Comprehensive Guide to Aluminium Bronze Alloys
Imagine a metal alloy that not only stands up to the harshest marine environments but also excels in high-strength industrial…
Imagine a material that boasts exceptional strength, superb corrosion resistance, and remarkable durability, making it indispensable in industries ranging from marine engineering to aerospace. Enter Aluminium Bronze UNS C95400, a high-performance alloy renowned for its impressive mechanical and physical properties. This unique combination of copper, aluminum, iron, nickel, and manganese creates a versatile alloy with applications that span the globe.
In this article, we delve into the fascinating world of Aluminium Bronze UNS C95400, exploring its precise chemical composition, standout mechanical properties, and the myriad of uses that make it a material of choice for engineers and manufacturers alike. Whether you’re seeking to understand its fabrication practices, evaluate its corrosion resistance, or discover its applications in demanding environments, this comprehensive guide will provide you with all the essential information. Prepare to uncover why UNS C95400 is a cornerstone in various cutting-edge industries and how it continues to drive innovation and excellence.
Aluminium Bronze UNS C95400, also known as Aluminum Bronze C, is a versatile and widely used copper-based alloy, particularly favored for casting. This alloy is well-known for its excellent mechanical properties and resistance to corrosion. It is widely utilized across various industries due to its unique combination of strength, durability, and resistance to harsh environments.
Historically referred to as ASTM Alloy 9C, UNS C95400 has been a preferred material in numerous applications since its development. Its introduction revolutionized several industries by providing a superior alternative to traditional bronze and steel, offering enhanced performance in demanding conditions.
The primary characteristics that make Aluminium Bronze UNS C95400 stand out include:
UNS C95400 is used in a variety of applications due to these properties:
Aluminium Bronze UNS C95400 remains essential in modern engineering, offering exceptional durability and performance in extreme conditions. Its ability to withstand harsh environments while maintaining structural integrity ensures its ongoing relevance in advanced manufacturing and engineering applications.
Aluminium Bronze UNS C95400 is engineered to offer high strength, excellent corrosion resistance, and superior wear resistance, thanks to its carefully balanced chemical composition.
Copper forms the base of Aluminium Bronze UNS C95400, making up 83% to 87% of the alloy. This high copper content provides excellent electrical and thermal conductivity along with inherent corrosion resistance.
Aluminum, which makes up 10% to 11.5% of the alloy, greatly increases its strength and hardness. It also forms a protective oxide layer on the surface, enhancing the alloy’s resistance to oxidation and corrosion, particularly in marine environments.
Iron, at 3% to 5%, boosts the alloy’s overall strength and durability. This addition improves toughness and wear resistance, making the alloy suitable for applications involving heavy loads and friction.
Nickel content ranges from 0% to 1.5%, enhancing strength and corrosion resistance. Even in small amounts, nickel contributes to the alloy’s resistance to stress corrosion cracking, which is critical in high-stress applications.
Manganese, up to 0.5%, improves casting properties and adds to the alloy’s strength. Residual elements like silicon, zinc, and tin are controlled to ensure high performance, making up a total of up to 0.5%.
This precise balance of elements gives Aluminium Bronze UNS C95400 its high strength, excellent corrosion resistance, and good machinability, making it ideal for various demanding industrial applications.
Aluminium Bronze UNS C95400 has high tensile strength, making it ideal for applications that need strong mechanical performance. With an ultimate tensile strength (UTS) ranging from 600 to 710 MPa (87 to 100 x 10^3 psi), UNS C95400 components can withstand significant stretching or pulling forces without failure.
The yield strength of Aluminium Bronze UNS C95400 ranges from 240 to 360 MPa (35 to 52 x 10^3 psi). This is crucial for applications needing to maintain structural integrity under load, as it ensures the material can withstand high stress before permanently deforming.
Elongation at break measures a material’s ductility, indicating how much it can stretch before breaking. For UNS C95400, elongation at break ranges from 8.1% to 16%. This high elongation percentage shows good ductility, allowing the material to absorb significant deformation before breaking, which is beneficial in dynamic and high-impact applications.
Aluminium Bronze UNS C95400 has a Brinell hardness ranging from 160 to 200. Hardness measures a material’s resistance to indentation and wear. This high hardness value contributes to the alloy’s excellent wear resistance, making it ideal for components subjected to continuous friction and mechanical wear, such as bearings and gears.
The elastic modulus, or Young’s modulus, of Aluminium Bronze UNS C95400 is approximately 110 GPa (17 x 10^6 psi), indicating the material’s stiffness and how much it will deform under a given load. A high elastic modulus means the alloy is relatively stiff, ensuring minimal deformation under mechanical stress, which is important for maintaining precise dimensions in engineering applications.
