Silicon Bronze Research Articles

Stress-Strain Characteristics and Electrical Conductivity of Niobium Nanopowder modified Silicon Bronze

Understanding the response of materials to various loads is crucial for fabricating resilient components capable of withstanding anticipated stresses. This experimental study addresses the limited information on the tensile behavior of silicon bronze by investigating the stress-strain characteristics of Cu-4wt%Si alloys modified with niobium nanopowder. The surface morphology of the fabricated alloys was analyzed using a Scanning Electron Microscope (SEM). SEM analysis of the Cu-4wt%Si alloy revealed columnar grains sparsely distributed in the copper matrix, contributing to low strain-to-fracture behavior. Doping the alloy with niobium nanopowder resulted in notable grain modification, increased grain boundary density, and improved grain distribution, correlating with higher strain-to-fracture values. Notably, the Cu-4wt%Si-1.1wt%Nb alloy exhibited significant changes in percentage elongation, ultimate tensile strength, yield strength, fracture strength, and tensile toughness. Furthermore, niobium nanopowder additions increase the hardness and electrical conductivity values, peaking at 305 HV and 54.9 %IACS with 1.1 wt% Nb.

Effect of solutionizing heat treatment on the structure and mechanical properties of silicon bronze (Cu-10wt%Si-2wt%Ni)

The effect of solutionizing temperature, soaking time, and quenching media on the structure and mechanical properties of silicon bronze (Cu-10wt%Si-2wt%Ni) has been examined. The samples were produced using the sand casting technique, machined to the required dimensions, and solutionized at temperatures of 700 oC, 800 oC, and 900 oC for 0.5, 1.5, 2.5, and 3.5 hrs and quenched in brine and oil respectively. The prepared as-cast and solution heat-treated samples were subjected to mechanical tests (hardness, and impact strength tests) as well as microstructural analysis. The results of the microstructural analysis revealed the presence of coarse grains and coarse sparse distribution of Ni2Si precipitate in the as-cast sample while the surface morphology of the heat-treated samples consisted of fine grains of intermetallic compounds evenly dispersed in the copper matrix. It was also observed that the microstructures of samples solutionized at lower temperatures (700 oC) revealed finer grains with better grain distributions compared with samples solutionized at higher temperatures (800 oC and 900 oC). These microstructural changes led to the improvement of the hardness and impact strength of the alloy. The hardness value of the as-cast sample 48.5 HRB, increased to 53.7 HRB and 57.8 HRB after solid solution heat treatment at 700 oC for 3.5 h and cooled in brine and oil, respectively. It was also observed that the hardness of the brine-cooled samples increased further to 72.45 HRB after 3.5 h at 900 oC. The results obtained also showed that the solid solution heat-treated samples gave an optimum impact strength value of 214 J/m3 and 183 J/m3 from the samples solutionized at 900 oC and 800 oC for 3.5 h and 1.5 h and cooled in brine and oil respectively. This was concluded to be a result of solid solution alpha and beta phases formed which improve energy absorption in the alloy.

Study of the influence of GMAW-CMT and PULSE processes of additive deposition of silicon bronze CuSi3Mn1 on the geometric characteristics of the surface, structure and stress strain state of finished products

Study of the influence of GMAW-CMT and PULSE processes of additive deposition of silicon bronze CuSi3Mn1 on the geometric characteristics of the surface, structure and stress strain state of finished products

