Copper alloy casting and method of casting the same

Abstract

Copper alloy casting contains Cu: 58-72.5 mass %; Zr: 0.0008-0.045 mass %; P: 0.01-0.25 mass %; one or more elements selected from Pb: 0.01-4 mass %, Bi: 0.01-3 mass %, Se: 0.03-1 mass %, and Te: 0.05-1.2 mass %; and Zn: a remainder, wherein [Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])=60-90, [P]/[Zr]=0.5-120, and 0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45-4 (the content of an element a is denoted as [a] mass %; the content of phase is denoted as []% by area ratio; and an element a that is not contained is denoted as [a]=0). The total content of phase and phase is 85% or more, phase content is 25% or less by area ratio, and mean grain size in the macrostructure during melt-solidification is 250 m or less.

Claims

1. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])=60 to 90, f2=[P]/[Zr]=0.5 to 120, and f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, wherein the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of the phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

2. The copper alloy casting according to claim 1, wherein when the copper alloy casting contains 0.0079 mass % of Zr, the copper alloy casting has a mean grain size of 35 m in a macrostructure at melt-solidification.

3. The copper alloy casting according to claim 1, wherein when the copper alloy casting satisfies f2=8.9, the copper alloy casting has a mean grain size of 35 m in a macrostructure at melt-solidification.

4. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; Sn: 0.05 to 4 mass % and/or Al: 0.01 to 4 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])0.5[Sn]1.8[Al]=60 to 90, f2=[P]/[Zr]=0.5 to 120, f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, f4=[Zn]+2.5[Sn]+3[Al]=15 to 42, f5=([Zn]+2.5[Sn]+3[Al])/[Zr]=500 to 20000, and f6=([Zn]+2.5[Sn]+3[Al])/[P]=75 to 3000, wherein the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

5. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; As: 0.02 to 0.2 mass % and/or Sb: 0.02 to 0.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])([As]+[Sb])=60 to 90, f2=[P]/[Zr]=0.5 to 120, and f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of -phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

6. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; one or more elements selected from Mn: 0.1 to 5 mass %, Si: 0.05 to 2 mass %, and Mg: 0.001 to 0.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])+[Mn]3.5[Si]0.5[Mg]=60 to 90, f2=[P]/[Zr]=0.5 to 120, and f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, wherein the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of -phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 M or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

7. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; Sn: 0.05 to 4 mass % and/or Al: 0.01 to 4 mass %; As: 0.02 to 0.2 mass % and/or Sb: 0.02 to 0.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])0.5[Sn]1.8[Al]([As]+[Sb])=60 to 90, f2=[P]/[Zr]=0.5 to 120, f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, f4=[Zn]+2.5[Sn]+3[Al]=15 to 42, f5=([Zn]+2.5[Sn]+3[Al])/[Zr]=500 to 20000, and f6=([Zn]+2.5[Sn]+3 [Al])/[P]=75 to 3000, wherein the content of each element a is denoted as [a] mass %, the content of -phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

8. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; Sn: 0.05 to 4 mass % and/or Al: 0.01 to 4 mass %; one or more elements selected from Mn: 0.1 to 5 mass %, Si: 0.05 to 2 mass %, and Mg: 0.001 to 0.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])0.5[Sn]1.8[Al]+[Mn]3.5[Si]0.5[Mg]=60 to 90, f2=[P]/[Zr]=0.5 to 120, f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, f4=[Zn]+2.5[Sn]+3[Al]=15 to 42, f5=([Zn]+2.5[Sn]+3[Al])/[Zr]=500 to 20000, and f6=([Zn]+2.5[Sn]+3[Al])/[P]=75 to 3000, wherein the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

9. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; As: 0.02 to 0.2 mass % and/or Sb: 0.02 to 0.2 mass %; and one or more elements selected from Mn: 0.1 to 5 mass %, Si: 0.05 to 2 mass %, Mg: 0.001 to 0.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])([As]+[Sb])+[Mn]3.5[Si]0.5[Mg]=60 to 90, f2=[P]/[Zr]=0.5 to 120, and f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, wherein the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

10. A copper alloy casting containing: Cu: 58 to 72.5 mass %; Zr: 0.0008 to 0.045 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Pb: 0.01 to 4 mass %, Bi: 0.01 to 3 mass %, Se: 0.03 to 1 mass %, and Te: 0.05 to 1.2 mass %; Sn: 0.05 to 4 mass % and/or Al: 0.01 to 4 mass %; As: 0.02 to 0.2 mass % and/or Sb: 0.02 to 0.2 mass %; one or more elements selected from Mn: 0.1 to 5 mass %, Si: 0.05 to 2 mass %, and Mg: 0.001 to 0.2 mass %; and Zn: a remainder, wherein the copper alloy casting satisfies the following equations, f1=[Cu]3[P]+0.5([Pb]+[Bi]+[Se]+[Te])0.5[Sn]1.8[Al]([As]+[Sb])+[Mn]3.5[Si]0.5[Mg]=60 to 90, f2=[P]/[Zr]=0.5 to 120, f3=0.05[]+([Pb]+[Bi]+[Se]+[Te])=0.45 to 4, f4=[Zn]+2.5[Sn]+3[Al]=15 to 42, f5=([Zn]+2.5[Sn]+3[Al])/[Zr]=500 to 20000, and f6=([Zn]+2.5[Sn]+3[Al])/[P]=75 to 3000, wherein the content of each element a is denoted as [a] mass %, the content of phase is denoted as []% by area ratio, and each element a that is not contained in the copper alloy casting is denoted as [a]=0; wherein the copper alloy casting forms a phase structure in which the total content of phase and phase is 85% or more by area ratio and the content of phase is 25% or less by area ratio; and wherein the copper alloy casting has a mean grain size of 250 m or less in a macrostructure at melt-solidification, and wherein the copper alloy casting has a shape determined by a mold.

11. The copper alloy casting according to any one of claims 1 to 10, the copper alloy casting comprising Fe or Ni, or Fe and Ni as inevitable impurities, wherein when either Fe or Ni is included, the content thereof is restricted to be 0.2 mass % or less, and when both Fe and Ni are contained, the total content of Fe and Ni is restricted to be 0.25 mass % or less.

12. The copper alloy casting according to claim 11, wherein a two-dimensional shape of grains during melt-solidification is circular, substantially circular, oval, cross-like, acicular, or polygonal.

13. The copper alloy casting according to claim 11, wherein the copper alloy casting is a water contact metal fitting used continuously or temporarily in contact with water, or a structural material thereof.

14. A method of casting the copper alloy casting according to claim 11, wherein Zr contained to refine the grains is added during the casting process in a form of a copper based master alloy containing Zr, thereby preventing Zr from being added in a form of an oxide or a sulfide, or in the oxide and sulfide forms.

15. The copper alloy casting according to any one of claims 1 to 10, wherein a primary crystal is phase during melt-solidification.

16. The copper alloy casting according to any one of claims 1 to 10, wherein a peritectic reaction occurs during melt-solidification.

17. The copper alloy casting according to claim 16, wherein the copper alloy casting is a water contact metal fitting used continuously or temporarily in contact with water, or a structural material thereof.

18. A method of casting the copper alloy casting according to claim 16, wherein Zr contained to refine the grains is added during the casting process in a form of a copper based master alloy containing Zr, thereby preventing Zr from being added in a form of an oxide or a sulfide, or in the oxide and sulfide forms.

19. The copper alloy casting according to any one of claims 1 to 10, wherein a dendrite network is divided in a crystal structure during melt-solidification.

