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Copper and Copper Alloy Castings

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Copper and Copper Alloy Castings Copper Development Association Copper & Copper Alloy Castings Properties & Applications Publication TN42, 1991 Copper & Copper Alloy Castings – Properties & Applications TN42 December 1991 Members as at 1st January 1991 – Thomas Bolton Ltd BP Minerals International Ltd Brandeis Ltd The British Non-Ferrous Metals Federation Chile Copper Ltd CIPEC (The Interngovenmental Council of Copper Exporting Countries) Columbia Metals Ltd Falconbridge Ltd Gecamines Commerciale Highland Valley Copper IMI plc Inco Europe Ltd McKechnie plc Minpeco (UK) Ltd Noranda Sales Corporation of Canada Ltd Palabora Mining Co Ltd RTZ Ltd Southern Peru Copper Corporation Wednesbury Tube Acknowledgements The major work in the preparation of this publication has been carried out by Mr E C Mantle. The Cop Development Association would also like to acknowledge useful help, comments and the provision illustrations by many British foundries. Funding for printing this publication has been provided by Code Chile. Copper Development Association Copper Development Association is a non-trading organisation sponsored by the copper producers fabricators to encourage the use of copper and copper alloys and to promote their correct and effic application. Its services, which include the provision of technical advice and information, are availabl those interested in the utilisation of copper in all its aspects. The Association also provides a link betw research and user industries and maintains close contact with other copper development associat throughout the world. Website: www.cda.org.uk Email: [email protected] Copyright: All information in this document is the copyright of Copper Development Association Disclaimer: Whilst this document has been prepared with care, Copper Development Association can giv warranty regarding the contents and shall not be liable for any direct, indirect or consequential loss arising of its use Contents Preface.......................................................................................................................................................... 3 Introduction................................................................................................................................................. 5 1. Advantages of Copper Alloy Castings 5 1.1. Good Castability...................................................................................................................... 5 1.2. In-built Corrosion Protection................................................................................................... 5 1.3. Low Frictional Properties and Good Resistance to Wear........................................................ 5 1.4. Non-Sparking Characteristics.................................................................................................. 5 1.5. High Electrical and Thermal Conductivity.............................................................................. 5 1.6. Good Mechanical Properties at Ambient and High Temperatures .......................................... 6 1.7. Enhanced Low Temperature Properties .................................................................................. 6 1.8. Machinability .......................................................................................................................... 6 1.9. Recycling................................................................................................................................. 6 1.10. Cost-Effectiveness................................................................................................................... 6 2. Applications of Main Alloy Groupings 6 2.1. High conductivity coppers....................................................................................................... 6 2.2. Brasses - copper-zinc alloys where zinc is the major alloying element................................... 6 2.3. Tin bronzes - copper-tin alloys where tin is the major alloying element ................................. 7 2.4. Phosphor bronzes - copper-tin alloys with an addition of phosphorus ................................... 7 2.5. Lead bronzes - copper-tin-lead alloys where lead is a substantial part of the alloy................. 7 2.6. Gunmetals - copper-tin-zinc-lead alloys where all are alloying elements................................ 7 2.7. Aluminium Bronzes - copper-aluminium alloys where aluminium is major element .............. 7 2.8. Copper-nickels - copper-nickel alloys where nickel is the major alloying element................. 8 2.9. Available Coppers and Copper Alloys .................................................................................... 8 Applications............................................................................................................................................... 11 3. Resistance to Corrosion 11 3.1. General.................................................................................................................................. 11 3.2. Alloys for Atmospheric Corrosion Resistance ...................................................................... 11 3.3. Service in fresh waters........................................................................................................... 12 3.4. Service in sea water............................................................................................................... 13 3.5. Resistance to chemical solutions ........................................................................................... 15 3.6. Superheated steam and industrial gases................................................................................. 16 3.7. Food products........................................................................................................................ 17 4. Bearings 17 4.1. Relevant basic properties....................................................................................................... 17 4.2. Shaft materials....................................................................................................................... 20 4.3. Backing for bearings. ............................................................................................................ 20 4.4. Alloys for high duty bearings with high load and high sliding velocities.............................. 20 4.5. Alloys for moderate loading and less critical applications .................................................... 21 4.6. Alloys for moderate loading and/or poor lubrication ............................................................ 21 4.7. Alloys for low loads in non critical applications ................................................................... 21 4.8. Aluminium bronze bearings .................................................................................................. 22 5. Gears and other Wear Resistant Applications 22 5.1. Gears ..................................................................................................................................... 22 5.2. Other wear resistant applications...........................................................................................24 5.3. Non-sparking tools ................................................................................................................ 24 6. Pressure-tight Castings 25 7. High Conductivity Applications 25 7.1. Electrical ............................................................................................................................... 25 7.2. Thermal ................................................................................................................................. 26 1 8. Elevated Temperature Uses 27 8.1. Mechanical properties ........................................................................................................... 27 8.2. Oxidation resistance .............................................................................................................. 29 9. Low Temperature Uses 29 10. Casting Design Stresses 30 10.1. Assessment of tensile properties............................................................................................ 30 10.2. Test bar properties................................................................................................................. 31 10.3. Allowance for casting structure............................................................................................. 31 10.4. Elastic modulus ..................................................................................................................... 31 10.5. Working stresses in castings.................................................................................................. 32 10.6. Compressive Strength............................................................................................................ 32 11. Selection of Casting Process 32 11.1. Processes using refractory moulds......................................................................................... 33 11.2. Permanent mould casting processes ...................................................................................... 35 12. Pattern Design 37 12.1. Alloy freezing ranges ............................................................................................................ 38 12.2. Design of junctions................................................................................................................ 39 12.3. Ribs ......................................................................................................................................
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