Metallurgy, Alloys, and Applications p. 1 Introduction and Overview p. 3 Major Groups of Copper and Copper Alloys p. 3 Properties of Importance p.

Transcription

1 Preface p. vii Metallurgy, Alloys, and Applications p. 1 Introduction and Overview p. 3 Major Groups of Copper and Copper Alloys p. 3 Properties of Importance p. 3 Fabrication Characteristics p. 5 Alloy Terminology p. 6 Temper Terminology p. 8 The Copper Industry: Occurrence, Recovery, and Consumption p. 10 Production of Copper p. 10 Copper Fabricators p. 13 Markets and Applications p. 13 Standard Designations for Wrought and Cast Copper and Copper Alloys p. 14 Alloy Designations p. 14 Temper Designations p. 14 International Alloy and Temper Designations p. 28 Physical Metallurgy: Heat Treatment, Structure, and Properties p. 31 Commercially Pure Copper p. 31 Copper-Zinc Alloys p. 35 Copper-Tin Alloys p. 45 Copper-Zinc-Tin Alloys p. 46 Copper-Base Leaded Alloys p. 46 Copper-Aluminum Alloys p. 51 Copper-Beryllium Alloys p. 52 Wrought Copper and Copper Alloys p. 54 Designating Copper and Its Alloys p. 54 Wrought Copper and Copper Alloy Families p. 54 Strengthening Mechanisms for Wrought Copper Alloys p. 65 Classification of Wrought Copper Products p. 67 Refinery Shapes p. 67 Wire Mill Products p. 68 Flat-Rolled Products p. 73 The Manufacture of Sheet and Strip p. 74 Tubular Products p. 79 Rod, Bar, and Shapes p. 82 Forgings p. 83 Cast Copper and Copper Alloys p. 85 Copper Casting Alloy Families p. 85 Selection Criteria p. 92 Applications p. 102 Powder Metallurgy Copper and Copper Alloys p. 105

2 The Powder Processing Route p. 105 Pure Copper P/M Parts p. 106 Bronze P/M Parts p. 107 Brass and Nickel Silver P/M Parts p. 110 Copper-Nickel P/M Parts p. 111 Copper-Lead P/M Parts p. 112 Copper-Base Friction Materials p. 112 Copper-Base Contact Materials p. 113 Copper-Base Brush Materials p. 113 Copper-Infiltrated Steels p. 114 Copper-Base Dispersion-Strengthened Materials p. 115 Nonstructural Applications of Copper and Copper Alloy Powders p. 118 Shape Memory Alloys and Composite Materials p. 121 Shape Memory Alloys p. 121 Copper-Matrix Composites p. 122 Tungsten-Copper P/M Composites p. 123 Molybdenum-Copper P/M Composites p. 123 Multifilament Composite Wires p. 123 Copper-Clad Brazing Sheet p. 124 Copper and Copper Alloy Coatings p. 127 Copper Plating p. 127 Alkaline Plating Baths p. 127 Acid Plating Baths p. 128 Surface Preparation Considerations p. 129 Bath Composition and Operating Variables p. 130 Plating in Dilute Cyanide Baths p. 131 Plating in Rochelle Cyanide Baths p. 131 Plating in High-Efficiency Sodium and Potassium Cyanide Baths p. 132 Plating in Noncyanide Copper Baths p. 133 Plating in Pyrophosphate Baths p. 133 Plating in Acid Sulfate Baths p. 134 Plating in Fluoborate Baths p. 134 Wastewater Control and Treatment p. 135 Copper Plating Equipment p. 135 Characteristics of Copper Plate p. 135 Copper in Multiplate Systems p. 136 Cost p. 136 Copper Alloy Plating p. 136 Brass Plating p. 137 Bronze Plating p. 139 Waste Water Treatment p. 139

