EP2989224B1 - Cast copper alloy for asynchronous machines - Google Patents
Cast copper alloy for asynchronous machines Download PDFInfo
- Publication number
- EP2989224B1 EP2989224B1 EP14718324.8A EP14718324A EP2989224B1 EP 2989224 B1 EP2989224 B1 EP 2989224B1 EP 14718324 A EP14718324 A EP 14718324A EP 2989224 B1 EP2989224 B1 EP 2989224B1
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- European Patent Office
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- alloy
- copper alloy
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- 229910000881 Cu alloy Inorganic materials 0.000 title claims description 63
- 229910045601 alloy Inorganic materials 0.000 claims description 68
- 239000000956 alloy Substances 0.000 claims description 68
- 229910052725 zinc Inorganic materials 0.000 claims description 61
- 229910052759 nickel Inorganic materials 0.000 claims description 46
- 229910052782 aluminium Inorganic materials 0.000 claims description 44
- 229910052718 tin Inorganic materials 0.000 claims description 43
- 239000010949 copper Substances 0.000 claims description 42
- 229910052709 silver Inorganic materials 0.000 claims description 41
- 229910052698 phosphorus Inorganic materials 0.000 claims description 35
- 229910052726 zirconium Inorganic materials 0.000 claims description 35
- 229910052719 titanium Inorganic materials 0.000 claims description 34
- 229910052787 antimony Inorganic materials 0.000 claims description 33
- 229910052785 arsenic Inorganic materials 0.000 claims description 33
- 229910052796 boron Inorganic materials 0.000 claims description 33
- 229910052749 magnesium Inorganic materials 0.000 claims description 33
- 239000000203 mixture Substances 0.000 claims description 32
- 239000012535 impurity Substances 0.000 claims description 28
- 239000004020 conductor Substances 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 11
- 238000010276 construction Methods 0.000 claims description 9
- 239000011701 zinc Substances 0.000 description 52
- 239000011135 tin Substances 0.000 description 43
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 42
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 29
- 229910052802 copper Inorganic materials 0.000 description 29
- 239000010936 titanium Substances 0.000 description 24
- 239000000463 material Substances 0.000 description 14
- 239000010944 silver (metal) Substances 0.000 description 14
- 230000002349 favourable effect Effects 0.000 description 11
- 229910052751 metal Inorganic materials 0.000 description 10
- 239000002184 metal Substances 0.000 description 10
- 238000005266 casting Methods 0.000 description 9
- 238000005275 alloying Methods 0.000 description 8
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 7
- 239000004332 silver Substances 0.000 description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 5
- 238000004512 die casting Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000006104 solid solution Substances 0.000 description 4
- 229910001316 Ag alloy Inorganic materials 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- YCKOAAUKSGOOJH-UHFFFAOYSA-N copper silver Chemical compound [Cu].[Ag].[Ag] YCKOAAUKSGOOJH-UHFFFAOYSA-N 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000010115 full-mold casting Methods 0.000 description 2
- 238000005495 investment casting Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 239000011574 phosphorus Substances 0.000 description 2
- 238000005204 segregation Methods 0.000 description 2
- 239000011265 semifinished product Substances 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 229910000967 As alloy Inorganic materials 0.000 description 1
- 229910003336 CuNi Inorganic materials 0.000 description 1
- 241000555745 Sciuridae Species 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- TVZPLCNGKSPOJA-UHFFFAOYSA-N copper zinc Chemical compound [Cu].[Zn] TVZPLCNGKSPOJA-UHFFFAOYSA-N 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000004881 precipitation hardening Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 229910052845 zircon Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K17/00—Asynchronous induction motors; Asynchronous induction generators
- H02K17/02—Asynchronous induction motors
- H02K17/16—Asynchronous induction motors having rotors with internally short-circuited windings, e.g. cage rotors
- H02K17/165—Asynchronous induction motors having rotors with internally short-circuited windings, e.g. cage rotors characterised by the squirrel-cage or other short-circuited windings
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/04—Alloys based on copper with zinc as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/02—Alloys based on copper with tin as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/06—Alloys based on copper with nickel or cobalt as the next major constituent
Definitions
- the invention relates to copper casting alloys and current-carrying structural parts made therefrom by means of primary molding processes.
- the invention relates to cast squirrel-cage rotors for asynchronous machines.
- the electrical conductivity is only slightly reduced by the alloy elements.
- the material must have good castability. Zirconium and / or chromium are often used as alloy components.
- JP 56010059 A a copper alloy containing zinc, chromium, zirconium and titanium is proposed for the die casting process.
- JP 2011 027280 A discloses a copper alloy with 0.1 to 2 wt% aluminum, tin from 0.1 wt% to aluminum content, zinc from 0.05 wt% to aluminum content and phosphorus from 0.001 to 0.1 wt. -%. Tubes for heat exchangers are made from the alloy.
- Copper materials processed by metal forming processes are characterized by a higher strength than copper materials in the as-cast state.
- the person skilled in the art can therefore give no indication of the above-mentioned prior art Find out which copper alloy has a favorable combination of properties with regard to electrical conductivity and strength even when cast.
