Cu-Ni-Sn Alloy Composition for Wear and Corrosion Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Copper-nickel-tin alloys face challenges in large-scale industrial production due to Sn-rich segregations at grain boundaries, which limit their castability, hot formability, and cold formability, and they have inadequate resistance to abrasive, adhesive, and fretting wear, as well as corrosion and stress relaxation.
Innovation Solution
A copper-nickel-tin alloy with a specific composition (2.0 to 10.0% Ni, 2.0 to 10.0% Sn, 0.01 to 1.5% Si, 0.01 to 1.0% Fe, 0.002 to 0.45% B, 0.001 to 0.15% P, and optional Co, Zn, and Pb) that includes Si-containing and B-containing phases, forming silicon borides, borosilicates, and borophosphosilicates, which act as wear and corrosion protectants, ensuring a uniform distribution of tin-enriched phases and absence of discontinuous precipitates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional casting methods are used for copper-nickel-tin alloys, then production can be carried out, but Sn-rich segregations form at grain boundaries which deteriorate castability, hot formability and cold formability
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical composition parameters of the alloy, specifically limiting Sn to 2-10 wt%, Ni to 2-10 wt%, and adding Si (0.01-1.5 wt%), B (0.002-0.45 wt%), P (0.001-0.15 wt%), and other elements within specified ranges. This compositional parameter optimization prevents Sn-rich segregation at grain boundaries while maintaining excellent castability, hot formability and cold formability without requiring complex processing techniques.
2Strength
If the alloy composition is optimized for strength, then mechanical properties improve, but resistance to wear and corrosion deteriorates
Solution Approach 1:
The patent creates a composite material system by combining Cu-Ni-Sn base alloy with multiple functional additives: Si and B form hard wear-resistant phases (silicon borides), while Si, B and P form protective surface phases (borosilicates and borophosphosilicates). This composite structure simultaneously achieves high mechanical strength from the Ni-Sn precipitation hardening and superior wear-corrosion resistance from the hard particles and protective surface phases.
Solution Approach 2:
The patent applies multi-functionality by designing an alloy system where each element serves multiple purposes: Si and B not only strengthen the matrix but also form hard wear-resistant particles; the same Si-B-P combination forms protective surface phases against corrosion; Ni and Sn provide both strength through precipitation and contribute to the overall mechanical properties. This multi-functional design achieves strength, wear resistance and corrosion resistance simultaneously.
3Productivity
If complex processing techniques like spray compacting or thin strip casting are used, then production efficiency improves, but device complexity and production cost increase
Solution Approach 1:
The patent applies self-service by designing an alloy composition that automatically prevents Sn-rich segregation during conventional casting through its optimized chemical composition (Sn 2-10 wt%, Ni 2-10 wt%, Si 0.01-1.5 wt%, B 0.002-0.45 wt%, P 0.001-0.15 wt%). The alloy composition itself provides the solution to the segregation problem, eliminating the need for external complex processing interventions like spray compacting or thin strip casting, thereby maintaining high productivity with simple conventional casting equipment.
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 exhibits excellent castability, hot and cold formability, high resistance to abrasive and fretting wear, improved corrosion resistance, and stress relaxation resistance, maintaining strength and hardness without the need for complex processing techniques like spray compacting or thin strip casting.
Implementation Method 1
Si-containing and B-containing phases, which are formed as silicon borides, borosilicates and borophosphosilicates
Implementation Method 2
the ratio of the elements nickel and tin for the temperature at which spontaneous spinodal segregation occurs in the Cu-Ni-Sn alloys
Implementation Method 3
the precipitation processes are essential for the adjustment of the properties of this group of materials
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a high-strength copper-nickel-tin alloy with excellent castability, hot workability and cold workability, high resistance to abrasive wear, adhesive wear and fretting wear and improved resistance to corrosion and stress relaxation stability, consisting of (in weight %): 2.0 - 10.0 % Ni, 2.0 - 10.0 % Sn, 0.01 - 1.5 % Si, 0. 01 - 1.0 % Fe, 0.002 - 0.45 % B, 0.001 - 0.15 % P, selectively up to a maximum of 2.0 % Co, optionally also up to a maximum 2.0 % Zn, selectively up to a maximum of 0.25 % Pb, the residue being copper and unavoidable impurities, characterised in that - the ratio Si/B of the element contents in wt.% of the elements silicon and boron is a minimum 0.4 and a maximum 8; such that the copper-nickel-tin alloy has Si-containing and B-containing phases and phases of the systems Ni-Si-B, Ni-B, Fe-B, Ni-P, Fe-P, Ni-Si and other Fe-containing phases which significantly improve the processing properties and use properties of the alloy. The invention also relates to a casting variant and a further-processed variant of the high-strength copper-nickel-tin alloy, to a production method, and to the use of the alloy.