FOUNDRY TECHNOLOGY WROUGHT COPPER ALLOYS

Transcription

1 FOUNDRY TECHNOLOGY

2 The Zollern factories The ZOLLERN GmbH & Co. KG is a company with worldwide operations, employing over 2400 employees in the business fields of transmission technology (automation, gears and winches, friction bearing technology), engineering elements, foundry technology and steel profiles. Aluminium-copper wrought alloys 4 Nickel-copper alloys 6 Copper-zinc alloys, special brass types 6 Copper and low alloy materials 8 Forms of delivery 10

3 FOUNDRY TECHNOLOGY 2 3 Forging on highest level For more than a century ZOLLERN forges copper and copper alloys. The former craftsman production has changed to industrial production. Forgings and wrought parts are nowadays made by forging hammers, a hydraulic 1,600 t press, an extrusion press as well as a ring rolling mill. The required pre-material is also produced in house. From the forging and wrought parts single or serial parts are preor finish-machined as per customers drawings in our well equipped machine shop with latest CNC lathes. In the laboratory and testing department all destructive and nondestructive tests and examinations are possible. Our production is certified to DIN EN ISO 9001 : Quality and service are our basis for successful work on the national and international market.

4 ALUMINIUM-COPPER WROUGHT ALLOYS Material International 1 Zollern Symbol No. standards brand DIN EBw Cu Al 9 Ni 3 Fe GB: CA F: U-A9 N Fe Cu Al 9 Ni 3 Fe 2 CW304G Chemical composition (guideline values %) Cu Al Fe Mn Ni Others Rem Strength values for size groups 2 Modulus Bending fatigue of elasticity strength under load stress I II III IV kn/mm 2 N/mm 2 Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ EBz Cu Al 10 Ni 5 Fe ISO: Cu Al 11 Fe 5 Ni USA: C Cu Al 10 Ni 5 Fe 4 CW307G GB: CA 104 (CA 105) F: U-A10 N Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ MEB Cu Al 9 Ni VG Bl. 1 Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ EBh Cu Al 11 Ni 6 Fe GB: CA F: U-A11 N Cu Al 11 Fe 6 Ni 6 CW308G Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ VB Cu Al 11 Ni 6 Fe GB: CA F: U-A11 N Cu Al 11 Fe 6 Ni 6 CW308G Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ TZB 28 TZB 32 TZB 36 Rem Special additives Rp0.2 N/mm 2 ca Rm N/mm 2 ca A5 (%) ca HB 10/1000 TZB 28: TZB 32: TZB 36: SMBm Cu Al 9 Mn ISO: Cu Al 9 Mn F: U-A9 M Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ SMBh Cu Al 9 Mn ISO: Cu Al 9 Mn F: U-A9 M Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ AMB 1 Cu Al 10 Fe 3 Mn ISO: Cu Al 10 Fe GB: CA 103 Cu Al 10 Fe 3 Mn 2 CW306G F: U-A10 Fe Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ AMB 2 Cu Al 8 Mn VG Bl. 1 Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/

