HIGH STRENGTH AND WEAR RESISTANT MULTI-ELEMENT COPPER ALLOY AND ARTICLE COMPRISING THE SAME

Abstract

A high strength and wear resistant multi-element copper alloy is disclosed. The multi-element copper alloy comprises: 80-90 atomic percent Cu, 0.1-4 atomic percent Al, 6-10 atomic percent Ni, 0.1-3 atomic percent Si, 0.1-2 atomic percent V and/or Nb, and 0.1-2 atomic percent M. Experimental data reveal that, after being applied with an aging treatment under 450 degrees Celsius for 50 hours, hardness and strength of the multi-element copper alloy are both significantly enhanced because of age hardening, and softening due to overaging is not observed on the multi-element copper alloy. Moreover, measurement data have indicated that, this novel multi-element copper alloy exhibits better wear resistance superior to that of the conventional copper alloys.

Claims

1. A high strength and wear resistant multi-element copper alloy, having a wear resistance greater than 415 m/mm.sup.3, and having an elemental composition of Cu.sub.wAl.sub.xNi.sub.ySi.sub.zN.sub.mM.sub.s; wherein w, x, y, z, m, and s are numeric values of Cu, Al, Ni, Si, N, and M in atomic percent, respectively; wherein N represents at least one refractory element selected from a group consisting of Nb and V, and M represents at least one additive element selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B; and wherein w, x, y, z, m, ands satisfy 80≤w≤90, 0.1≤x≤4, 6≤y≤10, 0.1≤z≤3, 0.1≤m≤2, and 0.1≤s≤2.

2. The high strength and wear resistant multi-element copper alloy of claim 1, being produced by using a manufacturing method selected from a group consisting of: vacuum arc melting process, electric resistance wire heating process, electric induction heating process, and rapid solidification process.

3. The high strength and wear resistant multi-element copper alloy of claim 1, being further processed to be a semi-finished product or a product through a plastic deformation that is selected from a group consisting of casting process, forging process, extrusion process, and wire drawing process.

4. The high strength and wear resistant multi-element copper alloy of claim 1, being further processed to a composite metal structure by being combined with at least one metal article.

5. The high strength and wear resistant multi-element copper alloy of claim 1, being processed to be in an as-cast state or a homogenization state.

6. The high strength and wear resistant multi-element copper alloy of claim 1, wherein the high strength and wear resistant multi-element copper alloy is in an age-hardened state after receiving a precipitation hardening treatment.

7. An article, being made of the high strength and wear resistant multi-element copper alloy having an elemental composition of Cu.sub.wAl.sub.xNi.sub.ySi.sub.zN.sub.mM.sub.s; wherein w, x, y, z, m, and s are numeric values of Cu, Al, Ni, Si, N, and M in atomic percent, respectively; wherein N represents at least one refractory element selected from a group consisting of Nb and V, and M represents at least one additive element selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B; and wherein w, x, y, z, m, and s satisfy 80≤w≤90, 0.1≤x≤4, 6≤y≤10, 0.1≤z≤3, 0.1≤m≤2, and 0.1≤s≤2.

8. A high strength and wear resistant multi-element copper alloy, having a wear resistance greater than 475 m/mm.sup.3, and having an elemental composition of Cu.sub.wAl.sub.xNi.sub.ySi.sub.zN.sub.mM.sub.s; wherein w, x, y, z, m, and s are numeric values of Cu, Al, Ni, Si, N, and M in atomic percent, respectively; wherein N represents at least one refractory element selected from a group consisting of Nb and V, and M representing at least one additive element selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B; and wherein w, x, y, z, m, and s satisfy 97≤w≤98.5, x≤0.1, 0.2≤y≤0.45, 0.1≤z≤0.3, 0.1≤m≤0.6, and 0.1≤s≤1.6.

9. The high strength and wear resistant multi-element copper alloy of claim 8, being produced by using a manufacturing method selected from a group consisting of: vacuum arc melting process, electric resistance wire heating process, electric induction heating process, and rapid solidification process.

10. The high strength and wear resistant multi-element copper alloy of claim 8, being further processed to be a semi-finished product or a product through a plastic deformation that is selected from a group consisting of casting process, forging process, extrusion process, and wire drawing process.

11. The high strength and wear resistant multi-element copper alloy of claim 8, being further processed to a composite metal structure by being combined with at least one metal article.

12. The high strength and wear resistant multi-element copper alloy of claim 8, being processed to be in an as-cast state or a homogenization state.