ЧИСЛОВЕ МОДЕЛЮВАННЯ НАПРУЖЕНО-ДЕФОРМОВАНОГО СТАНУ ПРИ АДИТИВНОМУ MIG НАПЛАВЛЕННІ КРЕМНІЄВОЮ БРОНЗОЮ CuSi3Mn1

The article analyzes in detail the stress-strain state during additive manufacturing using silicon bronze CuSi3Mn1 (БрКМц3-1), which is widely used in the machine-building industry for the manufacture of bushings, spring parts, and parts of chemical apparatus. The high cost of non-ferrous copper-based alloys makes it important to use Welding Arc Additive Manufacturing (WAAM) technologies. The processes of layer-by-layer surfacing of silicon bronzes lead to residual stresses at the tensile strength of the material, which can eventually provoke the development of critical defects in the form of cracks. Based on the simultaneous solution of the finite element method for the equations of heat balance and mechanics of a solid deformed body, the peculiarities of temperature distribution and parameters of the stress-strain state for the developed model of a triangular equilateral prism, which is additively generated from CuSi3Mn1 bronze, are determined. Verification of the experimental model with the calculated one was carried out by comparing the thermal cycles of surfacing. Based on the anal-ysis of the results of numerical modeling, it was found that the nature of the temperature change and the magnitude of its decrease in the corresponding layer after the deposition of subsequent layers are the same and do not depend on the deposition trajectory, and the largest residual equivalent plastic deformations are formed in the first layer with a gradual decrease inthe value in each subsequent deposited layer, which is associated with a decrease in the degree of volume of the VAT prism from the 1st to the 10th layer. The lower layers are characterized by a volumetric stress state due to the presence of rigid binders in the form of the substrate and the upper welded layers, which increases the probability of cracking in these layers during the cooling stage due to a decrease in the material's strength below σB< 170 MPa in the temperature range of 475-550 °C

Effect of sodium content on the structure and mechanical properties of silicon bronze (Cu-3wt%Si alloys)

In the present study, the effect of sodium content on the structure and mechanical properties of Cu-3wt%Si alloys were investigated. The experimental alloys were produced with various sodium concentrations of 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2 and 3% by weight using permanent mould casting technique. Tensile and hardness tests were carried out on the cast samples. Microstructures of the specimens were also analysed using optical microscopy. The results indicated that the addition of sodium to Cu-3wt%Si alloy refined and modified the structure of the alloy resulting in improvement in the ultimate tensile strength and hardness of the experimental alloy by 453.85% and 58.82% respectively at 1.5wt%Na content and percentage elongation by 168.81% at 0.1wt%Na content. The addition of sodium also led to the formation of the Na1.44Si136 intermetallic phase which further contributed to the increase in strength and hardness of the alloy.

Effect of Alloying Additives and Casting Parameters on the Microstructure and Mechanical Properties of Silicon Bronzes

Effect of Alloying Additives and Casting Parameters on the Microstructure and Mechanical Properties of Silicon Bronzes

Shock Treatment to Control the Structural State and Mechanical Properties of 3D-Printed Silicon Bronze

Shock Treatment to Control the Structural State and Mechanical Properties of 3D-Printed Silicon Bronze

Study of Properties and Structure of Silicon Bronze CuSi3Mn1 (C65500) Wire at Various Stages of Its Production by Continuous Casting and Subsequent Drawing

Study of Properties and Structure of Silicon Bronze CuSi3Mn1 (C65500) Wire at Various Stages of Its Production by Continuous Casting and Subsequent Drawing

Atmospheric corrosion of Cu-Si-Mn bronze for contemporary art under simulated runoff and continuous immersion conditions

Silicon bronze is widely used for monuments: corrosion of Cu-3Si-1Mn was studied with respect to Cu-5Sn-5Zn-5Pb during ageing tests (runoff/full immersion) in acid rain. Surface characterisation (FEG-SEM/EDS elaborated through PCA, TEM, Raman, FTIR, profilometry), metal release and EIS measurements were performed. Under runoff conditions, where mechanical action plays a role, the alloys showed comparable corrosion resistance. In full immersion the corrosion rate of Cu-3Si-1Mn was slightly higher than that of Cu-5Sn-5Zn-5Pb, due to the different nature of the corrosion products. Results showed that, compared to Sn oxide/hydroxide, Si tends to form less protective amorphous products, detaching from the surface.

The Effect of Heat Input, Annealing, and Deformation Treatment on Structure and Mechanical Properties of Electron Beam Additive Manufactured (EBAM) Silicon Bronze.

Electron beam additive wire-feed manufacturing of Cu-3wt.%S-0.8wt.%Mn bronze thin wall on a stainless steel substrate has been carried out at heat input levels of 0.19, 0.25, and 0.31 kJ/mm. The microstructures of as-deposited metal ranged from low aspect ratio columnar with equiaxed grain layers to zig-zagged and high aspect ratio columnar, as depended on the heat input. Post-deposition annealing at 900 °C for 6 h resulted in recrystallization of the high aspect ratio columnar grains with further grain growth by boundary migration. Pre-deformation by 10% thickness reduction and then annealing at 900 °C for 6 h also allowed obtaining recrystallized grain structures with less fraction of twin boundaries but higher fraction of high-angle ones, as compared to those of only annealed sample. Pre-deformation and ensuing annealing allowed simultaneous increasing of the ultimate tensile strength and strain-to-fracture.