3 Electroless Copper Plating p. 139 Bath Chemistry and Reactions p. 139 Deposit Properties p. 140 Applications p. 142 Pretreatment and Post-Treatment Processes p. 144 Controls p. 147 Performance Criteria p. 148 Equipment p. 148 Environmental and Safety Issues p. 150 Wear-Resistant and Corrosion-Resistant Copper Alloy Coatings p. 150 Wear-Resistant Coatings p. 150 Corrosion-Resistant Coatings p. 150 Applications p. 153 Building Construction p. 153 Electrical Applications p. 156 Electronic Equipment p. 159 Industrial Machinery and Equipment p. 161 Transportation p. 165 Consumer and General Products p. 167 Fabrication and Finishing p. 169 Melting and Casting p. 171 Casting Characteristics p. 171 Melting Practice p. 172 Fluxing of Copper Alloys p. 174 Degassing of Copper Alloys p. 176 Deoxidation of Copper Alloys p. 181 Grain Refining of Copper Alloys p. 183 Filtration of Copper Alloys p. 183 Melt Treatments for Group I to III Alloys p. 183 Production of Copper Alloy Castings p. 184 Casting Process Selection p. 186 Gating p. 187 Feeding p. 190 Forming p. 195 General Considerations p. 195 Effects of Composition, Cold Work, and Heat Treatment on Formability p. 195 Formability of Copper Alloys versus Other Metals p. 197 Blanking and Piercing p. 198 Bending p. 199 Drawing and Stretch-Forming p. 201 Coining p. 203

4 Spinning p. 204 Contour Roll Forming p. 204 Rubber-Pad Forming p. 204 Specialized Forming Operations p. 205 Springback p. 205 Forming Limit Analysis p. 207 Bending of Rod, Bars, and Shapes p. 208 Bending and Forming of Tubing p. 210 Rotary Swaging of Rod, Bars, and Tubes p. 211 Forming of Wire p. 211 Forging and Extrusion p. 213 Hot Forging p. 213 Cold Extrusion p. 218 Cold Heading p. 219 Coining p. 220 Hot Extrusion p. 221 Powder Metallurgy Processing p. 222 Production of Copper Powder by the Reduction of Copper Oxide p. 222 Production of Copper Powder by Electrolysis p. 225 Production of Copper Powder by Atomization p. 229 Production of Copper Powder by Hydrometallurgical Processing p. 231 Production of Copper Alloy Powders p. 232 Powder Pressing p. 234 Sintering Principles p. 235 Sintering Practices for Bronze p. 237 Sintering Practices for Brass and Nickel Silvers p. 238 Heat Treating p. 242 Homogenizing p. 242 Annealing p. 243 Stress Relieving p. 247 Hardening p. 248 Heat-Treating Equipment p. 249 Protective Atmospheres p. 251 Heat Treating of Beryllium-Copper Alloys p. 253 Heat Treating of Chromium-Copper Alloys p. 257 Heat Treating of Zirconium-Copper Alloys p. 259 Heat Treating of Miscellaneous Precipitation-Hardening Alloys p. 259 Heat Treating of Spinodal-Hardening Alloys p. 259 Heat Treating of Aluminum Bronzes p. 262 Machining p. 264 Defining Machinability p. 264

5 Machinability of Copper Alloys p. 265 Type I (Free-Cutting) Alloys p. 265 Type II (Short-Chip) Alloys p. 267 Type III (Long-Chip) Alloys p. 267 Additional Factors Affecting Machinability p. 268 Selecting Copper Alloys for Machinability p. 268 Recommended Machining Practices p. 269 Nontraditional Machining Methods p. 274 Welding p. 276 Arc Welding p. 276 Alloy Metallurgy and Weldability p. 276 Factors Affecting Weldability p. 278 Arc Welding Processes p. 278 Filler Metals p. 279 Welding of Coppers p. 281 Welding of High-Strength Beryllium Coppers p. 284 Welding of High-Conductivity Beryllium Copper p. 287 Welding of Cadmium and Chromium Coppers p. 287 Welding of Copper-Zinc Alloys p. 288 Welding of Copper-Zinc-Nickel Alloys p. 288 Welding of Phosphor Bronzes p. 288 Welding of Aluminium Bronzes p. 289 Welding of Silicon Bronzes p. 291 Welding of Copper-Nickel Alloys p. 292 Welding of Dissimilar Metals p. 293 Safe Welding Practices p. 294 Other Non-Arc Fusion Welding Processes p. 295 Oxyfuel Gas Welding p. 295 Resistance Welding p. 296 Electron Beam and Laser Beam Welding p. 299 Solid-State Welding p. 299 Brazing, Soldering, and Adhesive Bonding p. 303 Brazing p. 303 Soldering p. 313 Adhesive Bonding p. 318 Surface Engineering p. 320 Cleaning and Finishing Processes p. 320 Preparation for Plating p. 326 Plating, Coating, and Coloring Processes p. 328 Metallography, Microstructures, and Phase Diagrams p. 335 Metallography and Microstructures of Copper and Copper Alloys p. 337

