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C 8 6 0 8 8 0 8 9 9 9 2 7 8 6 2 8 8 0 8 8 5 9 2 3 pouring temperature,
Manganesebronze alloys.
P 9 9 9
r 5 5 5
o 2 4 5
p 0 0 0
e r t y C 0 C 9 5 3 0 0 0 C 0 melting point,
C 1 0 3 8 1 0 4 3 1 0 3 8 1 0 5 2 1 0 2 7 1 0 3 8 1 0 3 8 1 0 5 4 pouring temperature,
Cl i g h t c a s t i n g s 1 1 2 1 1 2 0 4 1 1 2 1 1 2 0 4 1 2 6 0 1 2 3 2 h e a v y c a s t i n g s 1 0 9 3 1 1 4 9 1 0 6 6 1 1 4 9 1 7 7 7 1 0 6 6 s p e c i c g r a v i t y 7 . 3 7 . 5 7 . 3 7 . 6 5 7 . 5 0 7 . 4 9 7 . 6 6 d r o s s g e n e r a t i o n
h h m m m
a
i i o o o
g g d d d
h h e e e
h g a r a t r a t r a t
i g h h i g h s s i n g e m o d e r a t e e e shrinkage,
c m / m 2 . 6 0 2 . 8 6 1 . 8 2 2 . 6 0 1 . 8 2 2 . 6 0 2 . 0 8
a
The melting precautions for aluminum bronzes are basically the same as those for the other copper-base alloys.Thedangerofgasabsorpti onisnotasgreataswithtinbronze
alloysbecauseoftheprotective lmofaluminumoxide on the surface of the melt. Nevertheless, the alloys do dissolve gas and therefore precautions must betaken to prevent this. Although pouring temperatures are not as critical, temperature control is needed. Thepouring range is 10651260
C, depending on casting size and section; ladle surfaces should be kept wellskimmed during pouring, and the melt should be exposed to air as little
as possible. The shortest distance fromthe pouring ladle to the mold should be used to hold turbulence to an absolute minimum. Every precaution toeliminate dross should be taken.The gating and risering system for cast aluminum bronze is extremely important and must be arrangedto introduce the metal quietly at the lowest portion of the mold. The alloys shrink well; hence the gating andrisering must be well adapted to the particular casting. See Table 12 for
properties of these alloys. Alloys C95300, C 95400, and C 95500 are heat-treatable for increased mechanical properties and the last two shouldbe temper-annealed if used in a corrosive environment. Aluminum bronze alloys have been successfully cast in the centrifugal, continuous, permanent, plaster,and sand molding methods. Depending on the alloy, the minimum tensile strengths of sand-cast test bars
Aluminum bronze alloy UNS C 95200 is used as acid-resistant pumps, pump rods, bushings, and gears; alloyUNS C 95300, as pickling baskets, gears, and marine equipment; alloy UNS C 95400, as bearings, gears, valve
C 8 6 0 9 7 1 8 2 1 9 1 6 8 2 1 9 1 7 pouring temperature,
Cl i g h t c a s t i n g s 1 0 9 3 1 1 7 7 1 0 9 3 1 1 7 7 1 0 9 3 1 1 7 7 h e a v y c a s t i n g s 1 0 3 8 1 0 6 6 1 0 3 8 1 0 6 6 1 0 3 8 1 0 6 6 s p e c i c g r a v i t y 8 . 3 0 8 . 4 4 8 . 3 0 8 . 4 4 8 . 3 0 8 . 4 4 d r o s s g e n e r a t i o n l o w l o w l o w g a s s i n g h i g h m o d e r a t e t o h i g h m o d e r a t e t o
h i g h c a s t i n g y i e l d m o d e r a t e m o d e r a t e m o d e r a t e p a t t e r n m a k e r s s h r i n k a g e , c m / m 1 . 8 2 1 . 8 2 1 . 8 2
seats, valve guides, and pickling hooks; and alloy UNS C 95500, as valve guides and seats, corrosion-resistantparts, bushings, gears, and worms.
6.6. Silicon Bronze and Silicon Brass Alloys
For silicon-containing alloys best casting results are obtained if the melting is accomplished
using slightlyoxidizing conditions. Rapid heating to the melting point is required to control dissolved gases in the melt.Superheating the melt to ca 85
C above the pouring temperature is desired. Undisturbed cooling to thepouring temperature allows the dross to oat on the melt surface. Both melting and pouring temperatures areimportant and should be
C, depending on sizeand section thickness of the casting. Prolonged holding of the melt at pouring temperature should be avoided.Molds should be ready to receive the melt as soon as it is at the proper temperature. Melting oily scrap shouldbe avoided. Silicon is a powerful deoxidizing element and can easily be lost from the melt in the form of dross.Covers for the melt can be used. Preburned
charcoal has been successfully used as a cover and is appliedhot directly from the preburner. Fluxing and deoxidation is not necessary because of the strong afnity siliconhas for oxygen. Siliconbearing scrap must be kept segregated from other scrap, because silicon as an impurityin other alloys can promote a very coarse dendritic structure and weak porous castings.If gas has been absorbed, some degassing treatment is necessary. The melt may be ushed using
drynitrogen or a degassing ux may be used. Coppersilicon alloys shrink less than manganese bronze andaluminum bronze but more than tin bronze. Good gating and risering systems are required. The properties of these alloys are listed in Table 13.The alloys in the coppersilicon group have been cast using centrifugal, investment, die, permanent,plaster, and sand molding methods. The minimum tensile strengths for
Usesforcopper siliconalloysaresiliconbronze, UNSC87200,asbearings,pumps ,valveparts,marinettings,and corrosion-resistant castings; silicon brass UNS C 87400 as bearings, gears, impellers, valve stems, andclamps; and silicon brass UNS C 87500 as small propellers, valve stems, gears, and bearings.
