COPPER ALLOY COMPOSITIONS HAVING ENHANCED THERMAL CONDUCTIVITY AND WEAR RESISTANCE
The present disclosure relates to powders and wires made from a copper-containing alloy. The copper-containing alloy is a copper-nickel-tin alloy or a copper-nickel-silicon-chromium alloy. Articles formed from the metal powder exhibit high thermal conductivity, high wear resistance, and thermal stability. The powders and wire also be used as a feed material for thermal spraying and copper-containing coatings are disclosed. The copper-containing alloy material promotes increased life of engine components and fuel efficiency when used as a cylindrical liner in an internal combustion engine.
1 . A composition comprising a copper-containing alloy, wherein the copper-containing alloy comprises copper, nickel, and either (i) tin or (ii) silicon and chromium, and wherein the alloy is in the form of a particulate or a wire.
2 . The composition of claim 1 , wherein the copper-containing alloy is a copper-nickel-silicon-chromium alloy that contains:
about 5 wt % to about 9 wt % nickel;
about 1 wt % to about 3 wt % silicon;
about 0.2 wt % to about 2.0 wt % chromium; and
balance copper.
3 . The composition of claim 1 , wherein the copper-containing alloy is a copper-nickel-tin alloy that contains:
about 5 wt % to about 20 wt % nickel;
about 5 wt % to about 10 wt % tin; and,
balance copper.
4 . The composition of claim 1 , wherein the copper-containing alloy is a particulate having an average particle size from about 2 micrometers to about 500 micrometers.
5 . The composition of claim 1 , further comprising a lubricant.
6 . The composition of claim 5 , wherein the lubricant comprises graphite, talc, MoS 2 , mica, or boron nitride.
7 . An article formed by sintering a copper-containing alloy particulate composition, wherein the copper-containing alloy comprises copper, nickel, and either (i) tin or (ii) silicon and chromium.
8 . The article of claim 7 , wherein the copper-containing alloy is a copper-nickel-silicon-chromium alloy that contains:
about 5 wt % to about 9 wt % nickel;
about 1 wt % to about 3 wt % silicon;
about 0.2 wt % to about 2.0 wt % chromium; and
balance copper.
9 . The article of claim 7 , wherein the copper-containing alloy is a copper-nickel-tin alloy that contains:
about 5 wt % to about 20 wt % nickel;
about 5 wt % to about 10 wt % tin; and,
balance copper.
10 . The article of claim 7 , wherein the article is a component for a combustion engine, a valve seat, a valve guide, a piston ring, or a bushing.
11 . A method of forming an article, comprising:
shaping a composition comprising a copper-containing alloy particulate into a precursor article; and
heating the precursor article at a temperature of about 500° C. to about 1100° C.;
wherein the copper-containing alloy particulate comprises copper, nickel, and either (i) tin or (ii) silicon and chromium.
12 . The method of claim 11 , further comprising homogenizing the composition.
13 . The method of claim 11 , wherein the shaping and heating comprise one or more of warm compaction, hot isotactic pressing, powder forging, powder injection molding, powder rolling, and powder extrusion.
14 . The method of claim 11 , further comprising performing at least one of the following steps after the heating step:
a secondary heat treatment;
a joining; a repressing;
a resizing;
a machining; and
a surface treatment.
15 . A method of forming a coating from a copper-containing alloy, comprising:
receiving a copper-containing alloy comprising copper, nickel, and either (i) tin or (ii) silicon and chromium, which is in the form of a particulate or a wire;
heating the copper-containing alloy to a molten or semi-molten state;
spraying the molten or semi-molten copper-containing alloy onto a substrate to form a coating.
16 . The method of claim 15 , wherein the copper-containing alloy is a copper-nickel-silicon-chromium alloy that contains:
about 5 wt % to about 9 wt % nickel;
about 1 wt % to about 3 wt % silicon;
about 0.2 wt % to about 2.0 wt % chromium; and
balance copper.
17 . The method of claim 15 , wherein the copper-containing alloy is a copper-nickel-tin alloy that contains:
about 5 wt % to about 20 wt % nickel;
about 5 wt % to about 10 wt % tin; and,
balance copper.
18 . An engine assembly, comprising:
a piston;
a piston ring; and
a cylindrical bore having a liner, the liner being formed from a copper-containing alloy that comprises copper, nickel, and either of (i) tin or (ii) silicon and chromium.
19 . The engine assembly of claim 18 , wherein the cylinder liner is in the form of an insert, or is in the form of a coating applied to a surface of a cylinder bore.
20 . The engine assembly of claim 18 , wherein the coating is thermal sprayed.
21 . An article comprising:
a substrate having at least one surface; and
a copper-containing alloy coating, the copper-containing alloy comprising copper, nickel and either (i) tin or (ii) silicon and chromium,
wherein the copper-containing alloy coating is applied to the at least one surface of the substrate.
22 . The article of claim 21 , wherein the copper-containing alloy is thermal sprayed onto the at least one surface of the substrate.
23 . The article of claim 21 , wherein the article is an engine component, a bushing, or a bearing.