Aluminium Bronze UNS C95400 has a shear modulus of approximately 43 GPa (6.2 x 10^6 psi). This property shows how the material responds to shear stress, which happens when forces are applied parallel to the surface. A high shear modulus signifies good resistance to shearing forces, enhancing the material’s performance in applications involving torsion and shear loads.
Poisson’s ratio for Aluminium Bronze UNS C95400 is 0.34. This ratio shows how the material tends to expand in directions perpendicular to the compression. A Poisson’s ratio of 0.34 indicates balanced deformation behavior, maintaining structural integrity under compression.
These mechanical properties collectively contribute to the high performance and versatility of Aluminium Bronze UNS C95400, making it suitable for demanding applications across various industries.
Aluminium Bronze UNS C95400 is known for its impressive density and thermal properties, making it ideal for demanding applications.
Aluminium Bronze UNS C95400 has a density of approximately 0.269 lb/in³ (7.45 g/cm³) and a specific gravity of 7.45 at room temperature (68°F or 20°C). This density contributes to its high strength and durability, making it suitable for heavy-duty applications.
Melting Point
With a liquidus temperature of 1900°F (1038°C) and a solidus temperature of 1880°F (1027°C), Aluminium Bronze UNS C95400 can withstand high temperatures without losing its strength.
Thermal Conductivity
The alloy’s thermal conductivity is 33.9 Btu · ft/(hr · ft² · °F) at 68°F (20°C), which helps it efficiently dissipate heat. This makes it perfect for components like bearings and bushings.
Coefficient of Thermal Expansion
With a coefficient of thermal expansion of 9.0 x 10^-6 per °F (68-572°F) or 20-300°C, UNS C95400 remains dimensionally stable across a wide range of temperatures.
Specific Heat Capacity
The specific heat capacity is 0.1 Btu/lb/°F at 68°F (20°C), indicating how much heat is needed to raise the alloy’s temperature, which is crucial for thermal management.
Electrical Conductivity
UNS C95400 has lower electrical conductivity compared to pure copper, making it suitable for applications where reduced conductivity is beneficial.
In summary, Aluminium Bronze UNS C95400 offers high density, excellent thermal properties, and moderate electrical conductivity, making it a versatile choice for industrial applications that demand durability and thermal stability. These physical properties make Aluminium Bronze UNS C95400 a reliable and robust material for various industrial uses, especially where high temperatures and mechanical stress are factors.
A key factor in the excellent corrosion resistance of Aluminium Bronze UNS C95400 is its ability to form a protective oxide layer. The high aluminum content in the alloy reacts with oxygen in the atmosphere or moisture to create an aluminum oxide layer on the surface. This oxide layer acts as a barrier, preventing further oxidation and protecting the underlying metal from corrosive elements. This characteristic is particularly beneficial in environments exposed to seawater and other corrosive substances.
Aluminium Bronze UNS C95400 is highly regarded for its exceptional performance in marine environments due to its resistance to saltwater corrosion. The combination of copper and aluminum in the alloy enhances its ability to withstand the harsh conditions of seawater, including exposure to chlorides and other aggressive agents commonly found in marine settings. This resistance extends to preventing biofouling, where marine organisms accumulate on surfaces, further enhancing the alloy’s suitability for marine applications.
Other alloying elements like nickel, iron, and manganese also enhance UNS C95400’s corrosion resistance. Nickel contributes to the alloy’s ability to resist stress corrosion cracking, a common issue in high-stress environments. Iron and manganese improve the overall stability of the protective oxide layer, ensuring consistent performance over time. These elements work synergistically to provide a robust defense against various forms of corrosion, including pitting and crevice corrosion.
Aluminium Bronze UNS C95400 is also resistant to corrosion in industrial and chemical environments. It can withstand exposure to a wide range of chemicals, including acids and alkalis, making it suitable for use in chemical processing plants and other industrial applications. The protective oxide layer and the inherent properties of the alloy ensure that it maintains its integrity even in the presence of harsh chemicals, contributing to its longevity and reliability in demanding industrial environments.
Galvanic corrosion happens when two different metals are in electrical contact in a corrosive environment, causing one to corrode faster. Aluminium Bronze UNS C95400 resists galvanic corrosion well when paired with other metals, making it ideal for marine applications. Its compatibility with various metals makes it a versatile choice for use in assemblies and structures where different metals are in contact, reducing the risk of galvanic corrosion and extending the service life of the components.