20. The copper alloy casting according to any one of claims 1 to 10, wherein a two-dimensional shape of grains during melt-solidification is circular, substantially circular, oval, cross-like, acicular, or polygonal.

21. The copper alloy casting according to claim 20, wherein the copper alloy casting is a water contact metal fitting used continuously or temporarily in contact with water, or a structural material thereof.

22. A method of casting the copper alloy casting according to claim 20, wherein Zr contained to refine the grains is added during the casting process in a form of a copper based master alloy containing Zr, thereby preventing Zr from being added in a form of an oxide or a sulfide, or in the oxide and sulfide forms.

23. The copper alloy casting according to any one of claims 1 to 10, wherein phase is divided finely in a matrix, and phase or high Sn-concentrated area that is generated by segregation is distributed uniformly in the matrix.

24. The copper alloy casting according to any one of claims 1 to 10, wherein, when the copper alloy casting contains Pb or Bi, Pb particles or Bi particles having a uniform diameter are distributed uniformly in the matrix.

25. The copper alloy casting according to any one of claims 1 to 10, wherein the copper alloy casting is a water contact metal fitting used continuously or temporarily in contact with water, or a structural material thereof.

26. A method of casting the copper alloy casting according to claim 25, wherein Zr contained to refine the grains is added during the casting process in a form of a copper based master alloy containing Zr, thereby preventing Zr from being added in a form of an oxide or a sulfide, or in the oxide and sulfide forms.

27. The copper alloy casting according to any one of claims 1 to 10, wherein the copper alloy casting is a friction engaging member making a relative movement to a facing member continuously or temporarily in contact with the facing member, or a structural material thereof.

28. A method of casting the copper alloy casting according to claim 27, wherein Zr contained to refine the grains is added during the casting process in a form of a copper based master alloy containing Zr, thereby preventing Zr from being added in a form of an oxide or a sulfide, or in the oxide and sulfide forms.

29. A method of casting the copper alloy casting according to any one of claims 1 to 10, wherein Zr contained to refine the grains is added during the casting process in a form of a copper based master alloy containing Zr, thereby preventing Zr from being added in a form of an oxide or a sulfide, or in the oxide and sulfide forms.

30. The method of casting the copper alloy casting according to claim 29, wherein the copper based master alloy containing Zr is a CuZr alloy, a CuZnZr alloy or an alloy further containing one or more elements selected from P, Mg, Al, Sn, Mn and B in addition to the said CuZr alloy or CuZnZr alloy.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 includes photos of etched surfaces (cross-sectional surfaces) of an embodiment No. 16, in which FIG. 1A shows a macrostructure, and FIG. 1B shows a microstructure.

(2) FIG. 2 includes photos of etched surfaces (cross-sectional surfaces) of a comparative example No. 204, in which FIG. 2A shows a macrostructure, and FIG. 2B shows a microstructure.

(3) FIG. 3 includes X-ray micro-analyzer photos of the etched surface (cross-sectional surface) of the embodiment No. 16, in which FIG. 3A shows a composition image; FIG. 3B shows the distribution of Sn; and FIG. 3C shows the distribution of Pb.

(4) FIG. 4 includes X-ray micro-analyzer photos of the etched surface (cross-sectional surface) of the comparative example No. 204, in which FIG. 4A shows a composition image; FIG. 4B shows the distribution of Sn; and FIG. 4C shows the distribution of Pb.

(5) FIG. 5 includes cross sectional views showing a result of the tatur shrinkage test, in which FIG. 5A shows good test result; FIG. 5B shows fair test result; and FIG. 5C shows poor test result.

(6) FIG. 6 is a front view of a vertically cross-sectioned test piece showing the casting state in a casting crack test.

(7) FIG. 7 includes front views showing test pieces cast in the casting crack test, in which FIG. 7A shows a test piece with no crack; FIG. 7B shows a test piece with a minute crack; and FIG. 7C shows a test piece with a noticeable crack.

(8) FIG. 8 includes perspective views showing the forms of chips generated during the machining test.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment

(9) As embodiments, the alloying materials listed in Tables 1 to 4 are melted in an electric furnace, and then each molten alloy obtained is poured into a iron-made mold preheated up to 200 C. so as to cast cylindrical (diameter: 40 mm, and length: 280 mm) castings (hereinafter referred to as embodiments) Nos. 1 to 107. In this case, Zr is added to each molten alloy in a granular form of CuZnZr alloy (a cubic body having several mm long sides) right before pouring in order to prevent Zr from being added in the form of oxide and/or sulfide. In addition, the pouring temperature is set at 100 C. above the liquidus line temperature of each copper alloy.

(10) In addition, as comparative examples, the alloying materials listed in Table 5 are melted in an electric furnace, and then each molten alloy is poured into an iron-made mold preheated up to 200 C. under the same conditions as those of the embodiments so as to cast cylindrical (diameter: 40 mm, length: 280 mm) castings (hereinafter referred to as comparative examples) Nos. 201 to 222.

(11) A No. 10 specimen pursuant to JIS Z 2201 is taken from each embodiment and each comparative example, and then tensile strength test is performed on each specimen by an AMSLER universal testing machine in order to measure the tensile strength (N/mm.sup.2), 0.2% proof stress (N/mm.sup.2), elongation (%), and fatigue strength (N/mm.sup.2). The results are illustrated in Tables 6 to 10.

(12) In order to verify the wear resistance (slidability) of the embodiments and the comparative examples, wear test is performed as follows.

(13) First of all, a ring specimen having the outer diameter of 32 mm and the thickness (axial direction length) of 10 mm is obtained from each embodiment and each comparative example by machining, drilling or the like. Next, the ring specimen is fit with a rotating shaft and then rotated with a load of 25 kg applied to the ring specimen by making a SUS304-made roll (outer diameter 48 mm) in contact with the outer circumferential surface of the ring specimen. After that, the rotating shaft is rotated at a speed of 209 r.p.m. while multipurpose oil is being dropped onto the outer circumferential surface of the specimen. When the specimen rotates hundred thousand times, the rotation of the specimen is stopped, and the mass difference before and after the rotation, that is, wear loss (mg) is measured. It can be said that a copper alloy showing smaller wear loss has more excellent wear resistance. The results are shown in Tables 6 to 10.

(14) In order to verify the corrosion resistance of the embodiments and the comparative examples, the following erosion corrosion tests I to IV and the dezincification corrosion test designated as ISO 6509 are performed.

(15) For the erosion corrosion tests I to IV, test liquid (30 C.) is sprayed at a specimen taken from each casting through a 1.9 mm diameter nozzle at a speed of 11 m/sec in a perpendicular direction to the axes of the specimen. After a given time, the mass loss (mg/cm.sup.2) is measured. As the test liquid, 3% saline solution is used for test I, a mixed saline solution of 3% saline solution and CuCl.sub.2.2H.sub.2O (0.13 g/L) for test II, a mixed liquid of Sodium Hypochlorite Ingestion (NaClO) with a small addition of hydrochloric acid (HCl) for test III, and a 3% saline solution containing glass beads of 0.115 mm in average diameter (5 vol %) for test IV. The mass loss is the mass difference per one square centimeter (mg/cm.sup.2) between the mass of the original specimen (before the test) and that of the specimen after T hours of being sprayed at with the test liquid. The testing time T (duration of spraying) is 96 hours for test I to III, and 24 hours for test IV. The results of the erosion corrosion test are illustrated in Tables 6 to 10.