6 Macroexamination p. 337 Microexamination p. 337 Metallography and Microstructures of Beryllium-Copper Alloys p. 354 Health and Safety p. 354 Specimen Preparation p. 354 Macroexamination p. 355 Microexamination p. 355 Microstructures of Beryllium-Copper Alloys p. 356 Solidification Structures of Copper Alloy Ingots p. 360 Dendrites p. 360 Grains p. 363 Ingot Defects p. 365 Phase Diagrams p. 369 Engineering Properties and Service Characteristics p. 383 Corrosion Behavior p. 385 Nature of the Protective Oxide Film p. 385 Effects of Alloy Compositions p. 385 Types of Attack p. 387 Factors Influencing Alloy Selection in Specific Environments p. 392 Atmospheric Corrosion p. 395 Corrosion in Soils and Groundwater p. 397 Corrosion in Waters p. 398 Corrosion in Acids p. 404 Corrosion in Alkalis p. 407 Corrosion in Salts p. 408 Corrosion in Organic Compounds p. 409 Corrosion in Gases p. 410 SCC of Copper Alloys in Specific Environments p. 411 Protective Coatings p. 414 Corrosion Testing p. 414 Stress-Corrosion Cracking p. 419 Environmental Effects p. 419 Metallurgical Effects p. 422 Mechanical and Geometrical Effects p. 425 SCC Test Methods p. 425 Mitigation of SCC p. 427 Cracking Mechanisms p. 427 Effect of Temperature on Properties p. 430 Low-Temperature Properties p. 430 High-Temperature Properties p. 431 Fatigue Properties p. 440

7 Alloy Metallurgy and General Mechanical Properties p. 440 Fatigue Testing p. 441 Fatigue Data p. 441 Structure, Processing, and Property Relationships p. 443 Properties of Pure Copper p. 446 Atomic and Electron Structures p. 446 Crystal Stucture p. 446 Density and Volume Change on Freezing p. 446 Electrical Properties p. 446 Thermal Properties p. 448 Magnetic Properties p. 449 Optical Properties p. 449 Nuclear Properties p. 450 Chemical Properties p. 451 Mechanical Properties p. 451 Properties of Wrought Copper and Copper Alloys p. 453 C10100, C10200 p. 453 C10300 p. 453 C10400, C10500, C10700 p. 456 C10800 p. 457 C Cu-0.04O p. 457 C Cu-0.04O-0.01Cd p. 460 C11300, C11400, C11500, C Cu + Ag-0.4O p. 462 C12500, C12700, C12800, C12900, C13000 p. 463 C14300, C Cu-0.1Cd; 99.8Cu-0.2Cd p. 464 C Cu-0.5Te p. 465 C Cu-0.4S p. 465 C Cu-0.15Zr p. 466 C Cu-0.1Zr p. 467 C Cu-0.11 Mg-0.06P p. 468 C Cu-0.2Al[subscript 2]O[subscript 3] p. 468 C Cu-0.4Al[subscript 2]O[subscript 3] p. 469 C Cu-0.7Al[subscript 2]O[subscript 3] p. 469 C Cu-1Cd p. 469 C Cu-1.7Be-0.3Co p. 470 C17200, C17300 p. 471 C Cu-0.3Be-0.5Co p. 473 C Cu-0.5Be-2.5Co p. 473 C17600 p. 475 C Cu-0.8Cr-0.16Zr-0.04Mg p. 476 C18200, C18400, C Cu-1Cr p. 476

