# US 2009/0260727 A1 · Sn-CONTAINING COPPER ALLOY AND METHOD OF MANUFACTURING THE SAME

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- Number: US 2009/0260727 A1
- Document ID: US20090260727A1
- Status: Published application
- Kind: A1
- Application number: 11/573,638
- Filed: 2005-08-10
- Published: 2009-10-22
- Earliest claimed: 2004-08-10
- Assignees: Sanbo Shindo Kogyo Kabushiki Kaisha
- Inventors: Keiichiro Oishi
- Web page: https://patentgrep.com/patent/US20090260727A1

## CPC

- C22C 9/04: with zinc as the next major constituent
- A61P 11/06: Antiasthmatics
- B22D 21/022: {Casting heavy metals, with exceedingly high melting points, i.e. more than 1600 degrees C, e.g. W 3380 degrees C, Ta 3000 degrees C, Mo 2620 degrees C, Zr 1860 degrees C, Cr 1765 degrees C, V 1715 degrees C}
- B22D 21/025: {Casting heavy metals with high melting point, i.e. 1000 - 1600 degrees C, e.g. Co 1490 degrees C, Ni 1450 degrees C, Mn 1240 degrees C, Cu 1083 degrees C}
- B22D 27/00: Treating the metal in the mould while it is molten or ductile (B22D7/12, B22D11/10, B22D43/00 take precedence); {Pressure or vacuum casting (B22D17/00 takes precedence)}
- C22C 1/03: using master alloys
- C22C 1/06: with the use of special agents for refining or deoxidising
- C22C 9/00: Alloys based on copper
- C22C 30/02: containing copper
- C22C 30/06: containing zinc
- C22F 1/08: of copper or alloys based thereon
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- A61P: SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- C22F: CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass, C23F17/00)

## Abstract

A Sn-containing copper alloy, contains Sn: 0.01 to 16 mass %, Zr: 0.001 to 0.049 mass %, P: 0.01 to 0.25 mass %, and Cu: remainder; satisfying f0=[Cu]−0.5[Sn]−3[P]=61 to 97, f1=[P]/[Zr] 0.5 to 100, f2=3[Sn]/[Zr]=30 to 15000 and f3=3[Sn]/[P]=3 to 2500 (the content of element ‘a’ is represented as [a] mass %). α and γ-phases and/or δ-phase are included and the total content of the α and γ-phases and/or δ-phase reaches 90% or more by area ratio, and the mean grain size of the macrostructure during melt-solidification is 300 μm or less.

## Claims

### Claim 1

A Sn-containing copper alloy, comprising:
Sn: 0.01 to 16 mass %, Zr: 0.001 to 0.049 mass %, P: 0.01 to 0.25 mass %, and Cu: remainder,
wherein f0=[Cu]−0.5[Sn]−3[P]=61 to 97, f1=[P]/[Zr]=0.5 to 100, f2=3[Sn]/[Zr]=30 to 15000 and f3=3[Sn]/[P]=3 to 2500, where the content of element ‘a’ is represented as [a] mass % are satisfied, and wherein
α and γ-phases and δ-phase, or α and γ-phases or δ-phase, are included and the total content of the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, reaches 90% or more by area ratio, and
a mean grain size in a macrostructure during melt-solidification is 300 μm or less.

### Claim 2

A Sn-containing copper alloy comprising:
Sn: 0.01 to 16 mass %, Zr: 0.001 to 0.049 mass %, P: 0.01 to 0.25 mass %, Zn: 0.01 to 38 mass %, and Cu: remainder,
wherein f0=[Cu]−0.5[Sn]−3[P]=61 to 97, f1=[P]/[Zr]=0.5 to 100, f2=([Zn]+3[Sn])/[Zr]=30 to 15000, f3=([Zn]+3[Sn])/[P]=3 to 2500 and f4=[Zn]+3[Sn]=10 to 48, wherein the content of each element ‘a’ is represented as [a] mass % are satisfied, and wherein
the α and γ-phases and δ-phase, or the α and γ-phases or δ-phase, are included and the total content of the α and γ-phases and δ-phase, or the α and γ-phases or δ-phase, reaches 90% or more by area ratio, and
the mean grain size in the macrostructure during the melt-solidification is 300 μm or less.