(16) For the dezincification corrosion test of ISO 6509, a specimen taken from each embodiment and each comparative example is embedded in a phenolic resin material so that the exposed surface of the specimen is perpendicular to the expanding direction of the specimen; and then the surface is polished with Emery paper up to No. 1200. After that, the surface is ultrasonic-cleaned in pure water and then dried. The corrosion test specimen thus prepared is soaked in an aqueous solution of 1.0% Cupric Chloride Dihydrate (CuCl.sub.2.2H.sub.2O) for 24 hours at 75 C., and then the specimen is taken out of the aqueous solution. After that, the maximum depth of dezincification corrosion, that is, the maximum dezincification corrosion depth (m) is measured. The results are illustrated in Tables 6 to 10.

(17) In addition, in order to verify the machinability of the embodiments and the comparative examples, the following cutting test is performed, and the main cutting force (N) is measured.

(18) That is, each casting of the invention is cut on the outer circumferential surface under the dry condition by a lathe having a point nose straight tool (rake angle: 6, and nose radius: 0.4 mm) at a cutting speed of 100 m/minute, a cutting depth of 1.5 mm, and a feed rate of 0.11 mm/rev. The cutting force is measured by three component dynamometers attached to the bite and then calculated into the main cutting force. The results are shown in Tables 6 to 10.

(19) Furthermore, the state of chips generated in the cutting test is observed, and the machinability of the copper alloy castings is determined by classifying the chips into seven categories on the basis of the shapes of chips: (a) trapezoidal or triangular small segment shape (FIG. 8A), (b) tape shape having a length of 25 mm or less (FIG. 8B), (c) acicular shape (FIG. 8C), (d) tape shape as long as 75 mm or less (excluding (b)) (FIG. 8D), (e) spiral shape having three or less windings (FIG. 8E), (f) tape shape longer than 75 mm (FIG. 8F), and (g) spiral shape having more than three windings (FIG. 8G). The results are shown in Tables 6 to 10. That is, when the chips have the shapes of (f) and (g), the chips are hard to handle (recovery, recycling or the like), and also cause the following troubles: the chips get tangled with the bite of a cutting tool; cut surfaces are damaged; or the like. As a result, satisfactory cutting work cannot be performed. In addition, when the chips have the shapes of (d) and (e), though they do not cause such serious troubles as those of (f) and (g), the chips of (d) and (e) are still hard to handle. They are likely to get tangled with the bite or cut surfaces may be damaged when a continuous cutting work is performed. On the other hand, when the chips have the shapes of (a) to (c), the troubles as described above are not induced, and the chips can be easily handled since they are not bulky unlike the chips of (f) and (g). However, in case the chips have the shape of (c), the chips are likely to creep in on the sliding table of a machine tool such as a lathe or the like under a certain working condition and cause mechanical problems, or the chips can be hazardous as they stick the operator in the eye or the finger. Therefore, in the determination of machinability, the shapes of (a) and (b) (particularly (a)) are graded as the best; the shape of (c) is graded as the second best; the shapes of (d) and (e) are graded as industrially acceptable; and the shapes of (f) and (g) are graded as unacceptable. In Tables 6 to 10, chips of (a) and (b) graded as the best are denoted as ; chips of (c) graded as the second best are denoted as ; chips having the acceptable shapes of (d) and (e) are denoted as ; and chips of (f) and (g) graded as unacceptable are denoted as x. Among the embodiments, on which the cutting test is performed, no chips denoted as x are observed.

(20) From the test results described above, it is verified that the embodiments are superior in machinability, mechanical properties (strength, elongation or the like) wear resistance and corrosion resistance to the comparative examples. In addition, although it is commonly considered that elongation is lowered by grain refinement, the result of the tensile strength test shows that the elongation of the copper alloy casting of the invention does not decrease by the grain refinement, but rather improves.

(21) In addition, in order to evaluate cold workability of the embodiments and the comparative examples, the following cold compression test is performed.

(22) That is, a cylindrical specimen of 5 mm in diameter and 7.5 mm in length is machined by a lathe from each embodiment and each comparative example, and then compressed by the AMSLER universal test machine. After that, the cold workability is evaluated on the basis of the relation between the existence of cracks and the compression rate (processing rate). The results are illustrated in Tables 6 to 8 and 10. In the tables, specimens having cracks at the compression rate of 35% are denoted as x to indicate poor cold workability; specimens having no crack at the compression rate of 50% are denoted as to indicate good cold workability; and specimens having no crack at the compression rate of 35%, but having cracks at the compression rate of 50% are denoted as to indicate fair cold workability. The cold compression workability can also be appreciated as caulking workability, and castings denoted as can be caulked easily and precisely; castings denoted as can be caulked fairly well; and castings denoted as x cannot be caulked properly. It is verified that all the embodiments, on which the cold compression workability test is performed, are evaluated or , that is, they have excellent cold workability or caulking workability.

(23) Furthermore, the metal structure (phase structure) after melt-solidification of each embodiment and each comparative example at room temperature is verified, and the area ratios (%) of phase and phase are measured by image analysis. That is, the structure of each casting, magnified 200 times by an optical microscope, is expressed in the binary system with an image processing software WinROOF, and then the area ratio of each phase is measured. The area ratio is measured in three different fields, and the average value of the three area ratios is regarded as the phase ratio of each phase. The results of the metal structures are illustrated in Table 1 to 5, and the results of the total area ratio of and phases and the area ratio of phase are illustrated in Tables 6 to 10. All the embodiments satisfy the condition (4). In addition, Tables 1 to 5 show what the primary crystal was during melt-solidification in casting process. All the embodiments satisfy the condition (9). Meanwhile, the embodiments containing a large amount of phase are annealed in order to increase the amount of phase, and thus the embodiments can have excellent properties due to the increased ratio of phase.

(24) Still furthermore, the mean grain size (m) of each embodiment and each comparative example during melt-solidification is measured. That is, a casting is cut, and the cross-sectional surface is etched by nitric acid. After that, the mean grain size of the microstructure displayed on the etched surface is measured. The measurement is based on the comparative method for estimating average grain size of wrought copper and copper alloys according to JIS H0501, in which grains having the diameter of more than 0.5 mm are observed by naked eyes, and grains having the diameter of 0.5 mm or less are magnified 7.5 times and then observed after the cut surface is etched by nitric acid. In addition, grains having the diameter of less than approx. 0.1 mm are etched by a mixed liquid of hydrogen peroxide and ammonia water and then magnified 75 times by an optical microscope for observation. The results are illustrated in Tables 6 to 10, and all the embodiments satisfy the condition (5). Meanwhile, in the comparative example No. 222 containing a proper amount of Zr but no content of P, the grains are refined only slightly. From this standpoint, it can be understood that the single addition of Zr is not sufficient enough to work on the grain refinement, and it is required to add Zr and P together to achieve grain refinement significantly. Furthermore, it is verified that the embodiments also satisfy the conditions (10) to (14). FIG. 1 to FIG. 4 are displayed as an example.

(25) FIG. 1 includes a photo of the macrostructure (FIG. 1A) and a photo of the microstructure (FIG. 1B) of the embodiment No. 16, and FIG. 2 includes a photo of the macrostructure (FIG. 2A) and a photo of the microstructure (FIG. 2B) of the comparative example No. 204. It is evident from FIG. 1 and FIG. 2 that the comparative example No. 204 does not satisfy the conditions (11) and (12), but the embodiment No. 16 satisfies the conditions (11) and (12).