- the invention is therefore based on the object of specifying improved copper casting alloys in terms of strength, conductivity and castability and improved current-carrying structural parts in terms of strength and conductivity.
- the invention is intended to provide improved, one-piece cast squirrel-cage rotors for asynchronous machines.
- the alloy elements should also be selected with regard to their effects on health and the environment. In particular, lead and cadmium should be avoided.
- the invention is given with respect to a copper alloy by the features of claim 1, with regard to a structural part with the features of claim 10 and alternatively with claim 12 and with respect to a squirrel-cage rotor with the features of claim 11 and alternatively with claim 13.
- the further back claims relate to advantageous developments and further developments of the invention.
- the invention is based on the consideration that the strength of metals is increased by the incorporation of foreign atoms. This effect is particularly interesting for cast alloys, because it enables high strength values to be achieved without further forming steps.
- a The elements Al, Sn, Ni and Zn have a particularly great effect on solid solution strengthening in copper. If the strength of pure copper is to be increased by solid solution strengthening, the addition of Al and Sn is particularly worthwhile. It is also known that the addition of alloy elements fundamentally worsens the electrical and thermal conductivity of pure copper. In the field of mixed crystal formation, however, the conductivity of copper is influenced relatively little by the elements Zn, Ag, Ni, Sn and Al. If the electrical conductivity of copper is to be impaired as little as possible, the addition of Zn and Ag is particularly worthwhile.
- a casting material can be found that has a particularly favorable combination of strength and conductivity.
- the content of the individual elements should be at least 0.05% by weight and at most 0.5% by weight.
- the effect of the alloy elements is too low for element contents less than 0.05% by weight.
- the sum of the element contents can preferably be at least 0.25% by weight.
- element contents greater than 0.5% by weight undesired segregation of the alloy or segregation can occur.
- the content of the individual elements can preferably be at most 0.3% by weight.
- Alloying three or more elements creates an alloy whose melting interval is longer than the melting interval of alloys with fewer elements. This has a favorable effect on the castability of the material.
- the copper alloy preferably contains the element Sn. This results in particularly favorable properties.
- the copper alloy contains the element Ag. This results in particularly favorable properties with regard to electrical conductivity.
- 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb can be added to the alloy. These elements result in grain refinement of the cast structure and thus increase the strength of the cast material. By deoxidizing the melt you can also reduce the gas intake.
- the sum of the contents of the elements Mg, Ti, Zr, B, P, As, Sb can be limited to a maximum of 0.5% by weight.
- the content of the individual elements can be limited to a maximum of 0.07% by weight.
- the increase in strength is not always sufficient at contents of less than 0.06% by weight. With element contents greater than 0.15% by weight, the electrical conductivity can be reduced too much, for example below 75% IACS.
- the sum of the proportions of the elements from the group consisting of Ag, Ni, Zn, Sn and Al is preferably at least 0.20% by weight and at most 0.35% by weight.
- the proportions of the alloy elements can preferably be selected such that the ratio by weight of two arbitrary alloy elements from the group consisting of Ag, Ni, Zn, Sn and Al is at most 1.5.
- the more common of the two alloying elements forms the numerator of the quotient to be calculated.
- This weight ratio is particularly preferably at most 1.3.
- the elements selected from the group consisting of Ag, Ni, Zn, Sn and Al for the respective alloy are alloyed in approximately equal parts by weight.
- the copper alloy can have the following composition in% by weight: Ag: 0.06 to 0.5% Ni: 0.06 to 0.5% Zn: 0.06 to 0.5% Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- Such an alloy has an electrical conductivity of at least 68% IACS and can exceed the strength of pure copper by up to 35%.
- the copper alloy can have the following composition in% by weight: Ag: 0.06 to 0.15% Ni: 0.06 to 0.15% Zn: 0.06 to 0.15% Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- IACS IACS
- such an alloy has an electrical conductivity that is approximately equal to that of a copper alloy which contains 1% by weight of Ag (CuAg1).
- the increase in strength compared to pure copper in the as-cast state is approximately 20%.
- Such an alloy thus has a very favorable combination of properties.
- the relative increase in strength is greater than the relative decrease in conductivity. Due to the low proportion of alloys, the alloy is at the cost level of commercially available copper alloys.
- the copper alloy can have the following composition in% by weight: Ag: 0.06 to 0.15% Sn: 0.06 to 0.15% Ni: 0.06 to 0.15% Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- Such an alloy has an electrical conductivity of approximately 85% IACS.
- the increase in strength compared to pure copper in the as-cast state is approximately 20%.
- Such an alloy thus has a very favorable combination of properties.
- the relative increase in strength is greater than the relative decrease in conductivity. Due to the low proportion of alloys, the alloy is at the cost level of commercially available copper alloys.
- the copper alloy can have the following composition in% by weight: Ag: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15% Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- Such an alloy has an electrical Conductivity of about 85% IACS. The increase in strength compared to pure copper in the as-cast state is approximately 10%. Due to the elements Zn and Al, this alloy is an inexpensive alternative.