These properties make Aluminium Bronze UNS C95400 a reliable and durable material for numerous applications, ensuring long-term performance and reduced maintenance in corrosive environments.
When fabricating Aluminium Bronze UNS C95400, welding requires specific techniques to maintain the alloy’s integrity and properties.
Gas Shielded Arc Welding
Gas shielded arc welding, including methods like TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) welding, is highly effective for UNS C95400. This process provides excellent control over the heat input and minimizes contamination, resulting in strong, reliable welds. The use of an inert gas shield, such as argon or a mixture of argon and helium, protects the weld pool from oxidation, ensuring high-quality welds.
Coated Metal Arc Welding
Coated metal arc welding, also known as stick welding, is another suitable method for UNS C95400. This technique is advantageous for its simplicity and flexibility in various positions. However, it requires careful selection of electrodes and control over welding parameters to prevent defects and maintain the alloy’s properties.
Oxyacetylene Welding
Oxyacetylene welding is generally not recommended for UNS C95400 due to the risk of excessive oxidation and difficulty in controlling the heat. This method can lead to poor weld quality and compromised mechanical properties.
Soldering
Soldering is a viable method for joining Aluminium Bronze UNS C95400, especially for smaller components and intricate assemblies. This process uses a filler metal with a lower melting point than the base metal, allowing for precise joins without compromising the base metal’s properties.
Brazing
Brazing involves heating the components to above 450°C and using a filler metal with a lower melting point than the base metals, creating strong, durable joints for high-stress applications.
Solution Heat Treating
Solution heat treating involves heating UNS C95400 to 1600°F to 1675°F (872°C to 914°C), followed by rapid cooling in water or oil. This process dissolves alloying elements into a solid solution, enhancing the material’s properties.
Annealing
Annealing is done at 1150°F to 1225°F (622°C to 663°C) to relieve internal stresses and improve ductility. The alloy is heated to the specified temperature, held for a set period, then cooled slowly.
Stress Relieving
Stress relieving is performed at around 600°F (316°C) for one hour per inch of wall thickness. This reduces residual stresses from machining or forming, improving stability and performance.
Aluminium Bronze UNS C95400 has a machinability rating of 60%, making it relatively easy to machine compared to other copper-based alloys. Using sharp, carbide-tipped tools and appropriate cutting fluids can enhance machinability, ensuring smooth finishes and prolonging tool life. Proper control of parameters like feed rate and cutting speed is essential to avoid work hardening and achieve precise dimensions.
Aluminium Bronze UNS C95400 is highly valued across various industries due to its exceptional properties. Here are some key applications of this versatile alloy:
In marine environments, Aluminium Bronze UNS C95400 is ideal due to its resistance to saltwater corrosion and biofouling. This makes it perfect for ship propellers, marine shafts, and fittings, where it withstands harsh seawater conditions, including chlorides and other aggressive agents. Its resistance to cavitation and erosion corrosion further enhances its suitability for marine hardware.
In aerospace, Aluminium Bronze UNS C95400 is used for components needing a high strength-to-weight ratio and excellent corrosion resistance. This includes bushings, bearings, and landing gear components. The alloy’s robustness and ability to maintain mechanical properties in tough environments make it ideal for critical aerospace applications.
Aluminium Bronze UNS C95400 is excellent for valve and pump components due to its wear resistance and durability. Its resistance to cavitation and erosion ensures reliable performance and longevity in fluid handling systems.
This alloy is widely used in bearings, bushings, and flange bushings due to its low friction and high wear resistance. These properties reduce friction in moving parts, extending the service life of machinery. Its ability to withstand high loads and resist deformation under stress makes it perfect for heavy-duty applications, including earth-moving equipment.
In the automotive and heavy equipment industries, Aluminium Bronze UNS C95400 is used for components requiring high strength and durability. This includes automotive weld guns, roll neck bearings, and large fasteners like nuts and hold-down screws. The alloy’s robust properties make it suitable for harsh operating conditions.
Its moderate electrical conductivity and corrosion resistance make Aluminium Bronze UNS C95400 suitable for electrical connectors and terminals. The alloy ensures reliable connections while resisting environmental degradation.
This alloy is used in ordnance fittings and other military hardware due to its high strength and environmental resistance. Its durability ensures reliable performance in demanding military applications.
Aluminium Bronze UNS C95400 is versatile for general industrial applications, including gears, gibs, slides, and valve bodies. Its high strength, wear resistance, and corrosion resistance make it valuable for components in chemical plants, steel mills, and machine tools. The alloy’s reliability in harsh environments ensures efficient operation of critical machinery.
