treatment). Tables 1 to 3 below show the aging temperature and aging time.

[0072] [Identification of Precipitate] [0073] A test piece with dimensions of 10 mm cube (10×10×10 mm) of each Example was processed with a focused ion beam (FIB) to form a thin film of the test piece. The resulting thin film was observed with a transmission electron microscope (TEM) to identify the composition and size of the compound at ten locations (each location had an area of 2 μm×2 μm) selected arbitrarily. Tables 1 to 3 below show the results.

[0074] [Measurement of Electric Conductivity] [0075] Test pieces each having dimensions of 3×2×60 mm were prepared. The electric resistance (Ω) of each test piece was measured by a four terminal method in accordance with “JIS C 2525” using a measurement system “TER-2000RH” available from ULVAC-RIKO, Inc. under the following conditions:

[0076] Temperature: 25° C.

[0077] Current: 4A

[0078] Voltage drop distance: 40 mm.

[0079] The electric resistivity ρ (Ωm) was calculated by the following expression:

ρ=R/I×S

where R represents the electric resistance (Ω) of the test piece, I representing the current (A), and S representing the cross-sectional area (m.sup.2) of the test piece. The electric conductivity (S/m) was calculated from the reciprocal of the electric resistivity p. The electric conductivity (% IACS) of each test piece was calculated where 5.9×10.sup.7(S/m) was defined as 100% IACS. Tables 1 to 3 below show the results.

[0080] [Rating] [0081] The powders were rated on the following criteria: [0082] Rating 1: The powder satisfies both of the following conditions (a) and (b): [0083] (a) electric conductivity 90% IACS, and [0084] (b) 0.2 D50/TD 20; [0085] Rating 2: The powder satisfies both of the following conditions (a) and (b): [0086] (a) 70% IACS electric conductivity <90% IACS, and [0087] (b) 0.2 D50/TD 20; [0088] Rating 3: The powder satisfies both of the following conditions (a) and (b): [0089] (a) 50% IACS electric conductivity <70% IACS, and [0090] (b) 0.2≤D50/TD≤20; [0091] Rating 4: The powder satisfies both of the following conditions (a) and (b): [0092] (a) 30% IACS electric≤conductivity<50% IACS, and [0093] (b) 0.2≤D50/TD≤20; and [0094] Rating 5: The powder satisfies any of the following conditions (a) to (c): [0095] (a) electric conductivity<30% IACS, [0096] (b) D50/TD<0.2, or [0097] (c) D50/TD>20.