8 C Cu-1Pb p. 477 C Cu-1.0Fe-0.03P p. 478 C Cu-0.1Fe-0.03P p. 478 C19400 Cu-2.35Fe-0.03P-0.12Zn p. 478 C Cu-1.5Fe-0.1P-0.8Co-0.6Sn p. 479 C Cu-0.75Fe-1.25Sn-0.03P p. 480 C Cu-0.6Fe-0.2P-0.05Mg p. 480 C Cu-5Zn p. 481 C Cu-10Zn p. 482 C Cu-12.5Zn p. 483 C Cu-15Zn p. 483 C Cu-20Zn p. 485 C Cu-30Zn p. 485 C26800, C Cu-35Zn p. 488 C Cu-40Zn p. 489 C Cu-9.1Zn-1.9Pb p. 490 C Cu-8.1Zn-1.9Pb-1Ni p. 490 C Cu-33.5Zn-0.5Pb p. 491 C Cu-32.4Zn-1.6Pb p. 491 C Cu-34.5Zn-0.5Pb p. 492 C Cu-34Zn-1Pb p. 492 C Cu-33.5Zn-2Pb p. 493 C Cu-36.2Zn-1.8Pb p. 493 C Cu-37.5Zn-0.3Pb p. 493 C Cu-36.4Zn-1.1Pb p. 494 C Cu-35.5Zn-2.5Pb p. 495 C Cu-35.5Zn-3Pb p. 495 C36500, C36600, C36700, C Cu-39.4Zn-0.6Pb p. 496 C Cu-39Zn-1Pb p. 496 C Cu-38Zn-2Pb p. 497 C Cu-40Zn-3Pb p. 497 C Cu-4Zn-1Sn p. 498 C Cu-2Sn-3Zn p. 498 C Cu-8.5Zn-0.5Sn p. 499 C Cu-7.2Zn-1.8Sn p. 499 C Cu-4.35Zn-5.15Sn p. 500 C Cu-11.4Zn-1.1Sn p. 500 C Cu-9.5Zn-2Sn p. 500 C Cu-10.8Zn-2.2Sn p. 501 C Cu-14.3Zn-0.7Sn p. 501 C Cu-18.1Zn-0.9Sn p. 502

9 C44300, C44400, C Cu-28Zn-1Sn p. 502 C46400, C46500, C46600, C Cu-39.2Zn-0.8Sn p. 504 C Cu-38Zn-0.8Sn-0.7Pb p. 505 C Cu-37.5Zn-1.8Pb-0.7Sn p. 505 C Cu-1.3Sn p. 506 C Cu-2.0Sn-0.3Ni p. 507 C Cu-5Sn-0.2P p. 507 C Cu-4.2Sn-0.2P p. 507 C Cu-8Sn p. 508 C Cu-10Sn p. 508 C Cu-4Pb-4Sn-4Zn p. 509 C Cu-5Al p. 509 C Cu-5Al p. 510 C Cu-8Al p. 510 C Cu-7Al-2.7Fe-0.3Sn p. 511 C Cu-7Al-2Fe p. 512 C Cu-8Al-2Ni p. 513 C Cu-10Al-3Fe p. 513 C Cu-11Al-3Fe p. 514 C Cu-4.3Fe-13Al p. 515 C Cu-10Al-5Ni-3Fe p. 515 C Cu-9Al-5Ni-4Fe p. 516 C Cu-3.5Al-1.0Si p. 516 C Cu-2.8Al-1.8Si-0.40Co p. 517 C Cu-1.5Si p. 518 C Cu-3.0Si-1.5Sn-0.1Cr p. 518 C Cu-3Si p. 518 C Cu-1.5Fe-0.5Co-11.5Zn p. 519 C Cu-22.7Zn-3.4Al-0.4Co p. 519 C Cu-22.7Zn-3.4Al-0.6Ni p. 520 C Cu-14.5Zn-4Si p. 521 C Cu-3.0Ni-0.6Si-0.1Mg p. 521 C Cu-5.5Ni-1.5Fe-0.6Mn p. 521 C Cu-10Ni p. 522 C Cu-20Ni p. 522 C Cu-30Ni p. 523 C Cu-30Ni-2.8Cr p. 524 C Cu-16.5Ni-0.5Cr p. 524 C Cu-9.5Ni-2.3Sn p. 525 C Cu-25Zn-10Ni p. 525 C Cu-18Ni-17Zn p. 526

