Sand Casting and Forging. Cu Alloys

Transcription

1 Sand Casting and Forging Cu Alloys

2 The ZOLLERN Group ZOLLERN is one of the pioneers of the metal industry. 3,000 employees at 14 production locations and seven subsidiaries in Europe, North and South America and Asia develop, manufacture and supervise a range of innovative metal products. ZOLLERN supplies sophisticated solutions for diverse applications through its business units drive technology, plain bearing technology, foundry technology, mechanical engineering elements and steel profiles. Contents Page Forging 3 Copper-aluminium wrought alloys (EN materials) 4 Copper-aluminium wrought alloys 5 Copper-nickel wrought alloys 6 Copper-zinc wrought alloys (special brass) 7 Copper wrought alloys with high conductivity 8 Low-alloy copper wrought alloys 9 Materials for short-circuit rods Dimensions and weights (approximate values) 11

3 Forging - Superior quality forging 02 // 03 Forging Superior quality forging ZOLLERN has been active in the area of non-cutting metal forming of copper and copper alloys through forging for more than 0 years. In the meantime, the transformation from purely manual production of the past to industrial production been consummated. Today, forgings and semi-finished products are manufactured through the use of forging hammers, a hydraulic forging press with 1,600 t compressive force, a pipe and extrusion press, as well as with a ring-rolling mill. The required ingoing material is largely produced in-house. Equipped with highly modern CNC machines, our machining workshops manufacture pre-processed or finished single or volume production parts from forgings or semi-finished products according to customer drawings. In the laboratory and materials inspection, all standard destructive and non-destructive tests and examinations are available. Production is certified according to DIN EN ISO 9001 : 8. For us, quality and delivery reliability are the prerequisites for success on the national and international market.

4 Copper-aluminium wrought alloys (EN materials) Zollern designation Standards Thickness Minimum values from the tensile specimen Min. hardness Intended use/ particular application examples mm R p0.2 N/mm 2 Rm A 5 N/mm 2 % HB /00 CuAl8Fe EBw AMB1 EBz EBh VB EBz EBz-Oe EBh EN 420 CW303G CuAl8Fe3 EN 1653 DIN CuAl8Fe3 EN 1653 CW304G CuAl9Ni3Fe2 DIN UK ~ CA3 F ~ U-A9NFe EN 420 CW306G CuAlFe3Mn2 EN 163* DIN UK CA3 F ~ U-AFe EN 420 CW307G CuAlNi5Fe4 EN 163*/ 167 / 1653, AD0 W6/2 DIN USA ~ C63000 GB CA4 F ~ U-A EN 420 CW308G CuAl11Fe6Ni6 EN 163* DIN (CuAl11Fe6Ni5) F ~ U-A11 VB - higher strength (non-standardised) Forged parts with heat treatment, up to 0 mm thickness with higher strength (EBz-Oe, higher alloyed than EBz=CW307G) HV EBz EBz-Oe EBh 250 (5) ~ ~ ~ 280 The toughness decreases with increasing Al content. Hardness, toughness, the very good cavitation and erosion resistance, abrasion and wear resistance increase with Al content. Selection of the alloy occurs predominantly according to the required strength properties. Good corrosion resistance compared to neutral and acidic aqueous media, alloyed with nickel also resistant against sea water and brine solutions good temperature resistance with low and increased temperatures, good resistance against scaling Fittings and hydraulic parts such as valve seats and plugs, guides, spindles, piston rods, axis, shafts, flanges, screws, spindle and pressure nuts, sliding strips and blocks, highly stressed bearings, cages for cage-type bearings, rotor bars, rotor wedge, shrink rings, pressure ladles, hinged blocks, worm, cog tooth and bevel wheels, bearing bushing, toggle bearings, plate floors for condensers, heat exchangers, parts for plastic forms and food processing industry, ship drive shafts, pump and agitator shafts AMB1 is predominantly used as bearing material. EBz is the alloy most often used for the applications specified above, as the material is a good combination of very high strength and good toughness, usable for sliding velocities of < 1 m/s and compressive loads per unit area up to approx. 20 KN/cm², good oil lubrication necessary EBw has better weldability properties than materials with less elongation EBh: compressive loads per unit area up to approx. 25 KN/cm² forged round and flat rods, rings, bushings wall thickness mm und mm mechanical properties pursuant to EN 420:1999, also for forged bars * extruded, drawn bars with wall thickness up to 50 mm, minimum quantity kg * mechanical properties pursuant to EN 163 Rectangular bars and profiles pursuant to EN 167 also possible, values are strongly dependent on wall thickness Young's modulus ~ 0-5 kn/mm 2 Electric conductivity ~ 4-6 MS/m Density ~ 7.6 kg/dm 3 Thermal conductivity ~ W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.9 µ r