- Another advantageous copper alloy can have the following composition in% by weight: Sn: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15% Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- Such an alloy has an electrical conductivity of approximately 80% IACS.
- the increase in strength compared to pure copper in the as-cast state is approximately 10%. Since this alloy does not contain silver, it is a particularly inexpensive alternative.
- a further aspect of the invention relates to current-carrying structural parts made of copper alloys, the structural parts being produced by means of an original molding process and the copper alloys having the following composition in% by weight: 0.05 to 0.5% Ag, in each case 0.05 to 0.5 % of at least two elements from the group consisting of Ni, Zn, Sn and Al, balance Cu and inevitable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb exists.
- the copper alloy of the structural part can have the following composition in% by weight: Sn: 0.06 to 0.15%, Zn: 0.06 to 0.15%, Al: 0.06 to 0.15%, Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- Such structural parts can be, for example, switches, commutators, grinding wheels, busbars, contacts, brushes, bridges, components for switching devices, conductor bars or short-circuit rings of cage rotors or other components.
- Primary molding processes are understood to mean casting processes such as, for example, die casting, investment casting, full mold casting or other processes.
- the above-mentioned casting process the cast body essentially already has the shape of the desired structural part. Separation processes can be used to carry out one or more further processing steps which slightly change the shape of the structural part. Examples of this are cutting off the sprue or reworking the surface of the structural part.
- the finished construction part is therefore in the as-cast state.
- the copper alloys according to the invention have a higher strength than pure copper due to the solidification of the solid solution in the as-cast state.
- the electrical conductivity is relatively little reduced compared to pure copper.
- the alloys according to the invention also have good castability: they show only a slight tendency to absorb gas and are characterized by a good mold filling capacity.
- an alloy adapted to the respective application can be found.
- the Ag content can be limited to 0.15% by weight.
- the metal costs of the alloys according to the invention are increased by a maximum of 15% compared to pure copper.
- Construction parts produced by master molding processes are less expensive to manufacture than construction parts that are made from semi-finished products.
- the total cost of the construction parts according to the invention can consequently be cheaper than the total costs of other construction parts.
- the alloy according to the invention can optionally contain 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. These elements result in grain refinement of the cast structure and thus increase the strength of the cast material. By deoxidizing the melt, they can also reduce gas absorption.
- the copper alloy has the following composition in% by weight: 0.05 to 0.5% Ag, in each case 0.05 to 0.5% of at least two elements from the group consisting of Ni, Zn, Sn and Al, Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- the copper alloy of the cage rotor can have the following composition in% by weight: Sn: 0.06 to 0.15%, Zn: 0.06 to 0.15%, Al: 0.06 to 0.15%, Balance Cu and unavoidable impurities, optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- the invention is based on the idea of casting conductor bars and short-circuit rings of cage rotors in one piece. Suitable casting processes for this can be die casting, investment casting, full mold casting and other processes. Due to their high electrical conductivity, copper alloys are well suited for the manufacture of cage rotors. Since the high speeds of the asynchronous machines exert large forces, in particular on the conductor bars of the squirrel-cage rotors, the copper alloys used must have high strength even when cast. Copper alloys which have the following composition in% by weight are therefore particularly suitable: 0.05 to 0.5% Ag, in each case 0.05 to 0.5% of at least two elements from the group consisting of Ni, Zn, Sn and Al exists, rest Cu and inevitable impurities.
- the copper alloys according to the invention have a higher strength than pure copper due to the solidification of the solid solution in the as-cast state.
- the electrical conductivity is relatively little reduced compared to pure copper.
- the alloys according to the invention also have good castability: they show only a slight tendency to absorb gas and are characterized by a good mold filling capacity.
- the alloy according to the invention can optionally contain 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. These elements result in grain refinement of the cast structure and thus increase the strength of the cast material. Through an appropriate selection of the alloying elements and the alloying composition, an alloy adapted to the respective application can be found.
- the following alloys have proven to be particularly advantageous: Copper alloy with the following composition in% by weight: Ag: 0.06 to 0.15% Ni: 0.06 to 0.15% Zn: 0.06 to 0.15% Balance Cu and unavoidable impurities; Alternatively: copper alloy with the following composition in% by weight: Ag: 0.06 to 0.15% Sn: 0.06 to 0.15% Ni: 0.06 to 0.15% Balance Cu and unavoidable impurities; Alternatively: copper alloy with the following composition in% by weight: Ag: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15% Balance Cu and unavoidable impurities; Alternatively: copper alloy with the following composition in% by weight: Sn: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15% Balance Cu and unavoidable impurities.
- Each of the aforementioned alloys can optionally have 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb added.
- the metal costs of the alloys according to the invention are increased by a maximum of 15% compared to pure copper.
- Table 1 shows a compilation of the alloys examined.
- the composition of the sample, the determined tensile strength R m in the as-cast state and the relative electrical conductivity, expressed by the IACS value, are given for each alloy.
- the metal costs resulting from the alloy composition are standardized to the metal costs of pure copper (sample no. 1).