13. The high strength and wear resistant multi-element copper alloy of claim 8, wherein the high strength and wear resistant multi-element copper alloy is in an age-hardened state after receiving a precipitation hardening treatment.

14. An article, being made of the high strength and wear resistant multi-element copper alloy having an elemental composition of Cu.sub.wAl.sub.xNi.sub.ySi.sub.zN.sub.mM.sub.s; wherein w, x, y, z, m, and s are numeric values of Cu, Al, Ni, Si, N, and M in atomic percent, respectively; wherein N represents at least one refractory element selected from a group consisting of Nb and V, and M representing at least one additive element selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B; and wherein w, x, y, z, m, and s satisfy 97≤w≤98.5, x≤0.1, 0.2≤y≤0.45, 0.1≤z≤0.3, 0.1≤m≤0.6, and 0.1≤s≤1.6.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The invention as well as a preferred mode of use and advantages thereof will be best understood by referring to the following detailed descriptions of an illustrative embodiment in conjunction with the accompanying drawings, wherein:

[0022] FIG. 1 shows a curve graph of time versus hardness;

[0023] FIG. 2 shows a curve graph of aging time versus hardness; and

[0024] FIG. 3 shows a curve graph of aging time versus hardness.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] To more clearly describe a high strength and wear resistant multi-element copper alloy and article comprising the same, embodiments of the present invention will be described in detail with reference to the attached drawings hereinafter.

First Embodiment

[0026] In the first embodiment, the high strength and wear resistant multi-element copper alloy is designed to have an elemental composition of Cu.sub.wAl.sub.xNi.sub.ySi.sub.zN.sub.mM.sub.s, so as to exhibit a specific property of wear resistance greater than 415 m/mm.sup.3. In which, N represents at least one refractory element selected from a group consisting of Nb and V, and M represents at least one additive element selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B. As described in more detail below, w, x, y, z, m, and s are numeric values of Cu, Al, Ni, Si, N, and M in atomic percent, respectively. Moreover, w, x, y, z, m, and s satisfy 80≤w≤90, 0.1≤x≤4, 6≤y≤10, 0.1≤z≤3, 0.1≤m≤2, and 0.1≤s≤2. For example, the high strength and wear resistant multi-element copper alloy is designed to comprise: 82 at % Cu, 2 at % Al, 9 at % Ni, 3 at % Si, 1 at % V, 1 at % Nb, 1 at % Sn, and 1 at % Mn. In such case, the high strength and wear resistant multi-element copper alloy has an elemental composition of Cu.sub.82Al.sub.2Ni.sub.9Si.sub.3V.sub.1Nb.sub.1Sn.sub.1Mn.sub.1. That is, w=82, x=2, y=9, z=3, m=1+1=2, and s=1+1=2.

Second Embodiment

[0027] In the second embodiment, the high strength and wear resistant multi-element copper alloy is also designed to have an elemental composition of Cu.sub.wAl.sub.xNi.sub.ySi.sub.zN.sub.mM.sub.s, thereby exhibiting a specific property of wear resistance greater than 475 m/mm.sup.3. In which, N represents at least one refractory element selected from a group consisting of Nb and V, and M represents at least one additive element selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B. As described in more detail below, w, x, y, z, m, and s are numeric values of Cu, Al, Ni, Si, N, and M in atomic percent, respectively. Moreover, w, x, y, z, m, and s satisfy 97≤w≤98.5, x≤0.1, 0.2≤y≤0.45, 0.1≤z≤0.3, 0.1≤m≤0.6, and 0.1≤s≤1.6. For instance, the high strength and wear resistant multi-element copper alloy is designed to comprise: 97 at % Cu, 0.1 at % Al, 0.45 at % Ni, 0.25 at % Si, 0.3 at % V, 0.3 at % Nb, 0.45 at % Zr, 0.45 at % Cr, 0.45 at % Ti, and 0.25 at % C. In such case, the high strength and wear resistant multi-element copper alloy has an elemental composition of Cu.sub.97Al.sub.0.1Ni.sub.0.45Si.sub.0.25V.sub.0.3Nb.sub.0.3Zr.sub.0.45Cr.sub.0.45Ti.sub.0.45C.sub.0.25. That is, w=97, x=0.1, y=0.45, z=0.25, m=0.3+0.3=0.6, and s=0.45+0.45+0.45+0.25=1.6.