5 Physical properties 3 Density Specific Coefficient Coefficient Electrical Permeaheat of thermal of thermal conduc- bility expansion conductivity tivity kg/dm 3 J/g K x 10-6 /K W/cm K MS/m µ r Material characteristics Application examples < 1.08 Engineering materials, strength and hardness increasing and ductility diminishing with the Al content, good corrosion and salt water resistance also under elevated temperature -, no danger of stress crack corrosion, extremely good cavitation and erosion resistance, high abrasion and wear resistance these four factors increase with the Al content-, good resistance to scaling. Good low temperature resistance. Fittings and hydraulic components such as valve seats and tapers, guides, lanterns, spindles, piston rods, axles, shafts, flanges, screws, nuts, sliding rails and blocks, cage bars, rotor keys, rotor and winding caps, shrink collars, pressure ladles, slipper pads, screws, worm gears, toothed and bevel wheels, bearing bushes, toggle bearings, panels (floors) for capacitors, heat exchangers, oil and gas coolers etc., plastics moulds, piping components, pump pistons, pump shafts, ships` propeller and agitator shafts < 1.90 See Ebw. Good bearing materials with hardened shaft and adequate oil lubrication particularly under dynamic stress: Permissible surface load increases to 25 kn/cm 2 with EBh. See EBw < 1.03 See EBw See Ebw, if additionally a non-magnetic material is required < 1.60 See EBw See EBw < 1.80 Engineering material with high strength and hardness, extremely high abrasion and wear resistance, good salt water and corrosion resistance, scaling resistant to appr. 700 C. Tools for deep-drawing and forming of austenitic steels and nickel alloys, plastics moulds, valve parts, hydraulic components, sliding blocks, guide rails, springs, glass moulds < 1.03 Engineering material under extremely high abrasion stress, low coefficient of friction, minimal cold set tendency, particularly as against austenitic steels and nickel alloys. Deep-drawing tools such as male and female dies, holding-down devices, as well as slide bars, guide rails and strips, grinding supports etc < 1.05 Wear-resistant sliding materials with good expansion values, also suitable as an engineering material. Using a hard counter material, load factors of c = N/cm 2 are possible, depending on the sliding speed and load. With SMBm, a soft counter material can also be used. SMBm is also suitable for cold forming. Forged parts for worm gears, bevel gears and other drive elements, compression nuts, spindle nuts, bearing bushes, guide rails, sliding rails etc. for machine tools, V-ledges, also suitable for plastics injection moulding machines < 1.05 See SMBm See SMBm < 1.50 Abrasion-proof, corrosion-resistant engineering and sliding material suitable for components in the chemical industry and for bearings subject to stress shocks, good scale resistance. Shafts, agitators, screws and nuts as well as other fixing hardware elements in the chemical industry, pickling frames, bearing bushes in conveyor chains and in machines subject to dynamic stress < 1.03 Engineering material with low permeability and low conductivity, alloy resistant to salt water, same type as standardized DIN casting material AMB 3. Amagnetic components for shipbuilding and marine technology such as ships` propeller shafts, screw and nuts, pump spindles, ships` harness, fittings and valves as well as components for valves (tapers, spindles, flanges etc.). 1 For ISO, F and GB the abbreviations, and for the USA the alloy number introduced in all standards (ASTM,SAE,MIL etc.) has been specified. largely in agreement; ( ) partially in agreement 2 Dimension type: I = dia., II = dia., III = dia. and hammer forgings up to a wall or thickness of 80 mm, IV = > 80 mm dia. and hammer forgings > 80 mm wall or thickness, washers, bushes, rings. The specified hardnesses are minimum values and apply accordingly to the specified group for drawn or forged bars, die-forged and free forged parts. Guarantee values are to be agreed. 3 Guideline values

6 NICKEL-COPPER ALLOYS Material International 1 Zollern Symbol No. standards brand DIN NB 1 Cu Ni 14 Al F: U-N14 A2 VG Bl. 1 Chemical composition (guideline values %) Cu Al Fe Mn Ni Others Rem Strength values for size groups 2 Modulus Bending fatigue of elasticity strength under load stress I II III IV kn/mm 2 N/mm 2 Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ NB 10 Cu Ni 10 Fe 1 Mn ISO: Cu Ni 10 Fe 1 Mn USA: C Cu Ni 10 Fe 1 Mn CW352H GB: CN 102 F: U-N10 Fe 1 Mn Rem Rp0.2 N/mm Rm N/mm with 30 % A5 (%) cold hardening HB 10/ and load changes NB 30 Cu Ni 30 Mn 1 Fe ISO: Cu Ni 10 Mn 1 Fe USA: C Cu Ni 30 Mn 1 Fe CW354H GB: CN 107 F: U-N30 M 1 Fe Rem Rp0.2 N/mm Rm N/mm with 30 % A5 (%) cold hardening HB 10/ and load changes COPPER-ZINC ALLOYS, SPECIAL BRASS TYPES Material International 1 Zollern Symbol No. standards brand DIN StBm Cu Zn 40 Al ISO: Cu Zn 39 Al Fe Mn GB: CZ 114 Cu Zn 39 Mn 1 F: U-Z36 N3 Al Pb Si CW718R Chemical composition (guideline values %) Cu Al Fe Mn Ni Others Zn Rem. Strength values for size groups 2 Modulus Bending fatigue of elasticity strength under load stress I II III IV kn/mm 2 N/mm 2 Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ StBh Cu Zn 40 Al 2 CW713R F: U-Z36 N Zn Rem. Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ BZ 2 Cu Zn 40 Al Cu Zn 37 Mn 3 Al 2 Pb Si CW713R Si, Pb Zn Rem. Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ ZB 68 Cu Zn 31 Si USA: C Cu Zn 31 Si CW708R 68 Si 1 Zn Rem. Rp0.2 N/mm Rm N/mm A5 (%) HB 10/