(26) FIG. 3 includes X-ray micro-analyzer photos of the embodiment No. 16, in which FIG. 3A shows a composition image; FIG. 3B shows the distribution of Sn; and FIG. 3C shows the distribution of Pb particles. FIG. 4 includes X-ray micro-analyzer photos of the comparative example No. 204, in which FIG. 4A shows a composition image; FIG. 4B shows the distribution of Sn; and FIG. 4C shows the distribution of Pb particles. It is evident from FIG. 3 that, in the embodiment No. 16, the high Sn-concentrated areas (white areas in FIG. 3B) and the Pb particles (white areas in FIG. 3C) are small and uniform in size, and are distributed evenly, thereby satisfying the conditions (13) and (14). On the other hand, in the comparative example No. 204, as shown in FIG. 4, the high Sn-concentrated areas (white areas in FIG. 4B) and the Pb particles (white areas in FIG. 4C) are not uniform in size and are distributed unevenly, thereby not satisfying the conditions (13) and (14).

(27) In addition, the comparative example No. 204 has almost the same composition as that of the embodiment No. 16 except that the content of Zr does not reach the lower limit of the above-described proper range. From this point of view, it can be understood that the grains can be refined effectively and the particles of Pb or the like can be made smaller and be dispersed when a proper amount of Zr and P is co-added under the above-described conditions. Furthermore, according to the results of the wear test (wear loss) and the cutting test, it is evident that the embodiment No. 16 is superior to No. 204 in wear resistance and machinability. Therefore, it can be understood that satisfying the conditions (11) to (14) is an important factor to further improve the wear resistance (slidability) and machinability.

(28) From the above facts, it is verified that, when the embodiment contains each alloying component in the above-described range and satisfies the conditions (1) to (5) (additionally the conditions (6) to (8) in the case of the second, fifth, sixth and eighth copper alloy casting), the embodiment has much more improved machinability, strength, elongation, wear resistance and corrosion resistance than the comparative example not satisfying at least any of the above conditions. In addition, it is also verified that the improved properties as described above can be achieved more effectively if the conditions (9) to (14) are satisfied in addition to the aforesaid conditions.

(29) Still furthermore, it is considered that the castability can also be improved by satisfying the condition (5), that is, by refining the grains. In order to verify this, the following Tatur shrinkage test and casting-cracking test are performed.

(30) That is, Tatur shrinkage test is conducted by using the molten alloys (of the copper alloy materials having the compositions listed in Tables 1 to 5 and poured at the same temperature) which are used in casting the embodiments and the comparative examples. Then the castability is evaluated by examining the shapes of internal shrinkage area and the existence of casting defects such as porosity, hole, shrinkage cavity or the like in the vicinity of the internal shrinkage area. The castability is evaluated as good for a casting having a smooth internal shrinkage area and no defect such as porosity or the like in the final solidification area as shown in FIG. 5A; poor for a casting having a remarkably uneven internal shrinkage area and defects such as porosity or the like in the final solidification area as shown in FIG. 5C, and slightly poor for a casting evaluated neither good nor poor as shown in FIG. SB. The results are illustrated in Tables 6 to 10. In the tables, good is denoted as ; slightly poor is denoted as ; and poor is denoted as x. In addition, the grain size in the macrostructure is measured for each casting obtained by the Tatur shrinkage test. The results are illustrated in Tables 6 to 10. In the tables, castings having the grain size of 100 m or less are denoted as ; castings having the grain size in the range of 100 to 250 m are denoted as ; and castings having the grain size of more than 250 m are denoted as x. The results correspond to the results of the mean grain size measured for the embodiments and the comparative examples as described above.

(31) From Tables 6 to 10 showing the results of the Tatur Shrinkage Test, it is verified that, although a few embodiments are graded as slightly poor, most of the embodiments have much more excellent castability due to the grain refinement than the comparative examples, most of which are graded poor.

(32) Still furthermore, in the casting crack test, a test piece 3 is cast by using the top mold 1 and the bottom mold 1, and the right mold 2 and the left mold 2 as shown in FIG. 6. Then the castability is examined whether cracks occur in the test piece 3. That is, the test piece 3 is cast in a shape of a two-headed arrow consisting of a band plate 31 in the midsection with two triangular plates 32 and 32 affixed to the both ends of the band plate. The central part of the band plate 31 is considered as crack judgment area 31a (Castability is measured by the cracks occurred in the area). The band plate 31 is cast in the cavity between the top and bottom molds (1 and 1). Inside the molds are partly placed heat insulation material 4 so that the crack judgment area 31a is cast in this particular area of the cavity surrounded by the heat insulation material 4 (where solidification slows down). There are two other cavities formed by the right and left molds (2 and 2) where the triangular plate 32 is cast in each mold. When a molten alloy is poured into the cavities, the solidification in the crack judgment area 31a proceeds slower than the other areas due to the heat insulation material 4. When the band plate 32 shrinks in the longitudinal direction by solidification, the triangular plates 32 and 32 restrict the shrinkage. Therefore, the stress arising from the shrinkage is centralized in the crack judgment area 31a where the molten alloy is solidified slower. As such, castability is evaluated by the presence of cracks in the crack judgment area 31a. In the casting crack test, L1, the length of the band plate 31, and L2, the length of the crack judgment area 31a are set to be 200 mm and 100 mm, respectively. As conducted in the Tatur Shrinkage Test, the test piece 3 is cast with a molten alloy having the same composition and the same temperature as the molten alloy used for the embodiments (Nos. 1 and 2) and the comparative examples (Nos. 204 to 209, 211, 213, 215, and 219 to 221). The results are illustrated in Tables 6 to 8 and 10. Upon the determination of castability, when a noticeable crack 33a in the crack judgment area 31a, as shown in FIG. 6C, is visually examined in a test piece casting, the casting is evaluated to have poor castability, thereby being denoted as x. In addition, when no crack is observed in the crack judgment area 31a with naked eye or even with five-time magnification glass, as shown in FIG. 6A, the casting is evaluated to have excellent castability, thereby being denoted as . Furthermore, as shown in FIG. 6B, when a test piece casting, in which no noticeable crack 33a can be found in the crack judgment area 31a by a visual examination, has a minor crack 33b observed with five-time magnification glass is evaluated to have normal castability, thereby being denoted as . All the embodiments, on which the casting crack test is performed, are graded as , and thus verified to have excellent castability.

(33) Meanwhile, if the solid phase is granulated in a semi-solid metal state, naturally, the semi-solid metal castability becomes excellent, and thus semi-solid metal casting can be performed satisfactorily. The flowability of a molten liquid containing solid phases at the final stage of solidification depends mainly on the shape of the solid phase and the viscosity or composition of the liquid phase in a semi-solid metal state. Specifically, the casting moldability (a property determining whether or not a robust casting can be obtained even when a precision casting or a casting of a complicated shape is required) is more influenced by the former, that is, the shape of the solid phase. If the solid phase begins to form a network of dendrite in a semi-solid metal state, the casting moldability deteriorates since the molten liquid containing the solid phase is hard to fill in every corner of a mold. Therefore, a precision casting or a casting of a complicated shape is difficult to be realized. Meanwhile, when the solid phase is granulated in a semi-solid metal state, and when the shape of the solid phase becomes more spherical (more circular in two-dimension) and smaller, castability including the semi-solid metal castability becomes more excellent. As a result, a robust precision casting or a casting of complicated shape can be obtained (Naturally, high-quality semi-solid metal castings can be obtained). Therefore, the semi-solid metal castability can be evaluated by examining the shape of the solid phase in a semi-solid metal state. Also, the other castability including complicated-shape castability, precision castability and semi-solid metal forgeability can be evaluated by the semi-solid metal castability. In general, the semi-solid metal castability can be graded as good when, in a semi-solid metal state including 30 to 80% of solid phase, the dendrite network is divided in the crystal structure and the two-dimensional shape of the solid phase is circular, substantially circular, oval, cross-like or polygonal; and further, in a semi-solid metal state including 60% of solid phase particularly, the semi-solid metal castability can be graded as excellent either when the mean grain size of the solid phase is 150 m or less (preferably 100 m or less, and more preferably 50 m or less), or when the average maximum length of the solid phase is 300 m or less (preferably 150 m or less, and more preferably 100 m or less.