10 C Cu-20Zn-15Ni p. 526 C Cu-23Zn-12Ni p. 527 C Cu-27Zn-18Ni p. 527 C Cu-25Zn-8Ni-2Pb p. 528 Properties of Cast Copper Alloys p. 529 C81100 p. 529 C81300 p. 529 C Cu-0.8Cr-0.06Be p. 529 C Cu-1Cr p. 530 C Cu-1.5Co-1Ag-0.4Be p. 530 C Cu-2.5Co-0.5Be p. 531 C Cu-1.5Ni-0.5Be p. 532 C Cu-1.7Be-0.3Co p. 532 C Cu-2Be-0.5Co-0.25Si p. 533 C Cu-2.4Be-0.5Co p. 535 C Cu-2.6Be-0.5Co-0.3Si p. 535 C83300 p. 536 C Cu-5Sn-5Pb-5Zn p. 536 C Cu-4Sn-6Pb-7Zn p. 537 C Cu-3Sn-7Pb-9Zn p. 538 C Cu-21/2Sn-61/2Pb-15Zn p. 538 C Cu-1Sn-3Pb-24Zn p. 539 C Cu-1Sn-3Pb-29Zn p. 539 C85700, C Cu-1Sn-1Pb-35Zn p. 539 C86100, C Cu-24Zn-3Fe-5Al-4Mn p. 540 C Cu-26Zn-3Fe-3Al-4Mn p. 540 C Cu-0.75Sn-0.75Pb-37Zn-1.25Fe-0.75Al-0.5Mn p. 540 C Cu-39Zn-1.3Fe-1Al-0.5Mn p. 541 C86700 p. 542 C86800 p. 543 C87300 (formerly C87200) p. 543 C87600 p. 544 C87610, Silicon Bronze p. 545 C87500, C Cu-4Si-14Zn p. 545 C87900 p. 545 C Cu-8Sn-4Zn p. 546 C Cu-10Sn-2Zn p. 546 C Cu-11Sn p. 547 C /2Cu-12Sn-11/2Ni p. 547 C Cu-6Sn-11/2Pb-41/2Zn p. 547 C Cu-8Sn-1Pb-4Zn p. 548

11 C Cu-11Sn-1Pb-1Ni p. 548 C Cu-10Sn-1Pb-2Zn p. 549 C Cu-10Sn-2Pb p. 549 C Cu-10Sn-21/2Pb-31/2Ni p. 550 C Cu-7Sn-7Pb-3Zn p. 550 C93400 p. 551 C Cu-5Sn-9Pb-1Zn p. 551 C Cu-10Sn-10Pb p. 552 C Cu-7Sn-15Pb p. 553 C Cu-6Sn-15Pb p. 554 C Cu-5Sn-25Pb p. 554 C Cu-7Sn-20Pb p. 554 C Cu-3Fe-9Al p. 555 C Cu-1Fe-10Al p. 555 C95400 (85Cu-4Fe-11Al) and C95410 p. 556 C Cu-4Fe-4Ni-11Al p. 557 C Cu-2Si-7Al p. 557 C Cu-3Fe-8Al-2Ni-12Mn p. 558 C Cu-4Fe-9Al-4Ni-1Mn p. 558 C Cu-10Ni p. 559 C Cu-30Ni p. 559 C Cu-30Ni-0.5Be p. 559 C Cu-2Sn-10Pb-20Zn-12Ni p. 560 C Cu-4Sn-4Pb-8Zn-20Ni p. 560 C Cu-5Sn-1.5Pb-2Zn-25Ni p. 560 C Cu-2.2Ni-2.0Fe-1.2Al-1.2Si-3.0Zn p. 561 C99500 p. 561 C Cu-5Ni-1Al-1.5Pb-12Mn-24Zn p. 561 C99750 p. 561 Beryllium copper 21C 97Cu-2Be-1Co p. 562 Beryllium copper nickel 72C 68.8Cu-30Ni-1.2Be p. 562 Appendix p. 565 Specification Cross-Reference for Wrought and Cast Products p. 567 Approximate Equivalent Hardness Numbers for Wrought Coppers p. 588 Approximate Equivalent Hardness Numbers for Cartridge Brass p. 589 Subject Index p. 591 Alloy Index p. 621 Table of Contents provided by Blackwell's Book Services and R.R. Bowker. Used with permission.