- Sample No. 2 is a reference alloy with 99% copper and 1% silver. This alloy has attractive properties in terms of strength and conductivity, but due to the high metal costs, it can only be used economically in very special applications.
- Sample No. 3 is a copper alloy with approximately 0.5% silver, 0.5% nickel and 0.5% zinc. This alloy achieves a strength that is approx. 35% higher than that of pure copper.
- the electrical conductivity is 68% IACS.
- Sample No. 4 is a copper alloy with approximately 0.1% silver, 0.1% nickel and 0.1% zinc. This alloy achieves a strength that is approx. 20% higher than that of pure copper.
- the electrical conductivity is 91% IACS.
- the relative increase in strength is thus significantly greater than the relative Decrease in electrical conductivity.
- This surprising combination of properties of the alloy is not to be expected from the individual contributions of the individual alloy elements.
- the relative increase in metal costs is less than the relative increase in strength and can therefore be compensated for, for example, by reducing the cross section of the conductor bars. This alloy thus offers a very attractive combination of properties for use in cast squirrel cage rotors.
- Sample No. 5 is a copper alloy with approximately 0.1% silver, 0.13% tin and 0.1% nickel. This alloy achieves a strength that is approx. 20% higher than that of pure copper.
- the electrical conductivity is 84% IACS.
- the relative increase in strength is therefore greater than the relative decrease in electrical conductivity. This surprising combination of properties of the alloy is not to be expected from the individual contributions of the individual alloy elements.
- the relative increase in metal costs is less than the relative increase in strength.
- Sample No. 6 is a copper alloy with approximately 0.1% silver, 0.1% zinc and 0.1% aluminum. This alloy achieves a strength that is approx. 6% higher than that of pure copper.
- the electrical conductivity is 84% IACS. Due to the elements Zn and Al, this alloy is an inexpensive alternative.
- Sample No. 7 is a copper alloy with approximately 0.1% tin, 0.1% zinc and 0.1% aluminum. This alloy achieves a strength that is approx. 8% higher than that of pure copper. The electrical conductivity is 78% IACS. Since this alloy does not contain silver, it is a particularly inexpensive alternative.
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- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
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- Organic Chemistry (AREA)
- Power Engineering (AREA)
- Conductive Materials (AREA)
Description
Die Erfindung betrifft Kupfergusslegierungen sowie daraus mittels Urformverfahren hergestellte, stromführende Konstruktionsteile. Insbesondere betrifft die Erfindung gegossene Käfigläufer für Asynchronmaschinen.The invention relates to copper casting alloys and current-carrying structural parts made therefrom by means of primary molding processes. In particular, the invention relates to cast squirrel-cage rotors for asynchronous machines.
Bereits aus der Patentschrift
Weitere Kupferlegierungen für Käfigläufer sind im Zusammenhang mit Herstellverfahren bekannt, bei denen der Käfigläufer nicht einstückig gegossen wird, sondern aus einzelnen Komponenten zusammengebaut wird. Dabei werden die Leiterstäbe und/oder die Kurzschlussringe mittels umformtechnischer Verfahren hergestellt. So wird beispielsweise in
Durch umformtechnische Verfahren bearbeitete Kupferwerkstoffe zeichnen sich durch eine höhere Festigkeit als Kupferwerkstoffe im Gusszustand aus. Aus dem oben genannten Stand der Technik kann der Fachmann also keinen Hinweis entnehmen, welche Kupferlegierung auch im Gusszustand eine günstige Eigenschaftskombination hinsichtlich elektrischer Leitfähigkeit und Festigkeit aufweist.Copper materials processed by metal forming processes are characterized by a higher strength than copper materials in the as-cast state. The person skilled in the art can therefore give no indication of the above-mentioned prior art Find out which copper alloy has a favorable combination of properties with regard to electrical conductivity and strength even when cast.
Der Erfindung liegt daher die Aufgabe zugrunde, hinsichtlich Festigkeit, Leitfähigkeit und Gießbarkeit verbesserte Kupfergusslegierungen sowie hinsichtlich Festigkeit und Leitfähigkeit verbesserte stromführende Konstruktionsteile anzugeben. Insbesondere soll die Erfindung verbesserte, einstückig gegossene Käfigläufer für Asynchronmaschinen angeben. Dabei soll die Auswahl der Legierungselemente auch im Hinblick auf Auswirkungen für Gesundheit und Umwelt erfolgen. Insbesondere sollen Blei und Cadmium vermieden werden.The invention is therefore based on the object of specifying improved copper casting alloys in terms of strength, conductivity and castability and improved current-carrying structural parts in terms of strength and conductivity. In particular, the invention is intended to provide improved, one-piece cast squirrel-cage rotors for asynchronous machines. The alloy elements should also be selected with regard to their effects on health and the environment. In particular, lead and cadmium should be avoided.