(34) In addition, in order to evaluate the semi-solid metal castability of the embodiments in comparison to the comparative examples, the following semi-solid metal castability test is performed.

(35) In the semi-solid metal castability test, the raw materials used for casting the embodiments and the comparative examples are charged into a crucible; heated up to the temperature where the raw materials come into the semi-solid metal state (solid phase ratio: about 60%). The semi-solid metal molten thus obtained is then held at the aforesaid temperature for 5 minutes and quenched rapidly (by water cooling) afterwards. Then, the shape of the solid phase in the semi-solid metal state is examined so as to evaluate the semi-solid metal castability. The results are illustrated in Tables 6 to 8 and 10. It is verified that each embodiment shows excellent semi-solid metal castability. Meanwhile, in the tables, a casting having the mean grain size of 150 m or less of the solid phase or the mean maximum grain length of 300 m or less is denoted as to indicate excellent semi-solid metal castability; a casting having a grain size bigger than the aforesaid, but having no dendrite network therein is denoted as to indicate industrially satisfactory semi-solid metal castability; and a casting having dendrite network therein is denoted as x to indicate poor semi-solid metal castability.

(36) In addition, a new casting (hereinafter referred to as recycled casting) is cast by using the copper alloy casting No. 25 (hereinafter referred to as casting product), which was obtained as an embodiment, as a raw material. That is, the casting product (the copper alloy casting No. 25) is re-melted at the temperature of 1000 C. under a charcoal coating and held for 5 minutes. Then CuZnZr alloy containing 3 mass % of Zr is added to the molten alloy to compensate for the Zr loss caused by oxidation while melting, based on the assumption that the Zr loss would be 0.002 mass %. After that, the molten alloy made from the casting product is poured into a mold. The recycled casting thus obtained contains almost the same amount of Zr (0.009 mass %) as that of the casting product No. 25 used as the raw material. The mean grain size of the recycled casting (30 m) is also almost the same as that of the casting product No. 25. From these points, for the copper alloy casting of the invention, it is verified that the surplus or unnecessary parts such as runner or the like, which are generated during the casting process, can be effectively reused as a recycling raw material without impairing the effect of grain refinement. Therefore, such surplus or unnecessary parts including runner or the like can be charged during a continuous operation as a replenishing material, which makes the continuous operation extremely efficient and effective costwise as well.

(37) TABLE-US-00001 TABLE 1 Casting Alloy Composition (mass %) Primary Metal No. Cu Zn Zr P Sn Al Pb Bi Se f1 f2 f3 f4 f5 f6 Crystal Structure EM- 1 64.5 33.631 0.009 0.06 1.8 65.2 6.7 1.80 33.6 3737 561 BODIMENT 2 65.7 33.322 0.008 0.07 0.9 65.9 8.8 0.90 33.3 4165 476 3 62.5 34.411 0.009 0.08 3 63.8 8.9 3.00 34.4 3823 430 + 4 61.3 37.217 0.013 0.07 1.4 61.8 5.4 1.40 37.2 2863 532 + 5 61.3 37.217 0.013 0.07 1.4 61.8 5.4 1.40 37.2 2863 532 + 6 61.4 35.93 0.01 0.06 2.6 62.5 6.0 2.60 35.9 3593 599 + 7 71.4 27.14 0.01 0.05 1.4 72.10 5.0 1.40 27.1 2714 543 8 64.7 34.413 0.017 0.07 0.8 64.9 4.1 0.80 34.4 2024 492 9 63.4 34.991 0.009 0.07 1.4 0.13 64.0 7.8 1.53 35.0 3888 500 10 64 35.021 0.009 0.07 0.9 64.2 7.8 0.90 35.0 3891 500 11 64.3 33.963 0.007 0.08 1.4 0.25 64.9 11.4 1.65 34.0 4852 425 12 64.1 34.284 0.016 0.1 1.3 0.2 64.6 6.3 1.50 34.3 2143 343 13 63.5 35.547 0.0034 0.05 1 0.9 63.3 14.7 1.05 37.0 10896 741 + + 14 63.5 34.635 0.0055 0.06 0.9 0.9 63.3 10.9 1.00 36.9 6706 615 + 15 63.8 340222 0.0079 0.07 1 0.9 63.5 8.9 1.05 36.7 4648 525 + 16 63.7 34.318 0.012 0.07 1 0.9 63.4 5.8 1.05 36.8 3068 526 + 17 63.4 34.614 0.026 0.06 1 0.9 63.2 2.3 1.05 37.1 1427 619 + + 18 63.5 34.596 0.034 0.07 0.9 0.9 63.3 2.1 1.00 36.8 1084 526 + + 19 63.8 34.276 0.009 0.015 1 0.9 63.7 1.7 1.00 36.8 4086 2452 + 20 63.5 34.665 0.01 0.025 0.9 0.9 63.4 2.5 1.05 36.9 3692 1477 + 21 63.4 34.658 0.009 0.033 1 0.9 63.3 3.7 1.00 37.2 4129 1126 + 22 63.7 34.246 0.009 0.045 1.1 0.9 63.5 5.0 1.05 37.0 4111 822 + 23 63.7 34.216 0.014 0.17 1 0.9 63.1 12.1 1.00 36.7 2623 216 + + 24 61.5 34.232 0.008 0.06 0.8 3.4 62.6 7.5 3.50 36.2 4529 604 + + 25 64.4 32.921 0.009 0.07 0.8 1.8 64.7 7.8 1.85 34.9 3880 499 + 26 65.7 35.521 0.009 0.07 0.8 0.9 65.5 7.8 0.95 34.5 3836 493 + 27 65.3 32.532 0.008 0.06 1.2 0.9 65.0 7.5 1.05 35.5 4442 592 + 28 64.3 32.422 0.088 0.07 2.3 0.9 63.4 8.8 1.50 38.2 4772 545 +

