High-wear-resistance and corrosion-resistance copper alloy material and preparation method thereof

Abstract

The application provides a high wear-resistant and corrosion-resistant copper alloy material and a preparation method thereof, and the material comprises the following components in percentage by weight: Cu 55-65%, Al 0.5-5%, Mn 2.0-4%, Si 2.0-5%, Fe≤0.35%, Ni≤0.25%, and the balance is Zn and inevitable impurities. By adding Mn, Si, Al and other elements in the copper alloy, a β phase matrix and a hard wear-resistant phase such as Mn-Si compound are formed, which can effectively hinder dislocation movement, improve the hardness and wear resistance of the material; the Al element can refine the grain, reduce the casting defects, and improve the yield strength and toughness. The preparation method comprises the steps of raw material weighing, smelting and centrifugal casting, and the obtained casting has a dense and uniform structure. The material has significantly improved wear resistance and corrosion resistance, and the service life can be improved by more than one time under the same working condition, and is suitable for high-load wear-resistant parts such as metallurgical rolling mills, hydraulic systems and large bearings.

Description

Technical Field

[0001] This invention relates to the field of copper alloy materials technology, and in particular to a high wear-resistant and corrosion-resistant copper alloy material and its preparation method. Background Technology

[0002] In the field of high-end equipment manufacturing, the service conditions of mechanical components are becoming increasingly demanding, and the boundaries of material performance are constantly being pushed. Copper alloys, due to their excellent electrical and thermal conductivity and good forming and processing characteristics, are widely used in key components in aerospace, marine engineering, metallurgical rolling, and heavy equipment. However, traditional copper alloys have significant shortcomings in wear resistance and corrosion resistance under complex service environments. Especially under extreme conditions such as high temperature, high pressure, and highly corrosive media (e.g., high humidity acidic environments or salt spray conditions), conventional brass alloys cannot meet the requirements for long service life, leading to increased equipment maintenance frequency, increased downtime losses, and higher life-cycle costs.

[0003] Taking metallurgical rolling equipment as an example, existing technologies mostly use ZCuSn25Al6Fe3Mn3 tin bronze material according to GB / T 1176-2013 standard to manufacture rolling mill wire nuts. The average service life of this type of material under continuous heavy load conditions is only 7-9 years, after which its wear reaches the scrap standard. Furthermore, the copper sliding plate friction pairs used in hydraulic transmission systems, due to the combined effects of water pressure, impact loads, and media corrosion, have a lifespan of less than 1.5 years. This problem has become a key factor restricting the reliability and economy of major equipment.

[0004] In contrast, the copper-based wire masterbatch material developed by Hitachi Metals Corporation of Japan for hot-rolled sizing mills achieved a performance breakthrough with less than 0.1 mm of wear after 14 years of continuous operation under similar working conditions, fully demonstrating the enormous potential of high-performance copper alloy materials in the field of wear and corrosion resistance. This shows that material composition design and microstructure control remain the core technological bottlenecks affecting the lifespan and performance of copper-based components.

[0005] Therefore, there is an urgent need to develop a high-wear-resistant and corrosion-resistant copper alloy material and its preparation method for service environments characterized by high temperature, high pressure, strong corrosion, and high wear. This material system needs to break through the traditional compositional design framework of copper alloys, achieving a synergistic improvement in hardness, toughness, and corrosion resistance through multi-element microalloying, second-phase dispersion strengthening, and microstructure control technologies. In particular, it must maintain stable service performance under the coupled effects of multiple fields such as boundary lubrication, fretting wear, and electrochemical corrosion. Its industrial application will significantly extend the replacement cycle of core components in high-end equipment, promoting a full-chain technological upgrade from materials to equipment in my country's major equipment manufacturing sector. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides a high-wear-resistant and corrosion-resistant copper alloy material and its preparation method. The invention primarily involves introducing multi-element alloying designs such as Mn, Si, and Al into a copper-based system to form a composite microstructure with a β-phase matrix and Mn-Si compounds as the wear-resistant phase. The Mn-Si wear-resistant phase is uniformly distributed within the copper matrix, effectively hindering dislocation movement and achieving a synergistic improvement in precipitation strengthening and wear resistance. By optimizing the smelting and centrifugal casting processes, a dense and uniformly composed casting structure is obtained, thereby significantly improving the wear and corrosion resistance of the casting under complex service conditions and extending its service life.

[0007] The technical means employed in this invention are as follows: A highly wear-resistant and corrosion-resistant copper alloy material, wherein the copper alloy material has the following components by weight percentage: Cu: 55–65 wt.%; Al: 0.5–5 wt.%; Mn: 2.0~4.0 wt.%; Si: 2.0–5 wt.%; Fe ≤ 0.35 wt.%; Ni ≤ 0.25 wt.%; The balance is Zn and unavoidable impurities; The microstructure of the copper alloy material consists of a β-phase copper matrix and a wear-resistant Mn-Si compound phase. The wear-resistant Mn-Si compound phase is dispersed in the copper matrix to hinder dislocation movement, thereby improving the hardness and wear resistance of the material.