Die Erfindung wird bezüglich einer Kupferlegierung durch die Merkmale des Anspruchs 1, bezüglich eines Konstruktionsteils durch die Merkmale des Anspruchs 10 und alternativ des Anspruchs 12 und bezüglich eines Käfigläufers durch die Merkmale des Anspruchs 11 und alternativ des Anspruchs 13 wiedergegeben. Die weiteren rückbezogenen Ansprüche betreffen vorteilhafte Aus- und Weiterbildungen der Erfindung.The invention is given with respect to a copper alloy by the features of claim 1, with regard to a structural part with the features of claim 10 and alternatively with claim 12 and with respect to a squirrel-cage rotor with the features of claim 11 and alternatively with claim 13. The further back claims relate to advantageous developments and further developments of the invention.
Die Erfindung schließt Kupferlegierungen mit folgender Zusammensetzung in Gewichts-% ein:
- 0,05 bis 0,5 % Ag, jeweils 0,05 bis 0,5 % von mindestens zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht,
- Rest Cu sowie unvermeidbare Verunreinigungen,
- optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht.
- 0.05 to 0.5% Ag, in each case 0.05 to 0.5% of at least two elements from the group consisting of Ni, Zn, Sn and Al,
- Balance Cu and unavoidable impurities,
- optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
Die Erfindung geht dabei von der Überlegung aus, dass die Festigkeit von Metallen durch den Einbau von Fremdatomen gesteigert wird. Insbesondere für Gusslegierungen ist dieser Effekt interessant, weil auf diese Weise ohne weitere Umformschritte bereits hohe Festigkeitswerte erreicht werden können. Eine besonders große Wirkung auf die Mischkristallverfestigung bei Kupfer haben die Elemente Al, Sn, Ni und Zn. Wenn die Festigkeit von Reinkupfer durch Mischkristallverfestigung gesteigert werden soll, ist der Zusatz von Al und Sn besonders verfolgenswert. Es ist ferner bekannt, dass der Zusatz von Legierungselementen grundsätzlich die elektrische und thermische Leitfähigkeit von Reinkupfer verschlechtert. Im Gebiet der Mischkristallbildung wird die Leitfähigkeit von Kupfer durch die Elemente Zn, Ag, Ni, Sn und Al jedoch relativ wenig beeinflusst. Soll die elektrische Leitfähigkeit von Kupfer möglichst wenig beeinträchtigt werden, ist der Zusatz von Zn und Ag besonders verfolgenswert. Durch eine geeignete Auswahl von mindestens drei Elementen aus der Gruppe, die aus den Elementen Ag, Ni, Zn, Sn und Al besteht, kann ein Gusswerkstoff gefunden werden, der eine besonders günstige Kombination von Festigkeit und Leitfähigkeit besitzt. Der Gehalt der einzelnen Elemente sollte dabei mindestens 0,05 Gew.-% und höchstens 0,5 Gew.-% betragen. Bei Elementgehalten kleiner als 0,05 Gew.-% ist die Wirkung der Legierungselemente zu gering. Bevorzugt kann auch bei weniger als fünf Legierungselementen die Summe der Elementgehalte mindestens 0,25 Gew.-% sein. Bei Elementgehalten größer als 0,5 Gew.-% kann es zu einem unerwünschten Entmischen der Legierung beziehungsweise zu Seigerungen kommen. Um solche Effekte sicher zu vermeiden, kann der Gehalt der einzelnen Elemente bevorzugt höchstens 0,3 Gew.-% betragen. Durch das Zulegieren von drei oder mehr Elementen entsteht eine Legierung, deren Schmelzintervall größer ist als das Schmelzintervall von Legierungen mit weniger Elementen. Dies wirkt sich günstig auf die Gießbarkeit des Werkstoffs aus. Bevorzugt enthält die Kupferlegierung das Element Sn. Dadurch ergeben sich besonders günstige Eigenschaften. Die Kupferlegierung enthält das Element Ag. Dadurch ergeben sich besonders günstige Eigenschaften hinsichtlich der elektrischen Leitfähigkeit. Optional kann der Legierung 0,01 bis 0,2 Gew.-% von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht, zugegeben werden. Diese Elemente bewirken eine Kornfeinung des Gussgefüges und erhöhen so die Festigkeit des Gusswerkstoffs. Durch Desoxidation der Schmelze können sie ferner die Gasaufnahme reduzieren. Um unerwünschte Wechselwirkungen zwischen den Elementen zu vermeiden, kann die Summe der Gehalte der Elemente Mg, Ti, Zr, B, P, As, Sb auf maximal 0,5 Gew.-% beschränkt sein. Alternativ kann der Gehalt der einzelnen Elemente auf maximal 0,07 Gew.-% beschränkt sein.The invention is based on the consideration that the strength of metals is increased by the incorporation of foreign atoms. This effect is particularly interesting for cast alloys, because it enables high strength values to be achieved without further forming steps. A The elements Al, Sn, Ni and Zn have a particularly great effect on solid solution strengthening in copper. If the strength of pure copper is to be increased by solid solution strengthening, the addition of Al and Sn is particularly worthwhile. It is also known that the addition of alloy elements fundamentally worsens the electrical and thermal conductivity of pure copper. In the field of mixed crystal formation, however, the conductivity of copper is influenced relatively little by the elements Zn, Ag, Ni, Sn and Al. If the electrical conductivity of copper is to be impaired as little as possible, the addition of Zn and Ag is particularly worthwhile. Through a suitable selection of at least three elements from the group consisting of the elements Ag, Ni, Zn, Sn and Al, a casting material can be found that has a particularly favorable combination of strength and conductivity. The content of the individual elements should be at least 0.05% by weight and at most 0.5% by weight. The effect of the alloy elements is too low for element contents less than 0.05% by weight. With less than five alloy elements, the sum of the element contents can preferably be at least 0.25% by weight. With element contents greater than 0.5% by weight, undesired segregation of the alloy or segregation can occur. In order to reliably avoid such effects, the content of the individual elements can preferably be at most 0.3% by weight. Alloying three or more elements creates an alloy whose melting interval is longer than the melting interval of alloys with fewer elements. This has a favorable effect on the castability of the material. The copper alloy preferably contains the element Sn. This results in particularly favorable properties. The copper alloy contains the element Ag. This results in particularly favorable properties with regard to electrical conductivity. Optionally, 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb can be added to the alloy. These elements result in grain refinement of the cast structure and thus increase the strength of the cast material. By deoxidizing the melt you can also reduce the gas intake. In order to avoid undesired interactions between the elements, the sum of the contents of the elements Mg, Ti, Zr, B, P, As, Sb can be limited to a maximum of 0.5% by weight. Alternatively, the content of the individual elements can be limited to a maximum of 0.07% by weight.
