Oxidation resistant high conductivity copper alloys
A micro-alloyed copper powder was produced using gas atomization reaction synthesis, with the alloy preferably comprising Cu-0.3Zr-0.15Ag wt. %. The novel copper alloy improves the manufacturability of copper in powder bed fusion manufacturing processes by minimizing or avoiding the prior art problems associated with oxidation of the copper precursor used in additive manufacturing. Advantageously, the provided copper alloy powder maintains the high electrical conductivity of copper while addressing the prior art oxidation issue.
1 . A copper alloy comprising:
about 0.26% by weight to about 0.34% by weight Zr; and
about 0.11% by weight to about 0.19% by weight Ag, with the balance being Cu and optionally incidental impurities, wherein, when present, said incidental impurities are present in an amount of 0.001% by weight or lower, said % by weight being based upon the weight of said copper alloy, said alloy having at least one of:
(i) an ultimate tensile strength of about 230 MPa to about 250 MPa; or
(ii) a yield strength of about 130 MPa to about 159 MPa; and
said alloy having an electrical conductivity of at least 94% IACS.
2 . The copper alloy of claim 1 , wherein said alloy comprises about 99.47% by weight to about 99.63% by weight Cu.
3 . The copper alloy of claim 1 , wherein said alloy consists of said Cu, said Zr, said Ag, and optionally said incidental impurities in an amount of 0.001% by weight or lower, when present in said alloy.
4 . The copper alloy of claim 1 , wherein said alloy has a % elongation of about 25% or more.
5 . The copper alloy of claim 1 , said alloy comprising about 0.28% to about 0.30% by weight Zr and about 0.14% to about 0.15% by weight Ag, with the balance being Cu and optionally incidental impurities.
6 . The copper alloy of claim 1 , said alloy having an electrical conductivity of at least 95% IACS.
7 . A copper alloy comprising:
about 0.26% by weight to about 0.34% by weight Zr; and
about 0.11% by weight to about 0.19% by weight Ag, with the balance being Cu and optionally incidental impurities, wherein, when present, said incidental impurities are present in an amount of 0.001% by weight or lower, said % by weight being based upon the weight of the copper alloy, said alloy having a % elongation of about 25% or more, said alloy having an ultimate tensile strength of about 230 MPa to about 250 MPa and an electrical conductivity of at least 94% IACS.
8 . The copper alloy of claim 7 , said alloy comprising about 0.28% to about 0.30% by weight Zr and about 0.14% to about 0.15% by weight Ag, with the balance being Cu and optionally incidental impurities.
9 . The copper alloy of claim 7 , said alloy having an electrical conductivity of at least 95% IACS.