TABLE-US-00001 TABLE 1 Element and content P TD D50/TD E.D. (mass %) (mass %) (Mg/m.sup.3) (10.sup.−5 m.sup.4/Mg) (J/mm.sup.3) Ex. 1 V 0.1 — — — — 0.1 0.4 12 120 Ex. 2 V 5.0 — — — — 5.0 0.4 14 120 Ex. 3 Fe 0.1 — — — — 0.1 0.4 10 120 Ex. 4 Fe 5.0 — — — — 5.0 0.5 12 120 Ex. 5 Zr 0.1 — — — — 0.1 0.5 14 120 Ex. 6 Zr 5.0 — — — — 5.0 0.5 10 120 Ex. 7 Nb 0.1 — — — — 0.1 0.5 0.2 80 Ex. 8 Nb 5.0 — — — — 5.0 0.5 0.5 80 Ex. 9 Hf 0.1 — — — — 0.1 0.5 10 120 Ex. 10 Hf 5.0 — — — — 5.0 0.5 15 120 Ex. 11 Ta 0.1 — — — — 0.1 0.4 12 120 Ex. 12 Ta 5.0 — — — — 5.0 0.5 12 120 Ex. 13 V 1.0 Nb 0.5 — — 1.5 0.4 10 120 Ex. 14 V 1.0 Ta 3.0 — — 4.0 0.4 8 120 Ex. 15 Fe 1.0 Nb 0.5 — — 1.5 0.6 12 120 Ex. 16 Fe 1.0 Hf 3.0 — — 4.0 0.6 12 120 Ex. 17 Zr 1.0 V 0.5 — — 1.5 0.4 14 120 Ex. 18 Zr 1.0 Fe 3.0 — — 4.0 0.4 13 120 Ex. 19 Nb 1.0 Zr 0.5 — — 1.5 0.5 15 120 Heat Relative Treatment Compound Electric density Temp. Time Size Conductivity (%) (° C.) (h) X/Y (μm) (% IACS) Rating Ex. 1 95.8 500 5 4.5 0.5 35 4 Ex. 2 99.4 500 5 4.0 2 70 2 Ex. 3 95.6 500 5 3.5 3 35 4 Ex. 4 99.3 500 5 4.5 0.5 75 2 Ex. 5 98.5 500 5 4.0 2 90 1 Ex. 6 99.8 500 5 3.5 3 85 2 Ex. 7 92.0 500 5 5.0 0.1 25 5 Ex. 8 98.4 500 5 4.0 3 45 4 Ex. 9 91.9 500 5 3.5 5 28 5 Ex. 10 99.9 500 5 3.5 0.01 50 3 Ex. 11 93.4 500 5 3.0 1 23 5 Ex. 12 98.3 500 5 2.0 2 80 2 Ex. 13 98.5 500 1 3.0 0.01 45 4 Ex. 14 99.0 500 3 2.0 1 60 3 Ex. 15 98.3 500 5 1.0 2 65 3 Ex. 16 99.0 500 5 4.5 1 70 2 Ex. 17 97.8 800 5 4.0 5 85 2 Ex. 18 99.2 1000 5 3.5 7 90 1 Ex. 19 96.0 500 5 3.5 0.01 40 4

TABLE-US-00002 TABLE 2 Element and content P TD D50/TD E.D. (mass %) (mass %) (Mg/m.sup.3) (10.sup.−5 m.sup.4/Mg) (J/mm.sup.3) Ex. 20 Nb 1.0 Ta 3.0 — — 4.0 0.5 12 120 Ex. 21 V 1.0 Fe 0.5 Zr 0.5 2.0 0.3 12 120 Ex. 22 V 1.0 Zr 0.5 Nb 0.5 2.0 0.2 10 120 Ex. 23 Fe 1.0 Zr 0.5 Ta 0.5 2.0 0.4 8 120 Ex. 24 Fe 1.0 Nb 0.5 Ta 0.5 2.0 0.4 12 120 Ex. 25 Zr 1.0 Nb 0.5 Ta 0.5 2.0 0.4 15 120 Ex. 26 Zr 1.0 Hf 0.5 Ta 0.5 2.0 0.4 18 120 Ex. 27 Nb 1.0 Ta 0.5 V 0.5 2.0 0.4 5 350 Ex. 28 Nb 1.0 Fe 0.5 V 0.5 2.0 0.4 20 350 Comp Ex. 1 Ti 1.0 — — — — 0.0 0.5 7 120 Comp Ex. 2 Ti 5.0 — — — — 0.0 0.5 10 120 Comp Ex. 3 Co 1.0 — — — — 0.0 0.5 8 120 Comp Ex. 4 Co 5.0 — — — — 0.0 0.5 9 120 Comp Ex. 5 Ni 1.0 — — — — 0.0 0.5 11 120 Comp Ex. 6 Ni 5.0 — — — — 0.0 0.5 12 120 Comp Ex. 7 Cd 1.0 — — — — 0.0 0.5 15 120 Comp Ex. 8 Cd 5.0 — — — — 0.0 0.5 21 120 Comp Ex. 9 Zr 1.0 Al 0.1 — — 1.0 0.5 9 120 Comp Ex. 10 Zr 1.0 Al 4.0 — — 1.0 0.5 8 120 Heat Relative Treatment Compound Electric density Temp. Time Size Conductivity (%) (° C.) (h) X/Y (μm) (% IACS) Rating Ex. 20 98.4 500 5 3.0 1 55 3 Ex. 21 99.5 350 10 2.0 2 60 3 Ex. 22 98.4 500 5 3.5 0.01 65 3 Ex. 23 98.6 500 5 2.0 4 55 3 Ex. 24 98.3 500 5 1.0 2 60 3 Ex. 25 98.3 500 5 4.5 0.5 80 2 Ex. 26 99.9 500 5 3.5 7 85 2 Ex. 27 96.0 500 5 3.5 11 60 3 Ex. 28 96.5 500 5 2.5 2 60 3 Comp Ex. 1 98.6 500 5 3.5 0.05 20 5 Comp Ex. 2 99.4 500 5 2.0 5 25 5 Comp Ex. 3 98.5 500 5 3.5 0.08 18 5 Comp Ex. 4 99.8 500 5 4.0 4 20 5 Comp Ex. 5 98.3 500 5 2.0 0.05 15 5 Comp Ex. 6 99.4 500 5 0.5 7 20 5 Comp Ex. 7 98.5 500 5 2.5 0.1 25 5 Comp Ex. 8 99.3 500 5 3.0 3 30 5 Comp Ex. 9 98.0 500 5 2.5 0.1 40 5 Comp Ex. 10 98.7 500 5 0.5 4 45 5

