Copper Alloy Rolled Sheet with Co-P Precipitates
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Solution Overview
Problem
Current copper alloys for industrial applications, such as connectors and heat sinks, face challenges in achieving high strength, high electrical conductivity, and heat resistance while maintaining cost-effectiveness, due to issues like high-temperature processing requirements, oxidation, and grain coarsening, which affect fatigue strength and stress relaxation properties.
Innovation Solution
A copper alloy with a composition of 0.14 to 0.34 mass% Co, 0.046 to 0.098 mass% P, 0.005 to 1.4 mass% Sn, and additional elements like Ni and Fe, with fine precipitates of Co and P, uniformly dispersed to enhance strength, conductivity, and heat resistance, processed through hot rolling and precipitation heat treatment to avoid high-temperature solution heat treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature solution heat treatment (950°C) is performed to achieve high strength and electrical conductivity in Cr-Zr copper alloy, then excellent tension strength and electrical conductivity are obtained, but oxidation loss occurs, energy consumption increases, and acid cleaning is required
Solution Approach 1:
The patent changes the temperature parameter from conventional 950°C to a lower range of 700-900°C, and modifies the alloy composition by replacing part of Cr with Co (0.1-0.5 mass% Co, 0.03-0.1 mass% P) to achieve the desired strength and conductivity without high-temperature processing, thereby preventing oxidation loss
Solution Approach 2:
The patent uses a simpler, shorter heat treatment process at lower temperature that achieves the required material properties without the need for expensive protective atmospheres or vacuum equipment, making the process more cost-effective and environmentally friendly
2Strength
If high-temperature solution heat treatment (950°C) is performed to achieve high strength, then excellent electrical conductivity is obtained, but grains become coarse and fatigue strength deteriorates
Solution Approach 1:
The patent reduces the heat treatment temperature to 700-900°C and adjusts the alloying elements (Co: 0.1-0.5 mass%, P: 0.03-0.1 mass%) to achieve fine-grained microstructure with high electrical conductivity and improved fatigue strength, avoiding grain coarsening
Solution Approach 2:
The patent creates a composite microstructure with fine precipitates of Co and P uniformly distributed in the copper matrix, achieving both high electrical conductivity and fine grain structure that prevents fatigue failure
3Strength
If conventional alloy composition (Cr-Zr copper) is used to achieve high strength, then excellent electrical conductivity is obtained, but production cost increases due to special management requirements
Solution Approach 1:
The patent modifies the alloy composition to contain Co (0.1-0.5 mass%) and P (0.03-0.1 mass%) instead of conventional Cr-Zr combination, enabling heat treatment at lower temperatures (700-900°C) that can be performed in ordinary air atmosphere without special management, thereby reducing production costs
Solution Approach 2:
The patent develops a self-sufficient heat treatment process that does not require protective atmospheres, vacuum equipment, or acid cleaning facilities, as the lower temperature process inherently prevents oxidation and eliminates the need for post-processing cleaning operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a copper alloy with improved strength, electrical conductivity, and heat resistance, maintaining a balance between these properties and reducing production costs by avoiding high-temperature processing, thus suitable for high-temperature applications like automotive and electronic components.
Implementation Method 1
in a metal structure, precipitates are formed, the shape of the precipitates is substantially circular or elliptical on a two-dimensional observation plan
Implementation Method 2
A copper alloy with a composition of 0.14 to 0.34 mass% Co, 0.046 to 0.098 mass% P, 0.005 to 1.4 mass% Sn, and additional elements like Ni and Fe, with fine precipitates of Co and P, uniformly dispersed to enhance strength, conductivity, and heat resistance
Implementation Method 3
processed through hot rolling and precipitation heat treatment to avoid high-temperature solution heat treatments
Data Source
AI summary
A high-strength and high-electrical conductivity copper alloy rolled sheet has an alloy composition containing 0.14 to 0.34 mass % of Co, 0.046 to 0.098 mass % of P, 0.005 to 1.4 mass % of Sn and the balance including Cu and inevitable impurities, wherein [Co] mass % representing a Co content and [P] mass % representing a P content satisfy the relationship of 3.0≤([Co]−0.007)/([P]−0.009)≤5.9. In a metal structure, precipitates are formed, the shape of the precipitates is substantially circular or elliptical, the precipitates have an average grain diameter of 1.5 to 9.0 nm, or 90% or more of all the precipitates have a diameter of 15 nm or less to be fine precipitates, and the precipitates are uniformly dispersed. With the precipitation of the fine precipitates of Co and P and the solid-solution of Sn, the strength, conductivity and heat resistance are improved and a reduction in costs is realized.