7 Physical properties 3 Density Specific Coefficient Coefficient Electrical Permeaheat of thermal of thermal conduc- bility expansion conductivity tivity kg/dm 3 J/g K x 10-6 /K W/cm K MS/m µ r Material characteristics Application examples < 1.01 Engineering material, high strength, corrosion and salt water resistant, cavitation and erosion resistant, abrasion resistant, low permeability, low electrical conductivity. Components for fittings, hydraulic parts, piston rods, screws, nuts, gears, bevel gears, cage bars, rotor keys, grinding pins, lead presses < 1.5 Very good corrosion resistance to salt water, brackish and harbour water, as well as aqueous solutions containing chloride, no danger of stress crack corrosion, extremely good cavitation resistance, high tenacity at low temperatures. Permissible computed flow velocity: 3.2 m/s. Panels (floors) for surface capacitors and heat exchangers (such as oil coolers, gas coolers etc.) for power stations, refineries, saltwater desalting plants, chemical and petrochemical industry, shipbuilding, oil rigs, crude oil transportation and processing, food industry, refrigeration technology, pipes, pipeline components and other components for the above-mentioned sectors < 1.1 See NB 10, permissible computed flow velocity 4.5 m/s. See NB 10 Physical properties 3 Density Specific Coefficient Coefficient Electrical Permeaheat of thermal of thermal conduc- bility expansion conductivity tivity kg/dm 3 J/g K x 10-6 /K W/cm K MS/m µ r Material characteristics Application examples < 1.03 Engineering materials with high (StBh) or mean (StBm) strength values as well as good sliding properties in the mean range of loading, resistant to atmospheric exposure, low permeability. Also available as BZ 2 = CuZn40 A12, DIN Suitable for components with low permeability, sliding rails, guide rails, fastening plates, floor and ground plates, spindle nuts, bottom bushes and gland bushes for heavy-duty machine engineering, pressure ladles, compression nuts < 1.03 See StBm See StBm < 1.03 Structural and sliding material with improved sliding characteristics by adding Si and Pb. BZ2 especially for worm wheels and bearing bushes, spindle nuts, pressure sockets, sliding wedges and other mechanical components < 1.01 Sliding and engineering material for mean range of loading with good sliding properties, also for use with unhardened countermaterials, high cold-toughness, good cold forming properties, soldering capability. Bearing bushes in vehicle and transmission construction, guide bushes and other sliding elements, hydraulic components, variety of uses in low-temperature engineering applications. 1 For ISO, F and GB the abbreviations, and for the USA the alloy number introduced in all standards (ASTM,SAE,MIL etc.) has been specified. largely in agreement; ( ) partially in agreement 2 Dimension type: I = dia., II = dia., III = dia. and hammer forgings up to a wall or thickness of 80 mm, IV = > 80 mm dia. and hammer forgings > 80 mm wall or thickness, washers, bushes, rings. The specified hardnesses are minimum values and apply accordingly to the specified group for drawn or forged bars, die-forged and free forged parts. Guarantee values are to be agreed. 3 Guideline values

8 COPPER AND LOW ALLOY MATERIALS Material International 1 Zollern Symbol No. standards brand DIN OF-Cu OF-Cu ISO: Cu-OFE USA: C GB: OFHC F: Cu-c2 Cu-OFE CW009 A Chemical composition (guideline values %) Cu Cr Ni Si Others at least Strength values for size groups 2 Modulus Bending fatigue of elasticity strength under load stress I II III IV kn/mm 2 N/mm 2 Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ SE-Cu SE-Cu GB: C F: Cu/c1 Cu-PHC CW020 A USA: C Cu-HCP CWO21 A Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ CuAg Cu Ag 0.1 P ISO: Cu Ag 0.1 (P) USA: C Cu Ag 0.10 P CW016 A Rem. Ag 0.1 Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ CCZr Cu Cr Zr ISO: Cu Cr USA: C Cu Cr 1 Zr CW106 C F: U-CrO.8 Zr GB: C C 102 Rem. 1 Zr 0.1 Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ NSB Cu Ni 2 Si USA: C F: U-N3 S Cu Ni 2 Si CW111 C Rem Rp0.2 N/mm Rm N/mm A5 (%) HB 10/ NSB 4 Cu Ni 3 Si USA: C Cu Ni 3 Si 1 CW112 C Rem. < Rp0.2 N/mm Rm N/mm A5 (%) HB 10/