Bevorzugt kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
- 0,05 bis 0,5 % Ag, jeweils 0,05 bis 0,5 % von zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht,
- Rest Cu sowie unvermeidbare Verunreinigungen,
- optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht.
- a) Kupferlegierung mit jeweils 0,05 - 0,5 Gew.-% aus Ag, Ni, Zn
- b) Kupferlegierung mit jeweils 0,05 - 0,5 Gew.-% aus Ag, Sn, Ni
- c) Kupferlegierung mit jeweils 0,05 - 0,5 Gew.-% aus Ag, Zn, Al Bevorzugt ist der Ag-Anteil hierbei maximal 0,15 Gew.-%.
Überraschenderweise ergibt auch folgende Kombination von Elementen eine Legierung mit günstigen Eigenschaften: - d) Kupferlegierung mit jeweils 0,05 - 0,5 Gew.-% aus Sn, Zn, Al.
- 0.05 to 0.5% Ag, each 0.05 to 0.5% of two elements from the group consisting of Ni, Zn, Sn and Al,
- Balance Cu and unavoidable impurities,
- optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
- a) copper alloy with 0.05-0.5% by weight of Ag, Ni, Zn
- b) copper alloy with 0.05-0.5% by weight each of Ag, Sn, Ni
- c) Copper alloy with 0.05-0.5% by weight each of Ag, Zn, Al. The Ag content is preferably a maximum of 0.15% by weight.
Surprisingly, the following combination of elements also results in an alloy with favorable properties: - d) copper alloy with 0.05-0.5% by weight of Sn, Zn, Al.
Zu den vorstehend mit a), b), c) und d) bezeichneten Legierungen können optional 0,01 bis 0,2 Gew.-% von einem oder mehreren Elementen aus der Gruppe hinzutreten, die aus Mg, Ti, Zr, B, P, As, Sb besteht.In addition to the alloys referred to above with a), b), c) and d), 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb exists.
Bevorzugt kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
- 0,06 bis 0,3 % Ag, jeweils 0,06 bis 0,3 % von zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht,
- Rest Cu sowie unvermeidbare Verunreinigungen,
- optional 0,01 bis 0,2 Gew.-% von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht.
- 0.06 to 0.3% Ag, each 0.06 to 0.3% of two elements from the group consisting of Ni, Zn, Sn and Al,
- Balance Cu and unavoidable impurities,
- optionally 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
Besonders bevorzugt kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
- 0,06 bis 0,15 % Ag, jeweils 0,06 bis 0,15 % von zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht,
- Rest Cu sowie unvermeidbare Verunreinigungen,
- optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht.
- 0.06 to 0.15% Ag, each 0.06 to 0.15% of two elements from the group consisting of Ni, Zn, Sn and Al,
- Balance Cu and unavoidable impurities,
- optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb.
