ABSTRACT CuNi2Si copper alloy has been utilised in electronics, resistance welding electrodes, and electrical connections. The industry is seeking new copper alloys with improved strength and electrical conductivity. Cu-Ni-Co-Si alloys have been designated as the next generation of high-performance copper alloys. In this study, the cast and hot-forged CuNi2Si and CuNiCoSi alloys were solid-solution treated and aged. Under optimum ageing conditions, alloys were tested for hardness, electrical conductivity, microstructure, mechanical properties, wear resistance, and corrosion resistance. Comparing the CuNiCoSi alloy to the Co-free CuNi2Si alloy, the Co element decreased grain size, accelerating Ni2Si and Co2Si precipitates. The CuNiCoSi alloy has 23% higher conductivity, 31% higher tensile strength, and 17% higher resistance under a 5 N load, 44% higher under a 10 N pressure, and 50% higher under a 20 N load in wear tests than the CuNi2Si alloy. Potentiodynamic studies showed that the CuNi2Si alloy removed 40% more metal per unit time than the CuNiCoSi alloy. The CuNiCoSi alloy outperforms the CuNi2Si alloy in hardness, conductivity, mechanical strength, wear resistance, and corrosion resistance. Due to its outstanding performance, the CuNiCoSi alloy will be vital in industrial equipment, aviation, space, nuclear energy, and electrical power generation.
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