(38) TABLE-US-00002 TABLE 2 Casting Alloy Composition (mass %) Primary Metal No. Cu Zn Zr P Sn Al Pb Bi Se f1 f2 f3 f4 f5 f6 Crystal Structure EM- 29 63.8 32.141 0.009 0.05 3.1 0.9 62.6 5.6 1.90 39.9 4432 798 + BODI- 30 64.6 32.52 0.01 0.07 2.3 0.5 63.5 7.0 1.10 38.3 3827 547 + MENT 31 64.1 32.231 0.009 0.06 3.1 0.5 62.6 6.7 1.50 40.0 4442 666 + 32 63 34.224 0.016 0.06 1.4 1.3 62.8 3.8 1.65 37.7 2358 629 + 33 64 34.476 0.014 0.06 0.15 1.3 64.4 4.3 1.30 34.9 2489 581 34 64.1 34.018 0.012 0.07 0.4 1.4 64.4 5.8 1.40 35.0 2918 500 35 64.5 33.526 0.014 0.06 0.6 1.3 64.7 4.3 1.33 35.0 2502 584 + 36 61.4 36.328 0.012 0.06 0.9 1.3 61.4 5.0 1.50 38.6 3215 643 + + 37 61.4 36.328 0.012 0.06 0.9 1.3 61.4 5.0 1.35 38.6 3215 643 + + 38 61.9 35.696 0.014 0.09 0.9 1.4 61.9 6.4 1.60 37.9 2710 422 + + 39 61.9 35.696 0.014 0.09 0.9 1.4 61.9 6.4 1.45 37.9 2710 422 + 40 67 28.926 0.014 0.06 0.9 3.1 67.9 4.3 3.15 31.2 2227 520 + 41 67.7 29.926 0.014 0.06 0.9 1.4 67.8 4.3 1.45 32.2 2298 536 + 42 71 26.926 0.014 0.06 1 1 70.8 4.3 1.05 29.4 2102 490 + 43 67.2 29.94 0.01 0.05 2.2 0.6 66.3 5.0 1.10 35.4 3544 709 + 44 64 33.626 0.038 0.036 1 1.3 64.0 0.9 1.45 36.1 951 1004 + 45 63.9 33.832 0.03 0.038 0.9 1.3 64.0 1.3 1.40 36.1 1203 950 + 46 63.9 33.505 0.005 0.19 1.1 1.3 63.4 38.0 1.45 36.3 7251 191 + + 47 64 33.153 0.007 0.14 1.1 1.4 63.7 20.0 1.55 36.1 5158 258 + 48 63 33.831 0.009 0.06 1 0.3 1.8 63.4 6.7 2.25 36.3 4037 606 + + 49 62.2 34.631 0.009 0.06 1 2.1 62.6 6.7 2.30 37.1 4126 619 + + 50 63 34.041 0.009 0.05 0.9 1.6 0.4 63.4 5.6 2.15 36.3 4032 726 + + 51 64.3 32.622 0.008 0.07 1.5 1.2 0.3 64.1 8.8 1.90 36.4 4547 520 + 52 64.5 32.621 0.009 0.07 2.3 0.5 63.4 7.8 1.10 38.4 4263 548 + 53 65 30.821 0.009 0.07 1.5 2.6 65.3 7.8 2.95 34.6 3841 494 + 54 63.5 34.432 0.008 0.06 1.2 0.8 63.1 7.5 1.00 37.4 4679 624 + + 55 63.8 32.551 0.009 0.1 2.8 0.7 0.4 62.5 11.1 1.64 39.6 4395 396 + 56 64.5 34.068 0.012 0.07 0.15 1.2 64.6 5.8 1.20 34.5 2877 493

(39) TABLE-US-00003 TABLE 3 Casting Alloy Composition (mass %) No. Cu Zn Zr P Sn Al Pb Bi Se As Sb Mn Si EMBODIMENT 57 62.5 33.908 0.012 0.08 0.4 3.1 58 65.8 32.106 0.014 0.08 0.8 1.2 59 71 25.725 0.015 0.06 2.5 0.7 60 63.5 33.826 0.014 0.06 0.3 2.3 61 63 35.165 0.015 0.07 0.25 1.2 0.3 62 63.8 34.14 0.01 0.07 1 0.08 0.9 63 65.3 31.891 0.009 0.08 1.8 0.12 0.8 64 64.5 32.071 0.009 0.07 2.3 0.35 0.7 65 64.8 32.812 0.008 0.06 1 0.22 1.1 66 64.5 32.721 0.009 0.07 0.8 0.6 1.3 67 66.8 27.911 0.009 0.08 2.8 1.4 1 68 62.3 35.526 0.014 0.06 1 0.2 0.9 69 63.8 33.941 0.009 0.05 1 0.2 1 70 63.4 33.222 0.008 0.07 0.8 0.2 1.8 0.5 71 63.7 33.321 0.009 0.07 1.8 0.2 0.9 72 63.8 34.319 0.011 0.07 0.6 0.2 1 73 64 35.577 0.013 0.06 1.2 0.2 0.8 0.15 74 64 33.429 0.011 0.08 0.8 0.08 1.6 75 63.8 34.12 0.01 0.07 1 1 76 64.1 33.821 0.009 0.07 1 1 77 65.2 33.682 0.008 0.07 1 0.4 78 63.5 35.282 0.008 0.06 1.1 0.05 79 64.1 30.032 0.008 0.06 1.2 3.5 1.1 80 65.8 25.511 0.009 0.08 2.3 4.7 1.6 81 66.8 32.11 0.01 0.08 1 Alloy Composition Casting (mass %) Primary Metal No. Mg Impurities f1 f2 f3 f4 f5 f6 Crystal Structure EMBODI- 57 63.1 6.7 3.10 35.1 2926 439 + MENT 58 64.7 5.7 1.20 34.5 2465 431 59 66.7 4.0 0.85 33.2 2215 554 + 60 63.9 4.3 2.30 34.7 2480 579 + 61 63.1 4.7 1.50 35.9 2394 513 + 62 63.4 7.0 1.05 36.9 36.88 527 + 63 64.3 8.9 1.30 36.8 4083 459 + 64 62.9 7.8 1.45 38.9 4319 555 + 65 64.3 7.5 1.20 36.0 4497 600 + 66 63.5 7.8 1.35 36.5 4.58 522 + + 67 63.1 8.9 2.20 39.1 4346 489 + 68 61.7 4.3 1.05 38.6 2759 644 + + 69 63.3 5.6 1.15 37.0 4116 741 + + 70 63.6 8.8 2.35 35.8 4478 512 + + 71 62.7 7.8 1.40 38.4 4269 549 + 72 63.4 6.4 1.03 36.4 3311 520 + + 73 63.3 4.6 1.20 37.2 2860 620 + 74 64.0 7.3 1.65 35.7 3243 446 + 75 0.008 0.02 63.6 7.0 1.10 36.6 3662 523 + 76 0.003 0.005 63.9 7.8 1.05 36.3 4.36 519 + 77 65.5 8.8 1.00 33.7 4210 481 78 63.8 7.5 1.10 35.3 4410 588 + 79 64.2 7.5 1.20 30.0 3754 501 80 65.8 8.9 2.35 25.5 2835 319 + 81 0.008 67.1 8.0 1.00 32.1 3211 401