5 Copper-aluminium wrought alloys (EN materials) / Copper-aluminium wrought alloys 04 // 05 Copper-aluminium wrought alloys Zollern designation Standards Thickness Minimum values from the tensile specimen Min. hardness Intended use/ particular application examples mm R p0.2 N/mm 2 Rm A 5 N/mm 2 % HB /00 MEBz WL CuAl9Ni Applications, properties see page 4 AMB 2 WL CuAl8Mn Both alloys are implemented if non-magnetic material is required, predominantly in shipbuilding and marine technology. MEBz, AMB 2 permeability < 1.03 SMBm SMBh DIN CuAl9Mn2 DIN forged (no EN standards available) SMBh forged, higher values DIN extruded, drawn 50 mm* ~ 0 Applications, properties see page 4 with 0.88 W/cm.K higher thermal conductivity, for inlets to cool in injection tools but also suitable as bearing material, due to the low hardness, better adaptability, counterpart material not required to be hardened steel TZB 28 TZB 32 TZB 36 non-standardised alloys, Al > 13% also for sand cast parts Deep drawing tools for reshaping of titanium, Hastelloy and austenitic steel, low friction coefficient, no welding, profile and straightening rolls, bending tools forged round and flat rods, rings, bushings wall thickness mm und mm mechanical properties pursuant to DIN 17678, also for forged bars * extruded, drawn bars with wall thickness up to 50 mm, minimum quantity kg * mechanical properties pursuant to DIN Forged parts deliverable also in alloys C61400, C62300, C62400, C63000, C63020 and C63 pursuant to ASTM B0, extruded, drawn bars pursuant to AMS 4 and 4640

6 Copper-nickel wrought alloys Zollern designation Standards Thickness Minimum values from the tensile specimen Min. hardness Intended use/ particular application examples mm R p0.2 N/mm 2 Rm A 5 N/mm 2 % HB /00 NB 1 WL 2.04 CuNi14Al3Fe1 (Values for thickness mm* and rings* non-standardised) F ~ U-N14A Rings* * Non-magnetic material - permeability < 1.01, very high strength, corrosion and sea water resistant, hardly any growth in sea water, erosion resistant, abrasion-proof, for highly stressed parts, also with simultaneous exposure to corrosion, such as screws, bolts, nuts and connection pieces with sea water contact, fitting parts such as spindles, seat rings and hydraulic parts, toothed gear and bevel wheels, inserts and cores in plastic injection moulding (thermal conductivity 0.71 W/cm.K), tension rod in industrial furnaces (high strength up to 400 C), retaining ring for electric motors NB EN 420 CW352H CuNiFe1Mn EN 163* / EN 1653 / AD0 W6/2 DIN USA C70600 UK CN2 F ~ U-NFe1Mn * Very good corrosion resistance against sea water, brackish and harbour water as well as chloride-containing aqueous solutions, no risk of stress-crack corrosion, high toughness, also in low temperatures, permitted calculated flow velocity NB m/s and NB m/s NB 30 EN 420 CW354H CuNi30Mn1Fe EN 163* / EN 1653 / AD0 W6/2 DIN USA C700 UK CN7 F ~ U-N30Mn1Fe * Plates and floors for condensers and heat exchangers, pipeline parts and other building components for power plants, refineries, desalination plants, chemical and petrochemical industry, ships, offshore plants forged round and flat rods, rings, bushings wall thickness 300 mm mechanical properties pursuant to EN 420:1999, also for forged bars * extruded, drawn bars with wall thickness up to 50 mm, minimum quantity kg * mechanical properties pursuant to EN 163 Young's modulus ~ kn/mm 2 Electric conductivity ~ 4-6 MS/m Density ~ 8.9 (NB1 ~ 8.5) kg/dm 3 Thermal conductivity ~ (NB1 ~ 0.71) W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.5 (NB1 < 1.01) µ r

