Copper Alloy for Selective Laser Melting Sanitary Fittings
Solution Overview
Problem
Copper alloys used in sanitary fittings are not suitable for generative manufacturing processes due to their high thermal conductivity and high melting point, limiting design freedom and increasing production costs.
Innovation Solution
A copper alloy with specific mass proportions of copper, zinc, and additional elements such as aluminum, iron, and arsenic, optimized for lower thermal conductivity and melting point, enabling its use in generative manufacturing processes like selective laser melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional copper alloys are used for sanitary fittings, then good corrosion resistance and strength are achieved, but high thermal conductivity and high melting point make them unsuitable for generative manufacturing processes
Solution Approach 1:
The patent modifies the chemical composition parameters of the copper alloy by limiting copper content to 46-53.5% and adding specific alloying elements (Al, Pb, Fe, Sn, B, As) within defined ranges. This parameter change lowers the melting point from traditional high values to 895-930°C, making the material suitable for generative manufacturing processes while maintaining other essential properties.
2Ease of manufacture
If traditional copper alloys are used for sanitary fittings, then good mechanical strength is achieved, but high thermal conductivity causes excessive zinc evaporation during processing
Solution Approach 1:
The patent changes the compositional parameters by reducing copper content and adding specific alloying elements (particularly Al 0.1-1.0%, Pb 0.5-1.5%, Fe 0.05-0.2%, Sn 0.1-0.3%, B 0.0001-0.001%, As 0.01-0.1%). These parameter changes stabilize the melt during processing, reducing zinc evaporation and improving manufacturing stability.
3Temperature
If copper alloy composition is optimized for generative manufacturing, then lower melting point and thermal conductivity are achieved, but design freedom and production costs are affected
Solution Approach 1:
The patent establishes specific compositional parameter ranges (Cu: 46-53.5%, Zn: balance, with controlled additions of Al, Pb, Fe, Sn, B, As) that enable generative manufacturing while maintaining adequate design freedom for sanitary fitting applications.
Solution Approach 2:
The patent creates a composite copper alloy system combining multiple elements (Cu-Zn-Al-Pb-Fe-Sn-B-As) where each component contributes specific properties. This composite material approach achieves the desired melting point and thermal conductivity while maintaining mechanical strength and corrosion resistance needed for design flexibility.
4Temperature
If copper alloy composition is optimized for generative manufacturing, then lower processing temperature is achieved, but material strength and corrosion resistance must be maintained
Solution Approach 1:
The patent optimizes compositional parameters within specific ranges to achieve a balance between lower melting point (895-930°C) and maintained material strength. The controlled addition of alloying elements strengthens the matrix while keeping processing temperature reduced for generative manufacturing.
Solution Approach 2:
The patent employs a multi-element composite alloy system where Cu-Zn provides the base matrix with reduced melting point, while Al, Pb, Fe, Sn, B, and As contribute to strength enhancement and property optimization, achieving both lower processing temperature and adequate mechanical strength.
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 alloy offers reduced thermal conductivity and melting point, improved strength, stability against stress corrosion, and reduced material costs, making it suitable for complex designs and thin-walled sanitary fitting housings.
Implementation Method 1
The alloy is particularly suitable for so-called selective laser melting (SLM) using the powder bed process, in which the processed material in powder form is applied in a thin layer to a base plate and locally melted using laser radiation.
Data Source
Figure 1
Figure 2A~2B
AI summary
The invention relates to a copper alloy, the elements of which have the following mass fractions: - 46 % to 53.5 % of copper (Cu); - 0 % to 1.0 % of aluminum (Al); - 0 % to 1.40 % of lead (Pb); - 0 % to 0.2 % of iron (Fe); - 0 % to 0.4 % of tin (Sn); - 0 % to 0.0002 % of boron (B); - 0 % to 0.2 % of arsenic (As); and - the remainder zinc (Zn). The invention further relates to a use of a corresponding copper alloy for a generative production method, a sanitary fitting (1) having a corresponding copper alloy and a method for producing a sanitary fitting (1) from a corresponding copper alloy.