Effect of nickel addition on microstructure, tensile and corrosion properties of cold rolled silicon bronze

In this study, silicon bronze (Cu-Si) with nickel addition was fabricated using double stir casting technique. The influence of nickel addition and cold deformation on the microstructure, hardness, tensile and corrosion properties of the fabricated alloys were investigated. The microstructure of the alloy was evaluated using an optical microscope. Microhardness tester was used to determine the hardness while the tensile property was obtained from the hardness data. Potentiodynamic polarization measurement was used to study corrosion behaviour in 0.5 M H2SO4. The result show that the Ni modified Cu-Si alloys revealed the presence of Cu rich α-phase and δ-Ni2Si precipitates along the α grain boundaries. The δ-Ni2Si precipitates increased with increase in Ni content. The addition of Ni reduces the grain sizes and refine the microstructure. The hardness and tensile strength of the Ni modified Cu-Si increased with an increase in Ni addition from 0.2 to 0.8 wt%. The silicon bronze showed excellent corrosion resistance in a sulfuric acid environment with Ni addition. This is evident from the reduction in corrosion current density (Icorr) with an increase in Ni content.

Estimates of environmental loading from copper alloy materials

Metal release rates were measured from four different copper alloy-based materials used by the aquaculture industry: copper sheet machined into a diamond mesh, copper alloy mesh (CAM), silicon bronze welded wire mesh, and copper sheeting, and compared with conventional nylon aquaculture net treated with a cuprous oxide antifouling (AF) coating. Release rates were measured in situ in San Diego Bay using a Navy-developed Dome enclosure system at nine different time points over one year. As expected, copper was the predominant metal released, followed by zinc and nickel, which were fractional components of the materials tested. Release rates followed a temporal trend similar to those observed with copper AF coatings applied to vessel hulls: an initial spike in copper release was followed by a decline to an asymptotic low. Leachate toxicity was consistent with prior studies and was directly related to the metal concentrations, indicating the alloys tested had no additional toxicity above pure metals.

Assessment of structure and selected mechanical properties of braze welded joints of copper-lined steel tubes

In the paper, results of a research on braze welded joints of copper-lined 10CrMo9-10 (10H2M) steel tubes made by CMT arc braze welding are presented. As a filler metal, silicon bronze was applied. Results of metallographic examinations with the use of light microscopy, electron scanning microscopy and X-ray microanalysis are presented. Mechanical properties of the joints were assessed on the grounds of static tensile test, technological bending test, as well as hardness measurements. Quality of the obtained joints was good. No cracks were observed in the brazed joints and the obtained mechanical properties were satisfactory.

Improvement in hardness, wear rate and corrosion resistance of silicon bronze using gas tungsten arc

This study examines the effects of Gas Tungsten Arc (GTA) modification of silicon bronze alloy on the microstructure of the alloys and their surface properties, viz., hardness, wear rate and corrosion resistance. The substrate was modified at three different heat inputs in either argon or nitrogen atmosphere. It is observed that modification in nitrogen atmosphere causes enhanced heat transfer to the substrate, resulting in improved hardness, depth of penetration and decreased wear rate, compared to that under argon atmosphere followed by quick solidification. Modification under nitrogen environment resulted in ∼60% reduction in corrosion rate, with evidence of significant localized corrosion. Thus, it may be concluded that surface modification of silicon bronze alloy by GTA results in finer grains, increased surface hardness, decreased wear rate and improved corrosion resistance.

Investigation of Formation of Titanium–Copper Coatings upon Argon Arc Surfacing of Silicon Bronze on Titanium

Abstract—Automated argon arc surfacing of silicon bronze wire on titanium items providing production of heat- and wear-resistant coatings based on intermetallic copper titanium alloys was proposed. The automated argon arc surfacing was studied using copper-based filler wire of solid cross section containing up to 3 wt % silicon and titanium samples, grade VT1-0. In the course of surfacing in the considered range of modes, the coatings based on titanium copper alloys doped with silicon were obtained on the surface of samples. In this case, the copper content was 9–40 wt %, and the silicon content was 0.3–1.5 wt %. The studies revealed the influence of surfacing modes on the parameters and quality of formation of surfaced coatings as well as their chemical and phase composition, structure, and properties. The hardness and resistance of the produced samples against abrasive wear was analyzed. The heat resistance of the surfaced coatings was tested at 800°C for 250 and 500 h. The wear resistance and heat resistance as a function of chemical composition of the coatings were determined.