9 Physical properties 3 Density Specific Coefficient Coefficient Electrical Permeaheat of thermal of thermal conduc- bility expansion conductivity tivity kg/dm 3 J/g K x 10-6 /K W/cm K MS/m µ r Material characteristics Application examples >58,6 < 1.01 Structural material with highest electrical and thermal conductivity, oxygen-free, resistant against hydrogen unsoundness, good welding and brazing properties. Free from deoxidation agents and practically free from elements volatile under vacuum. The residual resistance ratio RRR is min For electric and electronic industry for use under vacuum, e.g. vacuum switch tubes, radio and TV transmitting valves, high frequency tubes, accelerator cavities, klystrons, superconductors. Also suitable for glass-metal joints > 57 < 1.01 Engineering material with maximum electrical and thermal conductivity, oxygen-free, insensitive to hydrogen embrittlement, good welding and soldering properties. Short circuiting rings, conductor rails, contact bolts for the electrical industry, as well as other conductor and switch components, due to thermal conductivity used for continuous casting moulds, stationary moulds, lance buttons and similar in the iron and steel industry, cooling plates, firing chambers > 57 < 1.01 Extremely high electrical conductivity, greater resistance to tempering and improved creep behaviour at raised temperatures as against pure copper, oxygen-free, good welding and soldering properties. As SE-Cu, but primarily for parts subjected to higher thermal stress, recrystallization temperature appr. 320 C, moulds for continuous casting machines, semi-finished product for the electrical industry > 43 < 1.01 Highly conductive electrode material with high softening temperature due to hardening, with zirconium additive to increase notch impact strength at high temperatures. Contact rollers, electrode hub, jaws for flash butt welding plants, single components for welding tools, conductive components for the electrical industry, conductor rails, short-circuit rods, dies and cooling elements < 1.01 Engineering material with good abrasion resistance and mean electrical and thermal conductivity. Due to hardening, with NSB high strength values are achieved (without hardening, soft condition = HK2), corrosion-resistant. For electrically conductive elements subject to mechanical strain, connecting parts such as screws, bolts etc. in the electrical industry and overhead conductor installations, collector rings, shortcircuit rings, cage bars and rotor profiles appr. 1.8 appr. 20 < 1.01 Fit to be hardened corrosion-resistant material with high strength, mean electrical and thermal conductivity, good abrasion resistance. Suitable for electrically conductive parts subject to mechanical strain. Copper back-up bar in resistance welding machines, mould inserts and injection nozzles of plastics injection moulds, die casting pistons of all designs also machined ready for installation. 1 For ISO, F and GB the abbreviations, and for the USA the alloy number introduced in all standards (ASTM,SAE,MIL etc.) has been specified. largely in agreement; ( ) partially in agreement 2 Dimension type: I = dia., II = dia., III = dia. and hammer forgings up to a wall or thickness of 80 mm, IV = > 80 mm dia. and hammer forgings > 80 mm wall or thickness, washers, bushes, rings. The specified hardnesses are minimum values and apply accordingly to the specified group for drawn or forged bars, die-forged and free forged parts. Guarantee values are to be agreed. 3 Guideline values 4 Cold-hardened to order with higher values, e.g. F 24 or similar.