7 Copper-Nickel Wrought Alloys / Copper-Zinc Wrought Alloys (Special Brass) 06 // 07 Copper-Zinc Wrought Alloys (Special Brass) Zollern designation Standards Thickness Minimum values from the tensile specimen Min. hardness Intended use/ particular application examples mm R p0.2 N/mm 2 Rm A 5 N/mm 2 % HB /00 StBm BZ 1 DIN CuZn40Al1 (Zollern supplies lead-free) EN 420 CW718R CuZn39Mn1AlPbSi EN 163:1998* / EN 167 DIN CuZn40Al1 UK CZ114 F ~ U-Z36N3 40* (~ ) Resistant against weather influences, not against sea water, good sliding properties in medium stress range for average sliding velocities - max m/s, StBm is lead-free, because of additional Si and Pb content, BZ 1 and BZ 2 have better sliding properties, BZ 2 has higher stress-bearing capacity than StBm and BZ 1 Sliding and guiding properties, mounting, tube and bottom plates, pressure ladles, pressure nut, bushings in mechanical engineering, in particular BZ 2 for worm wheels, bearing bushings and spindle nuts BZ 2 EN 420 CW713R CuZn37Mn3Al2PbSi EN 164* / EN 167 DIN CuZn40Al2 40* ZB 68 forged - Zollern values**, non-standardised, EN 163* CW708R CuZn31Si DIN USA C69800 ** ** Properties and applications similar to StBm, high low-temperature toughness, therefore versatile implementation ability in low-temperature technology, also for hydraulic parts CuZn39Sn1 EN 1653(*) CW719R CuZn39Sn1 EN 163* DIN CuZn39Sn USA C46400 ( Naval Brass ) 0(*) 75(*) 40(*) 25* HV 85 HV 1 HV Good sliding properties and good resistance against wear and stress-crack corrosion, average strength, good sea water resistance, tube plate for condensers and heat exchangers, fittings, screws, nuts, rivets for boats forged round and flat rods, rings, bushings wall thickness mm und mm mechanical properties pursuant to EN 420:1999, also for forged bars * extruded, drawn bars with wall thickness up to 50 (40, 25) mm, minimum quantity kg * mechanical properties pursuant to EN 163 or EN 164 Rectangular bars and profiles pursuant to EN 167 also possible, values are strongly dependent on wall thickness Young's modulus ~ 85-1 kn/mm 2 Electric conductivity ~ 6- MS/m Density ~ kg/dm 3 Thermal conductivity ~ W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.03 µ r