OLIN BRASS ALLOY C19010

Abstract Olin Brass Alloy C19010 is a silicon bronze precipitation hardened alloy with high strength and good electrical conductivity. This datasheet provides information on composition, physical properties, and tensile properties. Filing Code: Cu-885. Producer or source: Olin Brass.

Evaluation of the protectiveness of an organosilane coating on patinated Cu-Si-Mn bronze for contemporary art

A 3-mercapto-propyl-trimethoxysilane coating (PropS-SH) applied on Cu-Si-Mn bronze, patinated by “liver of sulphur”, was investigated as a non-toxic alternative to Incralac®, usually applied on outdoor artistic bronzes. Electrochemical testing was performed in synthetic acid rain. Exposure to temperature/UV cycles and accelerated corrosion test simulating unsheltered exposure to rainwater was also carried out. The exposed samples were characterised by FEG-SEM coupled with EDS on FIB cross-sections and XPS on free surfaces. The black patina without protective coating was scarcely protective against bronze corrosion and easily transformed into cuprous oxide. PropS-SH coating fully preserved the black patina microstructure and phase constituents (cuprous oxide and cuprous sulphide). The PropS-SH coating also resulted more protective than Incralac® when aged under run-off conditions. Selective dissolution of copper from the silicon bronze alloy was observed on both uncoated and Incralac®-coated bronze, leading to the formation of an internal Si-rich corrosion layer.

Electrodeposition of silicon onto copper substrate from KF-KCl-KI-K2SiF6 melt

The electrochemical behavior of Si4+ deposited onto the Cu substrate, in comparison with one onto C substrate, in the KF-KCl-KI-K2SiF6 melt was investigated by the cyclic voltammetry at 993 K. It was found, that the electro reduction of silicon on the Cu substrate proceeds with formation of the Cu-Si alloy (silicon bronze). The electrolysis conditions were determined and the silicon bronze coatings were synthesized by electrolysis in the KF-KCl-KI-K2SiF6 melt. The surface of deposits was examined by the electron microsccopy with EDS analysis. The deposits contained only copper and silicon. The microhardness of the coatings achieved 1618 HV. The microhardness of the obtained films was tested in air during one month: it decreased from 1618 to 380 HV.

Microstructure and corrosion characteristics of cast silicon bronze in ammonia environment

Refrigerating systems operating on either the open re-circulation or chilled water circuits are proned to corrosion attacks. Often, the ensued corrosion products foul and inhibit efficient heat transfer within the system causing leaks resulting in catastrophic failures. Thus, the imperative to search for a material that can be an effective substitute for the conventional copper pipe used in most refrigerating systems. In this study, the microstructure and corrosion susceptibility of cast silicon bronze in anhydrous ammonia environment was investigated. The silicon bronze was produced by sand casting with the silicon varied from 1-4 wt. %. An accelerated electrochemical polarisation technique was employed to simulate the corrosion behavior of the cast alloy. The results show relatively low corrosion susceptibility, 0.75 mm/yr of the alloy in anhydrous ammonia. This may be attributed to the silicon dioxide (SiO2) passive film formed on the surface of the alloy. The effectiveness of the SiO2 passive film increases as the wt. % of silicon addition increased. The potential for drastic reduction in maintenance cost and frequency of call-backs of refrigerating units is enhanced by the outcome of this study.Kathmandu University Journal of Science, Engineering and TechnologyVol. 13, No. 1, 2017, Page: 56-65

A Novel Approach for Minimization of Tool Vibration and Surface Roughness in Orthogonal Turn Milling of Silicon Bronze Alloy

The advanced manufacturing system is aimed to produce components at right quantity, quality and cost. Turnmilling is one of the advanced machining techniques that combines turning and milling processes for high metal removal rate. In orthogonal turn milling, bottom surface of the end mill cutter removes material from the surface of a rotating workpiece. Optimization of process parameters plays an important role in machining to improve quality and productivity and reduce production cost. In the present work, an advanced teaching learning based optimization (TLBO) technique was introduced to optimize process parameters in orthogonal turn milling of Silicon Bronze. Experiments were conducted at five levels of cutting speed, feed and depth of cuts. Experimental results of surface roughness and amplitude of cutter vibration were analysed using analysis of variance. The experimental results were also used to optimize process parameters through TLBO. Experiments were also conducted using TLBO optimized process parameters and the results were compared with TLBO results. The TLBO results were found to be in good agreement with target values of the responses. Artificial neural networks were developed for the surface roughness and amplitude of cutter vibration to verify optimization.