[0028] The high strength and wear resistant multi-element copper alloy according to the present invention can be produced by using a specific manufacturing method, such as vacuum arc melting process, electric resistance wire heating process, electric induction heating process, or rapid solidification process. Moreover, according to different applications, material engineers are able to process the high strength and wear resistant multi-element copper alloy of the present invention to a semi-finished product or a product through a plastic deformation, e.g., casting process, forging process, extrusion process, or wire drawing process. Furthermore, according to different applications, the high strength and wear resistant multi-element copper alloy can also be processed to a composite metal structure by being combined with at least one metal article.

[0029] In a nutshell, the present invention discloses a high strength and wear resistant multi-element copper alloy having excellent wear resistance. The high strength and wear resistant multi-element copper alloy has a significant potential for replacing the conventional copper alloys so as to be applied in the manufacture of a variety of parts and/or components, which are demanded to possess excellent wear resistance, such as bearing, gear, piston, connector, conductor rail, lead frames, relay, probe, etc. Notably, for proving that the forgoing two embodiments of the high strength and wear resistant multi-element copper alloy of the present invention can indeed be made, inventors of the present invention have conducted a number of experiments.

[0030] First Experiment

[0031] In the first experiment, 12 samples of the high strength and wear resistant multi-element copper alloy according to the present invention are fabricated by vacuum arc melting process. The following table (1) lists each sample's elemental composition. Moreover, homogenization process, precipitation hardening process, hardness measurement, and dry sliding wear test for the 12 samples are also completed. It is worth explaining that, the high strength and wear resistant multi-element copper alloy in an as-cast state can be further homogenized to, so as to be a homogenization state. Homogenization mitigates the effects of dendritic segregation during solidification and generates a more uniform chemical composition within the alloy, thereby enhancing the precipitation hardening effect during the age hardening treatment of the high strength and wear resistant multi-element copper alloy.

[0032] The dry sliding wear test is carried out by operating a pin-on-disk test machine. The disk is made from SKD-61, and 12 test specimens, having dimensions of 8 mm in diameter and 3 mm in thickness, are cut from 12 samples of the high strength and wear resistant multi-element copper alloy, respectively. When conducting the dry sliding wear test, the test specimen is held pressed against a rotating SKD-61 disk by applying load that acts as counter weight and balances the test specimen. The wear resistance of each sample can be calculated by using formula Wsp=D/V, where D and V are total wear distance and the total wear volume, respectively.

[0033] In the first experiment, all samples are applied with a homogenization process at 900 degrees Celsius for 6 hours, and are subsequently applied with an age hardening process at 450 degrees Celsius for 50 hours. Therefore, related measurement data of the 12 samples are recorded in the following table (1).

TABLE-US-00001 TABLE (1) Hardness (HV) homo- age- wear high strength and wear resistant multi- geni- hard- resis- element copper alloy zation ened tance Samples Elemental composition state state (m/mm.sup.3) No. 1 Cu.sub.82Al.sub.4Ni.sub.10Si.sub.3V.sub.1 132 282 423 No. 2 Cu.sub.82Al.sub.4Ni.sub.10Si.sub.3Nb.sub.1 135 284 430 No. 3 Cu.sub.82Al.sub.3Ni.sub.9Si.sub.2.5V.sub.1Nb.sub.0.5Cr.sub.1Fe.sub.0.5P.sub.0.5 102 295 457 No. 4 Cu.sub.82Al.sub.2Ni.sub.9Si.sub.3V.sub.1Nb.sub.1Sn.sub.1Mn.sub.1 119 285 477 No. 5 Cu.sub.82Al.sub.3Ni.sub.8Si.sub.3V.sub.1Nb.sub.1Zr.sub.0.5Ti.sub.1Mn.sub.0.5 108 301 490 No. 6 Cu.sub.82Al.sub.3Ni.sub.8Si.sub.3V.sub.1Nb.sub.1Cr.sub.1Mg.sub.0.5C.sub.0.5 185 292 531 No. 7 Cu.sub.88Al.sub.1.5Ni.sub.7.5Si.sub.1Nb.sub.1Zr.sub.0.5P.sub.0.5 104 277 462 No. 8 Cu.sub.88Al.sub.1Ni.sub.8Si.sub.1V.sub.1Ti.sub.0.5Mg.sub.0.3B.sub.0.2 149 281 483 No. 9 Cu.sub.88Al.sub.1Ni.sub.8.5Si.sub.1Nb.sub.0.5Cr.sub.0.5Ti.sub.0.3Fe.sub.0.2 113 284 433 No. 10 Cu.sub.88Al.sub.1Ni.sub.7.5Si.sub.2V.sub.0.5Zr.sub.0.5Mn.sub.0.5 131 272 421 No. 11 Cu.sub.88Al.sub.1.5Ni.sub.7.5Si.sub.1V.sub.0.5Nb.sub.0.3Zr.sub.1Sn.sub.0.2 124 279 418 No. 12 Cu.sub.88Al.sub.1.5Ni.sub.7.5Si.sub.1V.sub.1Cr.sub.0.5Fe.sub.0.2C.sub.0.3 157 287 513