10 FORMS OF DELIVERY Material Zollern brands EBw EBz SMBm SMBh AMB 1 AMB 2 Construction Forged Pressed and bright drawn Unfinished, Bushes Rings Slabs Hammer Die forged Bars* and Pipes peeled or rough- Die-produced 450 lg forgings parts selectional material DIN 1755 turned bars Mandrel-prod lg A dia. mm kg/pc minimum wall 4 thickness mm MEB EBh VB A dia. mm kg/pc TZB A dia. mm kg/pc NB 1 A dia. mm kg/pc NB 10 NB 30 A dia. mm kg/pc minimum wall 3 thickness mm StBm StBh BZ 2 ZB 68 A dia. mm kg/pc minimum wall 3 thickness mm OF-Cu SE-Cu CuAg A dia. mm kg/pc minimum wall 3 thickness mm CCZr A dia. mm kg/pc minimum wall 4 thickness mm NSB NSB 4 A dia. mm kg/pc minimum wall 4 thickness mm * Bars, bright drawn, dia. to DIN 1756, square to DIN 1761, hexagonal to DIN 1763, flat to 1759 or to EN Above information is given best of our knowledge. No guarantee of properties is connected herewith. Liability as per contractual regulations resp. as per our General Terms of Sale, latest issue. Zollern have a policy of continuous product development and improvement; dimensions and specifications are subject to change without notice.

11 NOTES 10 11

12 NOTES

13 12 13

14 Plants of the Zollern group of companies Herbertingen plant ZOLLERN GmbH & Co. KG Drive Technology Heustraße 1 D Herbertingen Automation Tel Fax [email protected] Gears and Winches Tel Fax [email protected] Plain Bearings Tel Fax [email protected] France plant ZOLLERN TLC SAS 62, Rue Pierre Curie B.P.No 1055 F Les Mureaux CEDEX Tel Fax Mannheim plant ZOLLERN ISOPROFIL GmbH & Co. KG Steel Profiles Postfach D Mannheim Tel Fax [email protected] Sales: Tel Fax [email protected] Switzerland plant ZOLLERN- MIMTEC AG Säntisstrasse 11 CH-9401 Rorschach Tel Fax [email protected] Portugal plant ZOLLERN & Comandita Foundry Technology Rua Jorge Ferreirinha, 1095 Apartado 1027 P Vermoim MAIA Tel Fax [email protected] Sweden plant Kvalitetsstal AB P. O. Box 233 SE Arboga Tel Fax [email protected] China plant ZOLLERN (Tianjin) Maschinery Co., LTD. No. 33, 7th Avenue TEDA-TIANJIN Peoples Republic of CHINA Tel Fax [email protected] USA plant 9364 Wallisville Rd., Suite 150 Houston, Texas ZOLLERN USA North America L.P. Tel Fax [email protected] Dorsten plant ZOLLERN Dorstener Antriebstechnik GmbH & Co. KG Drive Technology Gears Hüttenstraße 1 D Dorsten Tel Fax [email protected] Romania plant Zollern S.R.L. RO Pecica Ferma 20 FN Jud. Arad Braunschweig plant ZOLLERN BHW Gleitlager GmbH & Co. KG Osterode plant ZOLLERN BHW Gleitlager GmbH & Co. KG Drive Technology Plain Bearings Postfach D Braunschweig Tel Fax [email protected] Drive Technology Plain Bearings Rolandsweg D Osterode am Harz Tel Fax Sales offices France Italy ZOLLERN S.à.r.l 13, Rue Allwies F Sarreguemines Tel Fax ZOLLERN Italiana S.r.L. Via C. Battisti, 1 I Gazzada (VA) Tel Fax [email protected] [email protected] Brazil plant ZOLLERN LTDA Drive Technology Plain Bearings Av. Manoel Inácio Peixoto, 2147 BR Cataguases MG Tel Fax [email protected] Great Britain Zollern UK Limited Castle Hill Kenilworth GB-CV8 1NB Tel Fax [email protected] Aulendorf plant ZOLLERN GmbH & Co. KG Mechanical Engineering Components Postfach D Aulendorf Tel Fax [email protected] Netherlands ZOLLERN Nederland B.V. Postbus 134 NL-5150 AC DRUNEN Tel Fax [email protected]

15 CONTACT ZOLLERN GmbH & Co. KG Foundry Technology Postfach D Sigmaringen Tel Fax [email protected] ZOLLERN GmbH & Co. KG Foundry Technology Postfach D Sigmaringen Steel Profiles Division Tel Fax [email protected] Foundry Technology Division Tel Fax [email protected] Laucherthal plant We offer comprehensive project management: Many years of project experience CAD masters Project meetings on-site and plant inspections Detailed, binding offers

16 ZOLLERN GmbH & Co. KG Postfach D Sigmaringen Tel Fax [email protected] Z Errors and Omissions excepted.