### Claim 3

A Sn-containing copper alloy comprising:
Sn: 0.01 to 16 mass %; Zr: 0.001 to 0.049 mass %; P: 0.01 to 0.25 mass %; one or more elements selected from Mn: 0.05 to 4 mass %, Al: 0.01 to 3 mass %, Si: 0.01 to 1.9 mass % and Co: 0.005 to 0.1 mass %; and Cu: remainder,
wherein f0=[Cu]−0.5[Sn]−3[P]+[Mn]−1.8[Al]−3.5[Si]=61 to 97, f1=[P]/[Zr]=0.5 to 100, f2=3[Sn]/[Zr]=30 to 15000, and f3=3[Sn]/[P]=3 to 2500, wherein the content of each element ‘a’ is represented as [a] mass %, and [a] =0 for each element ‘a’ that is not contained in the alloy, are satisfied, and
the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, are included and the total content of the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, reaches 90% or more by area ratio, and
the mean grain size in the macrostructure during melt-solidification is 300 μm or less.

### Claim 4

A Sn-containing copper alloy comprising:
Sn: 0.01 to 16 mass %; Zr: 0.001 to 0.049 mass %; P: 0.01 to 0.25 mass %; Zn: 0.01 to 38 mass %; one or more elements selected from Mn: 0.05 to 4 mass %, Al: 0.01 to 3 mass %, Si: 0.01 to 1.9 mass % and Co: 0.005 to 0.1 mass %; and Cu: remainder,
wherein f0=[Cu]−0.5[Sn]−3[P]+[Mn]−1.8[Al]−3.5[Si]=61 to 97, f1=[P]/[Zr]=0.5 to 100, f2=([Zn]+3[Sn])/[Zr]=30 to 15000, f3=([Zn]+3[Sn])/[P]=3 to 2500 and f4=[Zn]+3[Sn]=10 to 48, wherein the content of each element ‘a’ is represented as [a] mass %, and [a]=0 for each element ‘a’ that is not contained in the alloy, are satisfied, and
the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, are included and the total content of the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, reaches 90% or more by area ratio, and
the mean grain size in the macrostructure during melt-solidification is 300 μm or less.

### Claim 5

(canceled)

### Claim 6

A Sn-containing copper alloy comprising:
Sn: 0.01 to 16 mass %; Zr: 0.001 to 0.049 mass %; P: 0.01 to 0.25 mass %; Zn: 0.01 to 38 mass %; one or more elements selected from As: 0.02 to 0.2 mass %, Sb: 0.02 to 0.2 mass % and Mg: 0.001 to 0.2 mass %; and Cu: remainder,
wherein f0=[Cu]−0.5[Sn]−3[P]−0.5([As]+[Sb])+[Mg]+[Mn]−1.8[Al]−3.5[Si]=61 to 97, f1=[P]/[Zr]=0.5 to 100, f2=([Zn]+3[Sn])/[Zr]=30 to 15000, f3=([Zn]+3[Sn])/[P]=3 to 2500 and f4=[Zn]+3[Sn]=10 to 48, wherein the content of each element ‘a’ is represented as [a] mass %, and [a]=0 for each element ‘a’ that is not contained in the alloy, are satisfied, and
the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, are included and the total content of the α and γ-phases and δ-phase, or α and γ-phases or δ-phase, reaches 90% or more by area ratio, and
the mean grain size in the macrostructure during melt-solidification is 300 μm or less.

### Claim 7 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23, comprising:
Fe and Ni, or Fe or Ni, as inevitable impurities,
wherein when either of Fe or Ni is included, the content thereof is limited to be 0.25 mass % or less, and
when both of Fe and Ni are included, the total content thereof is limited to be 0.3 mass % or less.