Bezüglich der Elemente aus der Gruppe, die aus Ag, Ni, Zn, Sn und Al besteht, ist bei Gehalten kleiner als 0,06 Gew.-% die Steigerung der Festigkeit nicht immer ausreichend. Bei Elementgehalten größer als 0,15 Gew.-% kann die elektrische Leitfähigkeit zu stark reduziert sein, beispielsweise unter 75 % IACS. Bevorzugt beträgt die Summe der Anteile der Elemente aus der Gruppe, die aus Ag, Ni, Zn, Sn und Al besteht, mindestens 0,20 Gew.-% und maximal 0,35 Gew.-%. Bevorzugt können bei der erfindungsgemäßen Kupferlegierung die Anteile der Legierungselemente so ausgewählt sein, dass das Verhältnis der Gewichtsanteile zweier beliebiger Legierungselemente aus der Gruppe, die aus Ag, Ni, Zn, Sn und Al besteht, maximal 1,5 beträgt. Das häufigere der beiden Legierungselemente bildet hierbei den Zähler des zu berechnenden Quotienten. Besonders bevorzugt beträgt dieses Gewichtsverhältnis maximal 1,3. Es hat sich hinsichtlich Festigkeit und Leitfähigkeit im Gusszustand als günstig erwiesen, wenn die Elemente, die aus der Gruppe, die aus Ag, Ni, Zn, Sn und Al besteht, für die jeweilige Legierung ausgewählt sind, in ungefähr gleichen Gewichtsanteilen zulegiert sind.With regard to the elements from the group consisting of Ag, Ni, Zn, Sn and Al, the increase in strength is not always sufficient at contents of less than 0.06% by weight. With element contents greater than 0.15% by weight, the electrical conductivity can be reduced too much, for example below 75% IACS. The sum of the proportions of the elements from the group consisting of Ag, Ni, Zn, Sn and Al is preferably at least 0.20% by weight and at most 0.35% by weight. In the copper alloy according to the invention, the proportions of the alloy elements can preferably be selected such that the ratio by weight of two arbitrary alloy elements from the group consisting of Ag, Ni, Zn, Sn and Al is at most 1.5. The more common of the two alloying elements forms the numerator of the quotient to be calculated. This weight ratio is particularly preferably at most 1.3. In terms of strength and conductivity in the as-cast state, it has proven to be advantageous if the elements selected from the group consisting of Ag, Ni, Zn, Sn and Al for the respective alloy are alloyed in approximately equal parts by weight.
In bevorzugter Ausgestaltung der Erfindung kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Eine derartige Legierung weist eine elektrische Leitfähigkeit von mindestens 68 % IACS auf und kann die Festigkeit von Reinkupfer um bis zu 35 % übertreffen.In a preferred embodiment of the invention, the copper alloy can have the following composition in% by weight:
optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. Such an alloy has an electrical conductivity of at least 68% IACS and can exceed the strength of pure copper by up to 35%.
In besonders bevorzugter Ausgestaltung der Erfindung kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Eine derartige Legierung weist mit ungefähr 90 % IACS eine elektrische Leitfähigkeit auf, die ungefähr gleich zu einer Kupferlegierung ist, die 1 Gew.-% Ag enthält (CuAg1). Die Steigerung der Festigkeit gegenüber Reinkupfer beträgt im Gusszustand ungefähr 20 %. Damit weist eine solche Legierung eine sehr günstige Kombination von Eigenschaften auf. Die relative Steigerung der Festigkeit ist größer als die relative Abnahme der Leitfähigkeit. Aufgrund der geringen Legierungsanteile liegt die Legierung auf dem Kostenniveau handelsüblicher Kupferlegierungen.In a particularly preferred embodiment of the invention, the copper alloy can have the following composition in% by weight:
optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. With approximately 90% IACS, such an alloy has an electrical conductivity that is approximately equal to that of a copper alloy which contains 1% by weight of Ag (CuAg1). The increase in strength compared to pure copper in the as-cast state is approximately 20%. Such an alloy thus has a very favorable combination of properties. The relative increase in strength is greater than the relative decrease in conductivity. Due to the low proportion of alloys, the alloy is at the cost level of commercially available copper alloys.
Bei einer weiteren vorteilhaften Ausgestaltung der Erfindung kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Eine derartige Legierung weist eine elektrische Leitfähigkeit von ungefähr 85 % IACS auf. Die Steigerung der Festigkeit gegenüber Reinkupfer beträgt im Gusszustand ungefähr 20 %. Damit weist eine solche Legierung eine sehr günstige Kombination von Eigenschaften auf. Die relative Steigerung der Festigkeit ist größer als die relative Abnahme der Leitfähigkeit. Aufgrund der geringen Legierungsanteile liegt die Legierung auf dem Kostenniveau handelsüblicher Kupferlegierungen.In a further advantageous embodiment of the invention, the copper alloy can have the following composition in% by weight:
optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. Such an alloy has an electrical conductivity of approximately 85% IACS. The increase in strength compared to pure copper in the as-cast state is approximately 20%. Such an alloy thus has a very favorable combination of properties. The relative increase in strength is greater than the relative decrease in conductivity. Due to the low proportion of alloys, the alloy is at the cost level of commercially available copper alloys.
Bei einer weiteren vorteilhaften Ausgestaltung der Erfindung kann die Kupferlegierung folgende Zusammensetzung in Gewichts-% aufweisen:
optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Eine derartige Legierung weist eine elektrische Leitfähigkeit von ungefähr 85 % IACS auf. Die Steigerung der Festigkeit gegenüber Reinkupfer beträgt im Gusszustand ungefähr 10 %. Aufgrund der Elemente Zn und Al stellt diese Legierung eine kostengünstige Alternative dar.In a further advantageous embodiment of the invention, the copper alloy can have the following composition in% by weight:
optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. Such an alloy has an electrical Conductivity of about 85% IACS. The increase in strength compared to pure copper in the as-cast state is approximately 10%. Due to the elements Zn and Al, this alloy is an inexpensive alternative.