[0008] Furthermore, the average size of the wear-resistant Mn-Si compound phase in the copper alloy material is between 1 and 100 μm.

[0009] Furthermore, the copper used is high-purity electrolytic copper with a purity of over 99.9%; the silicon used is industrial silicon powder with a purity of over 98%; and the manganese used is electrolytic manganese flakes with a purity of over 99.8%.

[0010] Furthermore, the mechanical properties of the copper alloy material are: tensile strength ≥450 MPa, yield strength ≥245 MPa, elongation ≥5%, and Brinell hardness HB ≥150.

[0011] This invention also provides a method for preparing the above-mentioned high wear-resistant and corrosion-resistant copper alloy material, comprising the following steps: S1. Raw material weighing: Weigh the raw materials according to the following proportions: Cu: 55~65 wt.%; Al: 0.5~5 wt.%; Mn: 2.0~4.0 wt.%; Si: 2.0~5 wt.%; Fe≤0.35 wt.%; Ni≤0.25 wt.%; the balance is Zn; S2. Smelting: Electrolytic copper and zinc are added to the furnace in proportion, heated to 1100-1200℃ to melt and stirred thoroughly to make the composition uniform; then silicon powder and manganese flakes are added, the temperature is further raised to 1250-1350℃ and held for 1-2 hours to make silicon and manganese fully dissolve and form Mn-Si compounds; then aluminum ingots and zinc ingots are added to complete the multi-element alloying process. S3. Centrifugal casting: The molten alloy liquid is poured into a centrifugal casting mold at 1000-1200℃. The casting speed and mold temperature are controlled to obtain a copper alloy casting with a dense structure.

[0012] Furthermore, during the centrifugal casting process, the casting speed is selected according to the requirements of the parts, ranging from 100 to 1500 rpm, in order to suppress dendrite growth and improve the uniformity of the microstructure.

[0013] Compared with the prior art, the present invention has the following advantages: 1. This invention involves adding multiple alloying elements such as Mn, Si, and Al to a copper-based alloy to form a composite microstructure consisting of a β-phase copper matrix and hard, wear-resistant phases such as Mn-Si compounds. The Mn-Si compound wear-resistant phase is dispersed throughout the matrix, effectively hindering dislocation movement and achieving a significant precipitation strengthening effect, thereby improving the material's hardness and wear resistance.

[0014] 2. This invention also effectively refines the grain size and reduces casting defects by adding Al, thereby improving the yield strength and toughness of the alloy and enabling the material to maintain good impact resistance and stability under high load conditions. Ni further improves the alloy's corrosion resistance, allowing the material to maintain stable performance in high-temperature, high-pressure, and highly corrosive environments.

[0015] 3. This invention achieves a coordinated balance between the hardness, strength, wear resistance and corrosion resistance of the material through multi-element alloying design, forming a composite system with high strength, high toughness and high corrosion resistance.

[0016] 4. Under typical service conditions of fixed-width machine wire nut, compared with the currently used ZCuZn25Al6Fe3Mn3 brass material, the material of the present invention shows significant advantages in terms of friction and wear performance and corrosion resistance. Its friction and wear degree is significantly reduced, and the surface wear is more uniform and stable. In the same corrosive environment, the time for the sample to show obvious corrosion is significantly extended, and the overall corrosion resistance is significantly improved.

[0017] In summary, this invention significantly improves the mechanical properties and service stability of copper alloy materials through the synergistic effect of Mn-Si compound wear-resistant phase strengthening and Al grain refinement; it also exhibits excellent wear resistance and corrosion resistance under complex high temperature, high pressure and acid-alkali wet corrosion environments.

[0018] Based on the above reasons, the material of this invention is suitable for wear-resistant and corrosion-resistant key components such as large high-load sliding bearings, hydraulic cylinder bushings, and metallurgical rolling mill copper bushings. It can effectively extend service life and reduce maintenance costs, and has significant engineering application and economic value. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a metallographic diagram of the high wear-resistant and corrosion-resistant copper alloy material of the present invention.

[0021] Figure 2 This is a scanning electron micrograph of the high wear-resistant and corrosion-resistant copper alloy material of the present invention. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] The chemical composition (mass percentage) of the high wear-resistant and corrosion-resistant copper alloy material described in this embodiment is as follows: Cu: 60%; Al: 2%; Mn: 2%; Si: 3%; the balance is Zn and unavoidable impurities.

[0024] The preparation method of the above copper alloy material is as follows: S1. Material Preparation: The copper used is high-purity electrolytic copper with a purity of ≥99.9% to reduce the adverse effects of impurities on the alloy's performance; the silicon used is industrial silicon powder with a moderate particle size and a purity of ≥98%; the manganese used is electrolytic manganese flakes with a purity of ≥99.8%; the aluminum used is high-purity aluminum ingot with a purity of ≥99.5%; and the zinc used is electrolytic zinc ingot with a purity of ≥99.9%.