8 Copper wrought alloys with high conductivity Zollern designation Standards Thickness Minimum values from the tensile specimen Min. hardness Intended use/ particular application examples mm R p0.2 N/mm 2 Rm A 5 N/mm 2 % HB /00 SE-Cu CuAg EN 13605* CW021A Cu-HCP EN 420(*) (copper H045), EN DIN 1787 SE-Cu USA C300 UK C6 F Cu-c1 400(*) 5** 5** EN 13605* CW016A CuAg0,P EN 420(*) (copper H045), EN DIN CuAg0,1P USA C700 * 5* Very high thermal conductivity and electric conductivity (>57, cold-formed >56 MS/m), oxygen-free, insensitive to hydrogen embrittlement, good weldability and solderability, SE-Cu does not oxidise on the surface as quickly as OF-Cu, at increased temperatures the creep characteristics of CuAg are better, it does not lose the higher strength generated by cold-forming as quickly due to the higher recrystallisation temperature (~ 320 C compared to pure copper ~ 0 C) Short-circuit rings and rods for electric motors and generators, power rails and other circuit parts, continuous casting and other permanent moulds, cooling plates and other cooling elements, cooled combustion chambers for jet propulsion OF-Cu EN CW009A Cu-OFE EN 420(*) (copper H045) DIN 1787 OF-Cu USA C0 UK OFHC F Cu-c2 400(*) 5** 5** As SE-Cu, but with higher conductivity (>58,6; cold-formed >57 MS/m), free of deoxidant and virtually free of elements volatile in a vacuum, copper content at least 99.99%. The residual resistance ratio constitutes at least 400 Predominantly for applications in vacuum, lowtemperature and high-frequency technology, sockets and anodes for tubes, also parts with glass-metal connections, parts for linear and cyclone accelerators, beam stoppers in accelerator plants, microwave anodes, cooling elements and crucibles for vacuum processes forged round and flat rods, rings, bushings wall thickness 400 mm mechanical properties soft condition (H045; R, F20) pursuant to EN 420:1999, also for forged bars ** higher strength through work hardening up to 5 mm thickness (R220, F22 and R250, F25) - non-standardised, Zollern values * extruded, drawn profiles with wall thickness up to 50 mm, minimum quantity kg, not in OF-Cu CW009A material * mechanical properties pursuant to EN Young's modulus ~ kn/mm 2 Electric conductivity > 56 MS/m, depending on strength Density ~ 8.9 kg/dm 3 Thermal conductivity ~ W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.01 µ r

9 Copper wrought alloys with high conductivity / low-alloy copper wrought alloys 08 // 09 Low-alloy copper wrought alloys Zollern designation Standards Thickness Minimum values from the tensile specimen Min. hardness Intended use/ particular application examples mm R p0.2 N/mm 2 Rm A 5 N/mm 2 % HB /00 CCZr EN 420 CW6C CuCr1Zr EN 163* / EN 167 DIN CuCrZr USA C180 UK CC2 F ~ U-Cr0.8Zr * Very good combination of high electric (> 43 MS/m), thermal conductivity (~ 3.35 W/cm.K) and strength, is also, compared to copper, implemented with higher temperatures Short-circuit rings and bars for electric motors and generators, contact rails and bolts, switch parts, roller and spot welding electrodes as well as other parts for welding equipment, highly stressed parts in accelerator plants, continuous casting and other permanent moulds for cast iron and cast steel, also for non-ferrous metals, casting wheels for wire manufacture NSB EN 420 ~CW111C (mit Mn) CuNi2Si EN 163* / EN 167 DIN 17666: CuNi2Si USA ~ C64700 F U-N3S 30* As CCZr, higher strength but lower conductivity (11-16 MS/m and ~ 1.51 W/cm.K) and more wear-resistant for grinding and shortcircuit rings, rotor bars, connection pieces in the electronics industry and in overhead-line construction as well as other electrical circuit parts subject to mechanical stress NSB-CrZr non-standardised, Zollern values *Rings, flat and round rods **Profiles 0* 30** Similar to NSB, but with Cr+Zr ~ 0.3% for better creep rupture strength Slot wedges for motors, generators and application as NSB, higher electric conductivity ( > 19.0 MS/m) NSB 4 forged non-standardised, Zollern values EN 163:1998* CW1C CuNi3Si DIN 17666: USA ~ C * 500 ~ 7 ~ similar to NSB, but with higher strength, lower toughness, electric conductivity MS/m, thermal conductivity 1.8 W/cm.K Mould inserts and injection nozzles in plastic injection moulds, circuit parts subject to mechanical stress, copper back-up bar for resistance welding machines, pressure casting pistons forged round and flat bars, rings, bushings mechanical properties pursuant to EN 420:1999 (CuCr1Zr and CuNi2Si), also for forged bars * extruded, drawn profiles with thickness up to 50 mm, minimum quantity kg * mechanical properties pursuant to EN 163 (not NSB-CrZr) Young's modulus ~ kn/mm 2 Density ~8.8 kg/dm 3 Thermal expansion coefficient ~ /K Permeability < 1.01 µ r