(40) TABLE-US-00004 TABLE 4 Casting Alloy Composition (mass %) No. Cu Zn Zr P Sn Al Pb Bi Se As Sb Mn EM- 82 63 34.143 0.007 0.05 0.8 1.5 BODIMENT 83 64.1 33.76 0.01 0.08 1 1 0.05 84 64 33.449 0.011 0.09 0.8 1.6 0.02 0.03 85 64 34.637 0.013 0.1 0.2 1 0.05 86 64.2 33.413 0.007 0.08 1 0.2 1 0.1 87 63.9 33.411 0.009 0.08 0.8 0.3 1.4 0.1 88 63.3 34.477 0.013 0.08 0.8 0.7 0.5 89 62.8 32.51 0.01 0.08 0.8 2.3 1.2 90 63.8 34.286 0.014 0.05 0.8 0.9 0.15 91 63.2 34.841 0.009 0.08 0.8 1 92 64 33.942 0.008 0.05 0.8 1.2 93 64.9 28.111 0.009 0.08 0.4 1.3 4 94 65.5 28.31 0.01 0.08 0.7 1.6 3 95 66.1 29.959 0.011 0.08 1.6 0.9 1.1 96 72 23.282 0.008 0.06 3.1 0.7 0.7 97 63.8 29.717 0.013 0.07 1.3 1 3.1 98 65 31.395 0.015 0.09 0.6 0.8 1.6 99 66.3 27.01 0.01 0.08 1 1.4 3.2 100 64.8 32.061 0.009 0.08 0.15 0.8 1.2 0.7 101 63.9 32.222 0.018 0.11 0.6 0.3 1.1 0.2 1.2 102 63.9 34.131 0.009 0.08 0.6 1.2 103 63 34.183 0.007 0.06 1.4 0.05 1 104 64 32.167 0.013 0.08 0.5 1.4 0.04 1.4 105 63.2 33.33 0.02 0.09 0.6 1.3 0.06 1.1 106 64.1 33.849 0.011 0.08 0.7 1.2 0.06 107 64.5 31.242 0.008 0.08 0.08 0.8 1.2 0.04 1.6 Alloy Composition Casting (mass %) Primary Metal No. Si Mg f1 f2 f3 f4 f5 f6 crystal Structure EM- 82 0.5 63.0 7.1 0.80 34.1 4878 683 + BODIMENT 83 63.8 8.0 1.10 36.3 3626 453 + 84 64.1 8.2 1.65 35.4 3223 394 + 85 63.8 7.7 1.00 35.2 2711 352 + + 86 63.6 11.4 1.10 36.5 5216 456 + 87 63.4 8.9 1.45 36.3 4035 454 + + 88 013 63.1 6.2 0.75 36.5 2806 456 + + 89 0.3 63.5 8.0 2.40 34.5 3451 431 + + 90 63.9 3.6 0.95 36.3 2592 726 + 91 0.07 62.8 8.9 1.10 36.8 4093 461 + + 92 0.05 64.1 6.3 1.25 35.9 4493 719 + 93 1.2 64.4 8.9 1.30 29.3 3257 366 94 0.8 65.0 8.0 1.60 30.4 3041 380 95 0.25 63.7 7.3 0.90 34.8 3160 434 + 96 0.15 66.8 7.5 0.90 34.8 4073 543 + 97 1 61.4 5.4 1.00 33.6 2586 480 + 98 0.5 63.9 6.0 0.80 33.2 2213 369 99 1 64.7 8.0 1.40 30.0 3001 375 100 0.2 63.6 8.9 1.20 34.8 3871 435 101 0.35 63.4 6.1 1.30 34.6 1923 315 102 0.08 63.7 8.9 1.20 35.6 3959 445 103 0.3 63.4 8.6 1.40 34.2 4883 570 + 104 0.4 63.5 6.2 1.40 33.7 2590 421 + 105 0.3 63.3 4.5 1.35 34.8 1742 387 + + 106 0.005 64.1 7.3 1.25 35.6 3236 445 + 107 0.45 63.4 1.0 1.20 33.8 4320 423 +

(41) TABLE-US-00005 TABLE 5 Casting Alloy Composition (mass %) No. Cu Zn Zr P Sn Al Pb Bi Mn Si Impurities COMPARATIVE 201 65.7 33.901 0.009 0.09 0.3 Fe Ni EXAMPLE 202 65.7 34.216 0.009 0.07 0.005 203 59.2 39.304 0.016 0.08 1.4 204 63.5 34.55 0.0005 0.005 1 0.9 205 63.5 34.549 0.0012 0.05 1 0.9 206 63.8 34.176 0.054 0.07 1 0.9 207 63.4 34.52 0.09 0.09 1 0.9 208 63.3 34.784 0.009 0.007 1 0.9 209 64.2 33.6 0.01 0.29 1 0.9 210 60.5 36.22 0.01 0.07 2.3 0.9 211 64.3 29.925 0.015 0.06 4.4 1.3 212 59.3 38.506 0.014 0.08 0.9 1.2 213 63.8 33.835 0.045 0.02 1 1.3 214 64.1 33.369 0.0015 0.23 1 1.3 215 64 31.53 0.01 0.06 1.1 3.3 216 72 22.505 0.015 0.08 4.2 1.2 217 61.5 35.911 0.009 0.08 0.7 0.9 0.9 218 60 34.009 0.011 0.08 0.9 3.8 1.2 219 63.8 33.266 0.014 0.11 0.8 1.8 0.21 220 64.2 33.31 0.01 0.06 0.9 1.3 0.22 221 64.8 32.55 0.01 0.06 1 1.3 0.14 0.14 222 63.5 34.571 0.029 1 0.9 Casting Primary Metal No. f1 f2 f3 f4 f5 f6 Crystal Structure COMPARATIVE 201 65.6 10.0 0.30 33.9 3767 377 EXAMPLE 202 65.5 7.8 0.01 34.2 3805 489 203 59.7 5.0 1.40 39.3 2457 491 + 204 63.3 100.0 1.05 37.0 74099 741 + + 205 63.3 41.7 1.05 37.0 30874 741 + + 206 63.5 1.3 1.00 36.7 679 524 + + 207 63.1 1.0 1.10 37.0 411 411 + + 208 63.2 0.8 1.05 37.3 4143 5326 + + 209 63.3 29.0 1.05 36.1 3610 123 + + 210 59.6 7.0 1.60 42.0 4197 600 + + 211 62.6 4.0 2.80 40.9 2728 682 + 212 59.2 5.7 1.45 40.8 2911 509 + + 213 63.9 0.4 1.45 36.3 807 1817 + + 214 63.6 153.3 1.45 35.9 23912 156 + + 215 64.9 6.0 3.45 34.3 3428 571 + 216 64.8 5.3 1.95 35.1 2340 439 + 217 59.7 8.9 0.95 40.4 4485 505 + + 218 59.8 7.3 0.90 34.0 3092 425 + 219 64.0 7.9 1.80 35.3 2519 321 + + 220 64.2 6.0 1.30 35.6 3536 593 + + 221 64.8 6.0 1.35 35.1 3505 584 + 222 63.5 0 0.90 37.1 1278 + +

(42) TABLE-US-00006 TABLE 6 Corrosion Loss Machinability Area Mean Tatur Shrinkage Maximum (mg/cm.sup.2) Cutting Ratio Grain Test Corrosion Erosion .Math. corrosion Main Casting (%) Size Grain Casting Depth test component Chip No. + (m) Castability Size Crack (m) I II III IV (N) Type EMBODIMENT 1 100 0 40 40 101 2 100 0 50 30 45 64 278 595 127 3 98 0 50 160 53 91 4 96 0 250 290 108 5 99 0 90 106 6 97 0 120 230 7 100 0 60 20 8 100 0 45 40 9 100 0 40 50 10 100 0 40 40 11 100 0 60 50 42 12 100 0 40 60 13 99 3 120 140 38 53 222 460 128 14 100 2 65 80 34 51 193 415 126 15 100 3 35 40 30 44 176 390 125 16 100 3 30 50 31 45 163 372 126 17 99 3 75 80 32 127 18 99 2 120 120 36 129 19 100 2 250 150 33 129 20 100 3 200 120 33 129 21 100 2 80 90 30 126 22 100 3 50 30 29 126 23 98 2 120 140 124 24 98 2 80 190 42 25 100 1 30 30 31 26 100 1 30 10 or 30 42 158 314 129 less 27 100 3 25 10 or 26 42 143 295 124 less 28 100 12 25 70 29 49 186 281 112 Tensile Proof Fatigue Wear Semi-solid Casting Strength Stress Elongation Strength Cold Loss Metal No. (N/mm.sup.2) (N/mm.sup.2) (%) (N/mm.sup.2) Workability (mg) castability EMBODIMENT 1 2 312 103 26 110 430 3 4 5 6 7 8 9 10 11 12 13 305 109 23 116 14 316 128 25 135 15 331 135 24 142 210 16 328 139 25 146 17 310 115 24 18 306 112 22 121 19 290 101 20 X 20 299 108 21 113 21 308 119 22 22 324 136 24 143 23 302 103 13 24 25 26 338 137 26 142 27 349 152 22 165 195 28 334 165 16 172 164