[0034] As described in more detail below, the table (1) has listed each sample's elemental composition. According to the measurement data recorded in the table (1), it is found that, the alloy wear resistance can indeed be enhanced by making the multi-element copper alloy (CuAlNiSi) further contain at least one additive element (i.e., Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and/or B) with minor addition and at least one refractory element like Nb and/or V. Most important of all, the measurement data recorded in the table (1) have proved that, the high strength and wear resistant multi-element copper alloy of the present invention exhibits outstanding wear resistance superior to that of the conventional C17200 copper-beryllium alloy (390 m/mm.sup.3) Therefore, the high strength and wear resistant multi-element copper alloy according to the present invention has a significant potential for replacing the conventional copper alloy so as to be applied in the manufacture of a variety of parts and/or components, which are demanded to possess excellent wear resistance, such as bearing, gear, piston, connector, conductor rail, lead frames, relay, probe, etc.

[0035] FIG. 2 shows a curve graph of aging time versus hardness of sample No. 3 of the high strength and wear resistant multi-element copper alloy. As explained in more detail below, sample No. 3 of the high strength and wear resistant multi-element copper alloy is regularly applied with an aging treatment under 450 degrees Celsius for 50 hours, and there is no softening due to over-aging occurring on the sample No. 3 even if the aging time is prolonged to 100 hours. As a result, experimental data have proved that, the high strength and wear resistant multi-element copper alloy still exhibits excellent mechanical strength at a high environment temperature, and such important characteristic is found to be a key factor for enhancing the wear resistance of the high strength and wear resistant multi-element copper alloy of the present invention.

[0036] It is worth explaining that, making the multi-element copper alloy (CuAlNiSi) further contain at least one additive element (i.e., Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and/or B) with minor addition and at least one refractory element like Nb and/or V induces competition between elements in the multi-element copper alloy, thereby reducing solid-state diffusion rate of the elements in the alloy. As a result, rate of crystal nucleation in the alloy is reduced, such that the grain of each of the precipitations produced in the alloy grows smaller, thereby enhancing alloy hardness and preventing the alloy from softening due to overaging. For example, because V and Nb are both refractory elements with high melting point, they exhibit low solid-state diffusion rate in a Cu-based principal phase of the multi-element copper alloy. Moreover, there is a strong bonding energy between Si and V or Nb, that makes V—Si and/or Nb—Si compound be precipitated in the alloy as well as slows the formation rate of Ni—Si—V—Nb compound. In conclusion, making the multi-element copper alloy (CuAlNiSi) further contain at least one additive element (i.e., Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and/or B) with minor addition and at least one refractory element like Nb and/or V is helpful in enhancing the wear resistance of the alloy.

[0037] Second Experiment

[0038] In the second experiment, 8 samples of the high strength and wear resistant multi-element copper alloy according to the present invention are also fabricated by vacuum arc melting process. The following table (2) lists each sample's elemental composition. Moreover, homogenization process, precipitation hardening process, hardness measurement, and dry sliding wear test for the 8 samples are also completed. Therefore, related measurement data of the 8 samples are recorded in the following table (2).