10 Materials for short-circuit rods ZOLLERN ~ extensive conformity DIN EN (*) Temperature coefficient of the electric resistance at C Average values, for informational purposes only Number Designation Material Standard no. Standard Conductivity at 20 C IACS Resistance Temp. coeff. (*) 0.2 % Yield strength Tensile Elongation strength Hardness Density ms % Ω mm 2 /m 0 C -1 N/mm2 N/mm2 % HB kg/dm 3 // Copper, low-alloy 00 SE-Cu F25 Cu HCP CW021A & > 56.5 > 97.4 < SE-Cu F30 Cu HCP CW021A & > 56.5 > 97.4 < CuAg CuAg 0.P CW016A & > 56.0 > 96.6 < ZV45 ~CuTeP ~CW118C CCZr F44 CuCrZr CW6C 163 & 167 > 43.5 > 75.0 < V 422 CuNi0.5Mn NSB Cr-Zr ~CuNi2Si ~CW111C NSB4 CuNi3Si CW1V ZV NSB CuNi2Si ~CW111C HK 2 CuNi2Si ~CW111C // Copper, alloyed with silicon 20 HK 8 CuSi HK 7 CuSi HK 5 CuSi HK 4 CuSi HK 1 CuSi HK 9 CuSi HK 11 CuSi HK 6 CuSi HK CuSi // Copper-aluminium alloys 1722 AB8 SE 8 ~CuAl8 ~ ~ DIN EBz CuAlNi5Fe4 CW307G 163 & ~AMB 2 ~CuAl9Mn2 ~ ~ DIN // Copper-zinc brass 2650 Ms 95 CuZn5 CW500L ~ Ms 93 ~CuZn7 ~CW500L Ms 90 CuZn CW501L Ms 85 CuZn CW502L Ms 80 CuZn20 CW503L Ms 70 CuZn30 CW505L Ms 63 CuZn37 CW508L 163 & // Special brass 2740 Ms 59Pb2 CuZn39Pb2 CW6N 163 & Ms 58Pb2 CuZn40Pb2 CW617N 164 & StB ~CuZn39Mn1AlPbSi ~CW718R ~164 & ~ StB 8 ~CuZn39Mn1AlPbSi ~CW718R ~164 & ~ ZB 68 CuZn31Si1 CW708R ~ PBNi5 ~CuZn35Ni ~CC765S ~

11 Materials for short-circuit rods / dimensions and weights (approximate values) // 11 Dimensions and weights (approximate values) // maximum weight die-pressed parts Except TZB, VB, Ebh, NB1 and MEBz 25 kg // maximum weight as-forged TZB CuZn and CuNi14Al3Fe (NB 1) other CuCr1Zr Cu and CuAl upon request 800 kg 1 kg 0 kg 4000 kg // maximum wall thickness CuCr1Zr, CuNi2Si, CuNi3Si other 250 mm ~ 300 mm // maximum flat bar length as-forged CuAl (dependent on strength and thickness) meter // thin flat rods, forged (no sheet metals) length minimum thickness (milled) maximum width ~ 1 meter mm < x thickness // maximum ring outer diameter Cu, CuAl with sufficient thickness other 2.5 meter 1.5 meter // maximum bushings length inner diameter mm inner diameter mm inner diameter < 0 mm longer than 1 meter ~ 1 meter ~ 0.7 meter drilled drilled // profile wall thickness, thin extruded / drawn bars (minimum total weight per order kg) profiles bars, regular cross section 4-30 mm 8-50 mm pipes upon request, with inset approx. 1 mm

12 Subsidiaries & local offices Plants Hitzkofer Strasse Sigmaringendorf-Laucherthal Germany T F zgm@zollern.com All information presented in this brochure was prepared with great diligence. Any warranty of quality or qualities is not connected therewith. Zollern does not assume any guarantee or liability. Applicable are the provisions stipulated in arrangements and/or provisions as agreed on in the individual contract or in the General Terms and Conditions. ZOLLERN I I 083 I All images used are for illustrative purposes only. Group headquarters ZOLLERN GmbH & Co. KG IATF 16949