Aluminium Bronze UNS C95400 is a versatile material known for its strength and durability, governed by several ASTM standards to ensure quality and reliability.
ASTM B148 sets the standards for Aluminum-Bronze Sand Castings, specifying the required chemical composition and mechanical properties for consistent, high-quality materials.
ASTM B271 outlines the requirements for Copper-Base Alloy Centrifugal Castings, including dimensions and mechanical properties, ensuring they meet industrial needs.
ASTM B505 covers the standards for Copper Alloy Continuous Castings, detailing chemical composition, mechanical properties, and dimensions for consistent production.
In addition to ASTM standards, Aluminium Bronze UNS C95400 is subject to various other specifications that ensure its suitability for specific applications, particularly in high-performance and specialized industries.
AMS 4871 and 4873 specify the quality and performance standards for Aluminum Bronze C95400 in aerospace applications, ensuring it meets strict industry requirements.
ASME SB271 provides guidelines for producing high-quality centrifugal cast components from UNS C95400, crucial for applications needing high strength and reliability.
SAE J461 and J462 set the standards for wrought and cast copper alloys, ensuring Aluminum Bronze meets the needs of automotive and heavy equipment industries.
Federal specifications QQ-C-390 and QQ-B-671 Class 3 ensure Aluminum Bronze meets the quality standards for various government and military projects.
MIL-B-16033 Class 3 ensures UNS C95400 meets the rigorous standards for strength and durability required in military applications.
These standards and specifications collectively ensure that Aluminium Bronze UNS C95400 is produced and used in compliance with industry requirements, guaranteeing its performance and reliability across various applications.
Below are answers to some frequently asked questions:
The chemical composition of UNS C95400 Aluminium Bronze includes Copper (Cu) at 83-87%, Aluminum (Al) at 10.0-11.5%, Iron (Fe) at 3.0-5.0%, Nickel (Ni) up to 1.5% maximum, and Manganese (Mn) up to 0.5% maximum. This composition is consistent with various standards and specifications, such as ASTM B505, ASTM B271, and AMS 4871/4873.
The mechanical properties of UNS C95400 Aluminium Bronze are characterized by its strength, durability, and resistance to wear and corrosion. The ultimate tensile strength (UTS) ranges from 600 to 710 MPa, while the yield strength varies from 240 to 360 MPa. The Brinell hardness is typically between 150 to 200. Elongation at break is around 8.1 to 16%, indicating good ductility. The elastic modulus is 110 GPa, and the shear modulus is 43 GPa. Additionally, the Poisson’s ratio for this alloy is 0.34. These properties make UNS C95400 suitable for demanding applications, including marine hardware, aircraft components, and various high-wear parts.
UNS C95400 Aluminum Bronze is commonly used in various industries due to its excellent mechanical properties and corrosion resistance. Typical applications include marine hardware such as propellers and fittings, aircraft components, bearings and bushings, pump and valve components, gears and gear components, wear plates and strips, components for chemical and steel mills, machine tools, earth-moving machinery, and ordnance fittings. Its high strength, wear resistance, and ability to withstand harsh environments make it a versatile material for these demanding applications.
UNS C95400 Aluminum Bronze can be fabricated using methods such as gas shielded arc welding and coated metal arc welding, which are both recommended. Brazing and soldering are also suitable for this alloy. Machining is moderately easy with a machinability rating of 60%. Oxyacetylene welding is not recommended due to potential issues with porosity and control.
For heat treatment, stress relieving can be done at 600°F (316°C) for 1 hour per inch of wall thickness to reduce residual stresses. Solution heat treating involves temperatures between 1600°F and 1675°F (872°C to 914°C) for 1 hour per inch of wall thickness, with water as the solution medium. Annealing is performed at 1150°F to 1225°F (622°C to 663°C) for 1 hour per inch of wall thickness to reduce hardness and increase ductility. Heat treatment can significantly enhance the mechanical properties, such as tensile and yield strengths, of C95400 aluminum bronze.
UNS C95400 Aluminum Bronze exhibits excellent corrosion-resistant properties, particularly in seawater and other corrosive environments. This is largely due to its aluminum content, which forms a protective oxide layer on the alloy’s surface, enhancing its resistance to corrosion. The alloy’s chemical composition, including 10 to 11.5% aluminum, 3.0 to 5.0% iron, and smaller amounts of nickel and manganese, contributes to its durability and corrosion resistance. These properties make C95400 ideal for marine applications, shipbuilding, and other industries where exposure to seawater or corrosive substances is common. Additionally, C95400 maintains its strength at elevated temperatures, further enhancing its suitability for use in harsh environments.