TABLE-US-00002 TABLE (3) Hardness (HV) high strength and wear resistant multi- homogeni- age- wear element copper alloy zation hardened resistance Samples Elemental composition state state (m/mm.sup.3) No. 13 Cu.sub.97Al.sub.0.1Ni.sub.0.45Si.sub.0.25V.sub.0.3Nb.sub.0.3Zr.sub.0.45Cr.sub.0.45Ti.sub.0.45C.sub.0.25 92 155 510 No. 14 Cu.sub.97.3Al.sub.0.1Ni.sub.0.45Si.sub.0.3V.sub.0.3Nb.sub.0.2Cr.sub.0.45Fe.sub.0.45Mg.sub.0.3B.sub.0.15 87 149 488 No. 15 Cu.sub.97.3Al.sub.0.1Ni.sub.0.35Si.sub.0.3V.sub.0.45Zr.sub.0.45Ti.sub.0.45Mn.sub.0.45P.sub.0.15 89 152 503 No. 16 Cu.sub.97.75Al.sub.0.1Ni.sub.0.45Si.sub.0.2V.sub.0.25Nb.sub.0.15Cr.sub.0.45Sn.sub.0.2Fe.sub.0.3C.sub.0.15 58 142 479 No. 17 Cu.sub.98Ni.sub.0.35Si.sub.0.2V.sub.0.3Nb.sub.0.2Zr.sub.0.15Cr.sub.0.45Ti.sub.0.2C.sub.0.15 76 134 697 No. 18 Cu.sub.98Al.sub.0.1Ni.sub.0.45Si.sub.0.3Nb.sub.0.25Cr.sub.0.3Sn.sub.0.3Mg.sub.0.15P.sub.0.15 51 135 527 No. 19 Cu.sub.98.15Ni.sub.0.4Si.sub.0.2V.sub.0.15Zr.sub.0.3Cr.sub.0.45Mn.sub.0.2C.sub.0.15 55 139 586 No. 20 Cu.sub.98.5Ni.sub.0.25Si.sub.0.1V.sub.0.25Nb.sub.0.15Zr.sub.0.3Ti.sub.0.3C.sub.0.15 51 130 566

[0039] As described in more detail below, the table (2) has listed each sample's elemental composition. Moreover, FIG. 3 shows a curve graph of aging time versus hardness of sample No. 17 of the high strength and wear resistant multi-element copper alloy. As explained in more detail below, sample No. 17 of the high strength and wear resistant multi-element copper alloy is regularly applied with an aging treatment under 450 degrees Celsius for 50 hours, and there is no softening due to over-aging occurring on the sample No. 17 even if the aging time is prolonged to 100 hours. As a result, experimental data have proved that, the high strength and wear resistant multi-element copper alloy still exhibits excellent mechanical strength at a high environment temperature, and such important characteristic is found to be a key factor for enhancing the wear resistance of the high strength and wear resistant multi-element copper alloy of the present invention.

[0040] According to the measurement data recorded in the table (2), it is found that, making the multi-element copper alloy (CuAlNiSi) further contain at least one additive element (i.e., Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and/or B) with minor addition and at least one refractory element like Nb and/or V induces competition between elements in the multi-element copper alloy, thereby reducing solid-state diffusion rate of the elements in the alloy. As a result, rate of crystal nucleation in the alloy is reduced, such that the grain of each of the precipitations produced in the alloy grows smaller, thereby enhancing alloy hardness and preventing the alloy from softening due to overaging. Most important of all, the measurement data recorded in the table (2) have proved that, the high strength and wear resistant multi-element copper alloy of the present invention exhibits outstanding wear resistance superior to that of the conventional C17200 copper-beryllium alloy (390 m/mm.sup.3) Therefore, the high strength and wear resistant multi-element copper alloy according to the present invention has a significant potential for replacing the conventional copper alloy so as to be applied in the manufacture of a variety of parts and/or components, which are demanded to possess excellent wear resistance, such as bearing, gear, piston, connector, conductor rail, lead frames, relay, probe, etc.

[0041] Therefore, through above descriptions, all embodiments and their experimental data of the high strength and wear resistant multi-element copper alloy according to the present invention have been introduced completely and clearly; in summary, the present invention includes the advantages of:

[0042] (1) The present invention discloses a multi-element copper alloy with high strength and wear resistance, which comprises: 80-90 atomic percent Cu, 0.1-4 atomic percent Al, 6-10 atomic percent Ni, 0.1-3 atomic percent Si, 0.1-2 atomic percent V and/or Nb, and 0.1-2 atomic percent M. In which, M represents at least one additive element that is selected from a group consisting of Zr, Cr, Ti, Sn, Fe, Mn, Mg, C, P, and B. Experimental data reveal that, after being applied with an aging treatment under 450 degrees Celsius for 50 hours, hardness and strength of this novel multi-element copper alloy are both significantly enhanced because of age hardening, and softening due to overaging is not observed on the multi-element copper alloy. Moreover, measurement data have indicated that, this novel multi-element copper alloy exhibits better wear resistance superior to that of the conventional copper alloys. Therefore, the multi-element copper alloy according to the present invention has a significant potential for replacing the conventional copper alloy so as to be applied in the manufacture of a variety of parts and/or components, which are demanded to possess excellent wear resistance, such as bearing, gear, piston, connector, conductor rail, lead frames, relay, probe, etc.

[0043] The above descriptions are made on embodiments of the present invention. However, the embodiments are not intended to limit the scope of the present invention, and all equivalent implementations or alterations within the spirit of the present invention still fall within the scope of the present invention.