TABLE-US-00003 TABLE 3 Element and content P TD D50/TD E.D. (mass %) (mass %) (Mg/m.sup.3) (10.sup.−5 m.sup.4/Mg) (J/mm.sup.3) Comp Ex. Zr 1.0 Mg 0.1 — — 1.0 0.4 11 120 11 Comp Ex. Zr 1.0 Mg 4.0 — — 1.0 0.4 10 120 12 Comp Ex. Fe 1.0 Mn 0.1 — — 1.0 0.5 6 120 13 Comp Ex. Fe 1.0 Mn 4.0 — — 1.0 0.5 5 120 14 Comp Ex. Fe 1.0 Ga 0.1 — — 1.0 0.5 9 120 15 Comp Ex. Fe 1.0 Ga 4.0 — — 1.0 0.5 12 120 16 Comp Ex. Ti 1.0 V 1.0 Nb 1.0 2.0 0.5 10 120 17 Comp Ex. Co 1.0 V 1.0 Nb 1.0 2.0 0.5 8 120 18 Comp Ex. Ni 1.0 Fe 1.0 Hf 1.0 2.0 0.5 15 120 19 Comp Ex. Cd 1.0 Fe 1.0 Hf 1.0 2.0 0.5 10 120 20 Comp Ex. Mg 1.0 Zr 1.0 Ta 1.0 2.0 0.5 12 120 21 Comp Ex. Mn 1.0 Zr 1.0 Ta 1.0 2.0 0.5 15 120 22 Heat Relative Treatment Compound Electric density Temp Time Size Conductivity (%) (° C.) (h) X/Y (μm) (% IACS) Rating Comp Ex. 98.4 500 5 2.0 0.3 30 5 11 Comp Ex. 99.2 500 5 2.0 3 35 5 12 Comp Ex. 98.0 500 5 2.5 0.3 28 5 13 Comp Ex. 99.6 500 5 3.5 5 30 5 14 Comp Ex. 99.1 500 5 2.0 0.3 35 5 15 Comp Ex. 99.7 500 5 3.5 7 38 5 16 Comp Ex. 99.4 500 5 4.0 0.2 54 5 17 Comp Ex. 99.5 500 5 2.5 4 50 5 18 Comp Ex. 99.9 500 5 3.0 40 44 5 19 Comp Ex. 98.7 500 5 4.5 3 46 5 20 Comp Ex. 99.9 500 5 6.0 4 50 5 21 Comp Ex. 99.9 500 5 6.0 45 35 5 22

[0098] The results in Tables 1 to 3 evidentially demonstrate advantageous effects of the present invention.

[0099] The powder according to the present invention is also suitable for 3D printers that discharge powder from nozzles. The powder is also suitable for laser coating processes involving discharge of powder from nozzles.