[0025] S2, Smelting: Electrolytic copper and zinc are added to a furnace in a certain proportion and heated to 1100℃ to melt completely. The mixture is stirred thoroughly to ensure uniform composition. Then, silicon powder and manganese flakes are added, and the temperature is raised to 1300℃ and held for 2 hours to allow silicon and manganese to react fully and form Mn-Si compounds. After that, aluminum ingots and zinc ingots are added to adjust the composition, and copper is tapped at 1180℃ to obtain a uniform alloy liquid.

[0026] S3, Centrifugal casting: The molten alloy is poured into a centrifuge mold at 1100℃, and the centrifuge speed is controlled at 500 rpm to make the casting dense and uniform in composition, thus obtaining a well-formed copper alloy casting.

[0027] The mechanical properties of the prepared copper alloy material were tested, and the results are as follows: Tensile strength: 489 MPa; Yield strength: 295 MPa; Elongation: 6.68%; Brinell hardness HB: 178.

[0028] Test results show that the material has high strength and hardness, as well as good plasticity and toughness, and can meet the requirements for long-term service under high load and strong corrosion conditions.

[0029] like Figure 1 and Figure 2 The image shows the metallographic structure and scanning electron micrograph of the copper alloy material in this embodiment. It can be seen from the image that the Mn-Si phase is uniformly distributed in the matrix β phase, with an average size of 65 μm.

[0030] Example 2 This embodiment provides a method for preparing a high wear-resistant and corrosion-resistant copper alloy material. The preparation method is basically the same as that in Example 1, except that the Al content is 1 wt.%, the manganese content is 3 wt.%, and the balance is Zn.

[0031] The tensile strength was tested to be 474 MPa; yield strength to be 276 MPa; elongation to be 5.28%; and Brinell hardness (HB) to be 165. The average size of the Mn-Si phase was 82 μm.

[0032] In summary, this invention successfully prepared a dense, uniformly composed, and highly wear-resistant and corrosion-resistant copper-based composite material by introducing alloying elements such as Mn, Si, and Al into a copper-based system and employing precisely controlled smelting and centrifugal casting processes. The copper alloy material obtained by this invention exhibits superior mechanical and wear resistance compared to traditional copper alloy materials, possessing higher strength, hardness, and good plasticity. The Mn-Si compounds are uniformly dispersed in the β-phase matrix within the microstructure, playing a significant precipitation strengthening role. The material properties remain stable under different formulation conditions.

[0033] The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high wear-resistant and corrosion-resistant copper alloy material, characterized in that, The copper alloy material has the following components by weight percentage: Cu: 55–65 wt.%; Al: 0.5–5 wt.%; Mn: 2.0~4.0 wt.%; Si: 2.0–5 wt.%; Fe ≤ 0.35 wt.%; Ni ≤ 0.25 wt.%; The balance is Zn and unavoidable impurities; The microstructure of the copper alloy material consists of a β-phase copper matrix and a wear-resistant Mn-Si compound phase. The wear-resistant Mn-Si compound phase is dispersed in the copper matrix to hinder dislocation movement, thereby improving the hardness and wear resistance of the material.

2. The high wear-resistant and corrosion-resistant copper alloy material according to claim 1, characterized in that, The average size of the wear-resistant Mn-Si compound phase in the copper alloy material is 1–100 μm.

3. The high wear-resistant and corrosion-resistant copper alloy material according to claim 1, characterized in that, The copper used is high-purity electrolytic copper with a purity of over 99.9%; the silicon used is industrial silicon powder with a purity of over 98%; and the manganese used is electrolytic manganese flakes with a purity of over 99.8%.

4. The high wear-resistant and corrosion-resistant copper alloy material according to claim 1, characterized in that, The mechanical properties of the copper alloy material are: tensile strength ≥450 MPa, yield strength ≥245 MPa, elongation ≥5%, and Brinell hardness HB ≥150.

5. A method for preparing a high wear-resistant and corrosion-resistant copper alloy material according to any one of claims 1 to 4, characterized in that, Includes the following steps: S1. Raw material weighing: Weigh the raw materials according to the following proportions: Cu: 55~65 wt.%; Al: 0.5~5 wt.%; Mn: 2.0~4.0 wt.%; Si: 2.0~5 wt.%; Fe≤0.35 wt.%; Ni≤0.25 wt.%; the balance is Zn; S2. Smelting: Electrolytic copper and zinc are added to the furnace in proportion, heated to 1100-1200℃ to melt and stirred thoroughly to make the composition uniform; then silicon powder and manganese flakes are added, the temperature is further raised to 1250-1350℃ and held for 1-2 hours to make silicon and manganese fully dissolve and form Mn-Si compounds; then aluminum ingots and zinc ingots are added to complete the multi-element alloying process. S3. Centrifugal casting: The molten alloy liquid is poured into a centrifugal casting mold at 1000-1200℃. The casting speed and mold temperature are controlled to obtain a copper alloy casting with a dense structure.

6. The preparation method according to claim 5, characterized in that, During the centrifugal casting process, the casting speed is selected according to the requirements of the parts, ranging from 100 to 1500 rpm, in order to suppress dendrite growth and improve the uniformity of the microstructure.

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