### Claim 8 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23,
wherein a primary crystal is α-phase during melt-solidification.

### Claim 9 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23,
wherein peritectic reaction is generated during melt-solidification.

### Claim 10 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23,
wherein dendrite network is divided in crystal structure and a two-dimensional shape of grain is circular, substantially circular, oval, cross-like, acicular or polygonal during melt-solidification.

### Claim 11 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23,
wherein the α-phase in a matrix is minutely divided, and the δ and γ-phases or high Sn-concentration parts generated by segregation are distributed uniformly in the matrix.

### Claim 12 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23,
wherein, in a semi-solid metal state including 30 to 80% of solid phase, at least the dendrite network is divided in crystal structure and the two-dimensional shape of the solid phase is circular, substantially circular, oval, cross-like, acicular or polygonal.

### Claim 13 (depends on 12)

The Sn-containing copper alloy according to claim 12,
wherein, in the semi-solid metal state including 60% of the solid phase, a mean grain size of the solid phase is 150 μm or less and a mean maximum grain length of the solid phase is 200 μm or less, or the mean grain size of the solid phase is 150 μm or less or the mean maximum grain length of the solid phase is 200 μm or less.

### Claim 14 (depends on 1, 2, 3, 4, 6)

The Sn-containing copper alloy according to any one of claims 1 to 4, 6, or 23,
wherein the copper alloy is a casting product obtained in a casting process or a plastic-worked product, wherein the casting product is plastic-worked additionally one or more times.

### Claim 15 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the casting product is a wire, rod or hollow bar cast by horizontal continuous casting method, upward method or upcast method.

### Claim 16 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the casting product is a casting product, semi-solid metal casting product, semi-solid metal molding product, molten alloy forging product or die casing molding product.

### Claim 17 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the plastic-worked product is a hot extruding product, hot forging product or hot rolling product.

### Claim 18 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the plastic-worked product is a cold rolling product or cold drawing product.

### Claim 19 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the casting product is a gear, a worm gear, a bearing, a bush, an impeller, common mechanical parts, a metal fitting for water contact or a joint.

### Claim 20 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the plastic-worked product is electronic·electric device spring, switch, lead frame, connector, bellow, fuse grip, bush, relay, gear, cam, joint, flange, bearing, machine screw, bolt, nut, metal eyelet, heat exchanger pipe, heat exchanger, metallic mesh, sea net, breeding net, fish net, header material, washer, seawater condenser tube, ship parts shaft, seawater intake of a ship or metal fitting for water contact.

### Claim 21 (depends on 1, 2, 3, 4)

A method of manufacturing the Sn-containing copper alloy according to any one of claims 1 to 4, or 6,
wherein, in a casting process, Zr is added in a form of copper alloy containing Zr in order to prevent Zr from being added in a form of oxide or sulfide, or oxide and sulfide.

### Claim 22 (depends on 21)

The method of manufacturing the Sn-containing copper alloy according to claim 21,
wherein the copper alloy containing Zr is one of Cu—Zr alloy, Cu—Zn—Zr alloy, Cu—Zr alloy, to which one or more element selected from P, Mg, Al, B, Sn and Mn are added, and Cu—Zn—Zr alloy, to which one or more element selected from P, Mg, Al, B, Sn and Mn are added.