(43) TABLE-US-00007 TABLE 7 Corrosion Loss Machinability Area Mean Tatur Shrinkage Maximum (mg/cm.sup.2) Cutting Ratio Grain Test Corrosion Erosion .Math. corrosion Main Casting (%) Size Grain Casting Depth test component Chip No. + (m) Castability Size Crack (m) I II III IV (N) Type EMBODIMENT 29 100 20 40 100 32 105 a 30 100 12 25 50 28 42 182 276 126 a 31 100 20 30 80 28 120 a 32 100 7 30 30 26 33 100 0 40 60 37 34 100 0 35 50 36 35 100 0.5 30 40 34 36 96 4 200 280 56 37 99 1 80 35 38 97 4 150 200 44 65 256 545 39 100 1 40 32 49 176 406 40 100 1 35 10 or less 41 100 1 35 10 or less 42 100 1 35 20 29 43 100 10 25 10 or 23 39 141 255 125 a less 44 100 3 200 120 116 a 45 100 2 120 80 113 a 46 99 3 250 220 41 114 a 47 100 3 120 60 31 48 99 3 30 80 33 49 98 4 40 160 39 50 99 3 35 90 33 99 a 51 100 8 25 10 or 24 41 145 263 101 a less 52 100 12 25 40 24 43 148 254 130 a 53 100 7 30 20 23 94 c 54 99 4 30 90 30 129 a 55 100 18 35 30 24 43 152 243 110 a 56 100 0 30 40 38 Tensile Proof Fatigue Wear Semi-solid Casting Strength Stress Elongation Strength Cold Loss Metal No. (N/mm.sup.2) (N/mm.sup.2) (%) (N/mm.sup.2) Workability (mg) castability EMBODIMENT 29 30 336 166 18 171 162 31 32 33 322 112 26 34 35 36 37 38 39 40 41 42 43 340 166 19 175 155 44 298 107 19 112 45 46 290 103 18 47 48 49 50 51 348 151 17 52 53 54 341 144 20 55 56

(44) TABLE-US-00008 TABLE 8 Corrosion Loss Machinability Area Mean Tatur Shrinkage Maximum (mg/cm.sup.2) Cutting Ratio Grain Test Corrosion Erosion .Math. corrosion Main Casting (%) Size Grain Casting Depth test component Chip No. + (m) Castability Size Crack (m) I II III IV (N) Type EMBODIMENT 57 98 0 35 160 41 58 100 0 30 50 35 56 192 435 121 a 59 100 3 45 30 29 50 159 310 143 e 60 99 0 35 80 61 99 0 35 90 62 100 3 30 40 31 130 a 63 100 10 25 10 or 22 39 141 223 124 a less 64 100 15 30 50 27 43 148 247 119 a 65 100 2 25 10 or 25 42 151 266 124 a less 66 99 1 30 70 31 117 a 67 100 24 40 60 25 68 97 3 200 280 48 69 99 3 30 90 33 70 99 1 25 70 33 97 c 71 100 10 35 50 29 45 155 253 120 a 72 99 0.5 35 100 36 73 100 5 35 60 30 124 a 74 100 1 30 50 32 49 177 435 106 a 75 100 2 60 50 76 100 1 70 50 35 49 185 404 129 a 77 100 0 45 40 78 99 0 50 70 79 100 0 40 80 41 64 255 305 125 a 80 100 1 30 60 81 100 0 45 30 Tensile Proof Fatigue Wear Semi-solid Casting Strength Stress Elongation Strength Cold Loss Metal No. (N/mm.sup.2) (N/mm.sup.2) (%) (N/mm.sup.2) Workability (mg) castability EMBODIMENT 57 322 117 27 122 58 330 139 26 145 220 59 356 153 23 163 145 60 61 62 63 345 152 21 164 185 64 342 165 18 178 150 65 345 138 27 146 66 67 68 69 70 342 136 27 146 205 71 340 132 20 140 72 73 338 134 22 145 74 342 132 25 75 76 324 123 22 133 77 78 79 384 156 20 166 4.7 80 81

(45) TABLE-US-00009 TABLE 9 Corrosion Loss Machinability Mean Tatur Shrinkage Maximum (mg/cm.sup.2) Cutting Area Grain Test Corrosion Erosion .Math. corrosion Main Casting Ratio (%) Size Grain Depth test component Chip No. + (m) Castability Size (m) I II III IV (N) Type EMBODIMENT 82 99 0 50 100 140 a 83 100 2 35 30 30 84 100 1 30 30 31 85 99 0 40 80 40 86 100 2 40 40 31 87 99 1 35 90 35 51 198 402 110 a 88 99 1 30 80 35 50 192 365 138 a 89 99 2 40 80 35 49 187 312 100 a 90 100 1 35 30 31 91 99 2 35 100 92 100 1 25 30 30 93 100 0 40 40 94 100 0 30 50 34 53 204 296 115 a 95 99 0 35 90 42 55 193 275 136 e 96 100 4 60 40 30 47 190 253 141 a 97 95 0 200 300 98 100 0 40 60 141 e 99 100 0 40 40 100 100 0 35 50 101 100 0 40 40 31 48 194 268 124 a 102 100 0 35 40 103 99 0 40 80 40 104 99 0 45 90 105 99 1 40 70 36 106 100 1 30 30 107 98 0 40 140 Tensile Proof Fatigue Wear Casting Strength Stress Elongation Strength Loss No. (N/mm.sup.2) (N/mm.sup.2) (%) (N/mm.sup.2) (mg) EMBODIMENT 82 356 143 22 149 24 83 84 85 86 87 338 125 26 88 350 135 23 145 54 89 32 90 91 92 93 94 436 168 20 182 3 95 408 157 21 170 18 96 97 98 380 152 20 162 26 99 100 101 362 148 20 155 36 102 103 104 105 106 107

(46) TABLE-US-00010 TABLE 10 Corrosion Loss Machinability Area Mean Tatur Shrinkage Maximum (mg/cm.sup.2) Cutting Ratio Grain Test Corrosion Erosion .Math. corrosion Main Casting (%) Size Grain Casting Depth test component Chip No. + (m) Castability Size Crack (m) I II III IV (N) Type COMPARATIVE 201 100 0 40 30 183 G EXAMPLE 202 100 0 40 40 258 G 203 86 0 500 X 900 65 119 430 850 108 A 204 97 3 1000 X X X 400 50 74 323 588 134 E 205 98 3 250 X X 220 42 61 265 504 128 E 206 99 2 350 X X X 190 41 132 E 207 99 4 400 X X X 230 43 60 260 480 134 E 208 98 3 800 X X X 350 48 133 E 209 98 3 150 X X 230 128 a 210 95 14 350 X 500 54 211 100 30 50 X X 120 31 212 84 5 700 X 750 61 213 99 3 500 X X X 260 45 120 A 214 99 3 800 X X 320 48 124 a 215 100 3 30 X X 40 33 216 100 15 120 X 80 217 85 1 800 X 600 59 218 88 0 500 X 800 219 99 0 500 X X X 320 59 74 338 595 105 a 220 99 0 550 X X X 280 52 221 100 1 550 X X X 222 98 2 450 X X X 300 46 134 e Tensile Proof Fatigue Wear Semi-solid Casting Strength Stress Elongation Strength Cold Loss Metal No. (N/mm.sup.2) (N/mm.sup.2) (%) (N/mm.sup.2) Workability (mg) castability COMPARATIVE 201 EXAMPLE 202 203 285 86 16 87 550 X 204 261 90 19 91 320 X X 205 298 106 22 206 288 95 21 207 278 94 18 96 208 258 91 20 94 345 209 294 105 9 98 X 210 294 92 8 91 X 211 X 212 286 90 12 89 213 278 92 19 92 214 262 93 16 89 215 216 217 X 218 219 268 93 20 98 X 220 221 222 268 92 17 93 X