Cl i g h t c a s t i n g s 1 3 1 6 1 4 2 7 13711483 12601427
13161427 1204 1316heavy castings 1204 1316 13161399 1232 1316 12601316 1993 1204s p e c i c g r a v i t y 8 . 9 4 8 . 9 4 8 . 8 8 . 9 8 . 8 8 . 9 8 . 9 8 . 9 5 dross generation low moderate moderate to high moderate to high highg a s s i n g h i g h h i g h moderate to high moderate to high moderatec a s t y i e l d l o w l o w m o d e r a t e m o d e r a t e m o d e r a t e pattern makers shrinkage, cm/m 1.56 1.82 1.56 1.56 1.041.56
High pouring temperatures cause most casting troubles with this group. The temperatures make a sand moldof low permeability practically unusable because the steam generated may exceed the venting power of thesand. Gases dissolve more readily at the higher temperatures and should be removed before pouring the melt.Degasiers are used as a matter of standard practice. Coppernickel alloys should be melted under slightlyoxidizing
conditions. Scrap must be clean. Cutting oils or compounds or other organic matter must be removedbefore melting to control dissolved gases in the melt that can lead to inferior castings.Time must be allowed for the degasier to be effective, and the treated melt should be tested with asocalled pitch test to determine the condition of the melt. An accurate and rapid method for evaluating the gas content of melts has been developed. The methodconsists of solidifying a
sample of the melt in a vacuum and measuring the degree of swelling in the solidiedsample. Melting and pouring temperatures must be controlled by measurement and the melt poured at 10951425
C,dependingonthealloy,casting size,andsectionthickness.Gatin gandriseringareespeciallyimpo rtant,and careful consideration of the particular casting must be made.Properties of copper nickel alloys are listed in Table 14. The alloys in the copper
nickel group have beensuccessfully cast using the centrifugal, investment, permanent, and sand molding methods. The minimumtensile strengths on test bars cast in sand molds are 207310 MPa (30,00045,000 psi).
6.7.1. Uses
Coppernickeliron alloys, UNS C 96200 (90:10 copper:nickel) and UNS C 96400 (70:30 copper:nickel), areusedincorrosion-resistant marine(seawater)applications. UNSC96400isusedforcorrosion
-resistant marineelbows,anges,valves,a ndpumps.Leadednickel brass,UNSC97300(12%nickel silver),isusedforhardwaretting s, valves, and statuary and ornamental castings.Theleaded nickel bronzes, UNS97600 (20%nickelsilver) andUNSC97800 (25%nickel silver),are usedfor marine, ornamental, and sanitary castings, and valves and pumps, and for ornamental hardware, sanitarycastings, valves, and
BIBLIOGRAPHY
Cast Copper Alloys under Copper Alloys in ECT 1st ed., Vol. 1, pp. 458467, by G. P. Halliwell, H. Kramer & Co.; in ECT 2nd ed., Vol. 6, pp. 244265, by R. E. Ricksecker, Chase Brass & Copper Co.; in
ECT 3rd ed., Vol. 7, pp. 6996, R. E.Ricksecker, Chase Brass & Copper, Inc. Cited Publications 1. Casting Copper-Base Alloys , American Foundrymens Society, Des Plaines, Ill., 1984, 232233. General References 2. P. R. Beeley, Foundry Technology , Halsted Press, New York, 1972.3. Casting Defects Handbook , American Foundrymens Society, Des Plaines, Ill., 1972.4. Casting Design
, American Foundrymens Society, Des Plaines, Ill., 1987.5. G. J. Cook, Engineered Castings , McGraw-Hill Book Co., New York, 1961.6. Copper and Copper Alloys , ASTM Standards Book, vol. 2.01 , American Society for Testing Materials, Philadelphia,1989.7. F. Dunlevey, Casting Beryllium Copper Alloys, Modern Casting Magazine (Nov. 1991).8. C. J. Evans, Foundry Trade J. , 143 (Dec. 22, 1977).9.
Gating and Risering of Copper-Base Alloys, American Foundrymens Society, Des Plaines, Ill., 1986.10. R. W. Heine and P. C. Rosenthal, Principles of Metal Casting , McGraw-Hill Book Co., Inc., New York, 1955.11. A. W. Hudd, Development of Continuous Casting of Copper Slab and Billet at IMI Reners Limited, Metall. Mater.Technol. 9 (11), (1977).12. Metals handbook
, 9th ed., vol. 2, American Society for Metals, Metals Park, Ohio, 1979.13. J. L. Morris, Metal Castings , Prentice-Hall Inc., Englewood Cliffs, N.J., 1957.14. D. G. Schmidt, The Challenge of Copper Alloy Castings in the 21st Century, Transactions AFS , 1991.15. I. D. Simpson and N. Standish, Metallography 10 (4), 433 (Oct. 1977).16. Unied Numbering System for Metals and Alloys
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Related Articles
Copper; Copper Alloys, Wrought Copper and Wrought Copper Alloys; Corrosion and corrosion control; Bearingmaterials