### Claim 23

A Sn-containing copper alloy comprising:
Sn: 0.01 to 16 mass %; Zr: 0.001 to 0.049 mass %; P: 0.01 to 0.25 mass %; Zn: 0.01 to 38 mass %; one or more elements selected from As: 0.02 to 0.2 mass %, Sb: 0.02 to 0.2 mass % and Mg: 0.001 to 0.2 mass %; one or more elements selected from Mn: 0.05 to 4 mass %, Al: 0.01 to 3 mass %, Si: 0.01 to 1.9 mass % and Co: 0.005 to 0.1 mass %; and Cu: remainder,
wherein f0=[Cu]−0.5[Sn]−3[P]−0.5([As]+[Sb])+[Mg]+[Mn]−1.8[Al]−3.5[Si]=61 to 97, f1=[P]/[Zr]=0.5 to 100, f2=([Zn]+3[Sn])/[Zr]=30 to 15000, f3=([Zn]+3[Sn])/[P]=3 to 2500 and f4=[Zn]+3[Sn]=10 to 48, wherein the content of each element ‘a’ is represented as [a] mass %, and [a]=0 for each element ‘a’ that is not contained in the alloy, are satisfied, and
the α and γ-phases and δ-phase, or the α and γ-phases or δ-phase, are included and the total content of the α and γ-phases and δ-phase, or the α and γ-phases or δ-phase, reaches 90% or more by area ratio, and
the mean grain size in the macrostructure during melt-solidification is 300 mm or less.

### Claim 24 (depends on 7)

The Sn-containing copper alloy according to claim 7,
wherein the copper alloy is a casting product obtained in a casting process or a plastic-worked product, wherein the casting product is plastic-worked additionally one or more times.

### Claim 25 (depends on 9)

The Sn-containing copper alloy according to claim 9,
wherein the copper alloy is a casting product obtained in a casting process or a plastic-worked product, wherein the casting product is plastic-worked additionally one or more times.

### Claim 26 (depends on 10)

The Sn-containing copper alloy according to claim 10,
wherein the copper alloy is a casting product obtained in a casting process or a plastic-worked product, wherein the casting product is plastic-worked additionally one or more times.

### Claim 27 (depends on 11)

The Sn-containing copper alloy according to claim 11,
wherein the copper alloy is a casting product obtained in a casting process or a plastic-worked product, wherein the casting product is plastic-worked additionally one or more times.

### Claim 28 (depends on 25)

The Sn-containing copper alloy according to claim 25,
wherein the casting product is a wire, rod or hollow bar cast by horizontal continuous casting method, upward method or upcast method.

### Claim 29 (depends on 25)

The Sn-containing copper alloy according to claim 25,
wherein the casting product is a casting product, semi-solid metal casting product, semi-solid metal molding product, molten alloy forging product or die casing molding product.

### Claim 30 (depends on 25)

The Sn-containing copper alloy according to claim 25,
wherein the plastic-worked product is a hot extruding product, hot forging product or hot rolling product.

### Claim 31 (depends on 25)

The Sn-containing copper alloy according to claim 25,
wherein the plastic-worked product is a cold rolling product or cold drawing product.

### Claim 32 (depends on 25)

The Sn-containing copper alloy according to claim 25,
wherein the casting product is a gear, a worm gear, a bearing, a bush, an impeller, common mechanical parts, a metal fitting for water contact or a joint.

### Claim 33 (depends on 25)

The Sn-containing copper alloy according to claim 25,
wherein the plastic-worked product is electronic electric device spring, switch, lead frame, connector, bellow, fuse grip, bush, relay, gear, cam, joint, flange, bearing, machine screw, bolt, nut, metal eyelet, heat exchanger pipe, heat exchanger, metallic mesh, sea net, breeding net, fish net, header material, washer, seawater condenser tube, ship parts shaft, seawater intake of a ship or metal fitting for water contact.

### Claim 34 (depends on 14)

The Sn-containing copper alloy according to claim 14,
wherein the casting product includes a semi-solid metal casting product.

### Claim 35 (depends on 27)

The Sn-containing copper alloy according to claim 27,
wherein the plastic-worked product is a cold rolling product or cold drawing product.

### Claim 36 (depends on 27)

The Sn-containing copper alloy accoring to claim 27,
wherein the plastic-worked product is electronic·electric device spring, switch, lead frame, connector, bellow, fuse grip, bush, relay, gear, cam, joint, flange, bearing, machine screw, bolt, nut, metal eyelet, heat exchanger pipe, heat exchanger, metallic mesh, sea net, breeding net, fish net, header material, washer, seawater condenser tube, ship parts shaft, seawater intake of a ship or metal fitting for water contact.