Eine weitere vorteilhafte Kupferlegierung kann folgende Zusammensetzung in Gewichts-% aufweisen:
optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Eine derartige Legierung weist eine elektrische Leitfähigkeit von ungefähr 80 % IACS auf. Die Steigerung der Festigkeit gegenüber Reinkupfer beträgt im Gusszustand ungefähr 10 %. Da diese Legierung kein Silber enthält, stellt sie eine besonders kostengünstige Alternative dar.Another advantageous copper alloy can have the following composition in% by weight:
optionally 0.01 to 0.2% of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. Such an alloy has an electrical conductivity of approximately 80% IACS. The increase in strength compared to pure copper in the as-cast state is approximately 10%. Since this alloy does not contain silver, it is a particularly inexpensive alternative.
Ein weiterer Aspekt der Erfindung betrifft stromführende Konstruktionsteile aus Kupferlegierungen, wobei die Konstruktionsteile mittels eines urformtechnischen Verfahrens hergestellt sind und wobei die Kupferlegierungen folgende Zusammensetzung in Gewichts-% aufweisen: 0,05 bis 0,5 % Ag, jeweils 0,05 bis 0,5 % von mindestens zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht, Rest Cu sowie unvermeidbare Verunreinigungen, optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Alternativ kann die Kupferlegierung des Konstruktionsteils folgende Zusammensetzung in Gewichts-% aufweisen:
Solche Konstruktionsteile können beispielsweise Schalter, Kommutatoren, Schleifkörper, Stromschienen, Kontakte, Bürsten, Brücken, Komponenten für Schaltgeräte, Leiterstäbe oder Kurzschlussringe von Käfigläufern oder andere Bauteile sein. Unter urformtechnischen Verfahren werden Gießverfahren wie beispielsweise Druckguss, Feinguss, Vollformguss oder andere Verfahren verstanden. Im Gegensatz zum Kokillenguss, mit dem vorwiegend Ausgangsmaterial für die Halbzeugfertigung gegossen wird, hat bei den vorstehend genannten Gießverfahren der Gusskörper im Wesentlichen bereits die Gestalt des gewünschten Konstruktionsteils. Mittels Trennverfahren können ein oder mehrere weitere Bearbeitungsschritte durchgeführt werden, die die Gestalt des Konstruktionsteils geringfügig verändern. Beispiele hierfür sind das Abtrennen des Angusses oder die Nachbearbeitung der Oberfläche des Konstruktionsteils. Umformtechnische Bearbeitungsschritte, durch die der Werkstoff des Konstruktionsteils in einen anderen Zustand gebracht wird, schließen sich jedoch nicht an. Das fertige Konstruktionsteil befindet sich folglich im Gusszustand. Die erfindungsgemäßen Kupferlegierungen weisen aufgrund der Mischkristallverfestigung im Gusszustand eine höhere Festigkeit auf als Reinkupfer. Die elektrische Leitfähigkeit ist gegenüber Reinkupfer verhältnismäßig wenig reduziert. Die erfindungsgemäßen Legierungen weisen ferner eine gute Gießbarkeit aus: Sie zeigen nur eine geringe Tendenz zur Gasaufnahme und sind durch ein gutes Formfüllvermögen gekennzeichnet. Durch eine geeignete Auswahl der Legierungselemente und der Legierungszusammensetzung kann eine auf die jeweilige Anwendung angepasste Legierung gefunden werden. Insbesondere kann der Gehalt an Ag auf 0,15 Gew.-% beschränkt werden. Die Metallkosten der erfindungsgemäßen Legierungen sind gegenüber Reinkupfer um maximal 15 % erhöht. Durch urformtechnische Verfahren hergestellte Konstruktionsteile weisen einen geringeren Herstellaufwand auf als Konstruktionsteile, die aus Halbzeugen gefertigt sind. Die Gesamtkosten der erfindungsgemäßen Konstruktionsteile können folglich günstiger sein als die Gesamtkosten anderer Konstruktionsteile. Optional kann die erfindungsgemäße Legierung 0,01 bis 0,2 Gew.-% von einem oder mehreren Elementen aus der Gruppe enthalten, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Diese Elemente bewirken eine Kornfeinung des Gussgefüges und erhöhen so die Festigkeit des Gusswerkstoffs. Durch Desoxidation der Schmelze können sie ferner die Gasaufnahme reduzieren.Such structural parts can be, for example, switches, commutators, grinding wheels, busbars, contacts, brushes, bridges, components for switching devices, conductor bars or short-circuit rings of cage rotors or other components. Primary molding processes are understood to mean casting processes such as, for example, die casting, investment casting, full mold casting or other processes. In contrast to gravity die casting, which is mainly used to cast starting material for semi-finished products, the above-mentioned casting process the cast body essentially already has the shape of the desired structural part. Separation processes can be used to carry out one or more further processing steps which slightly change the shape of the structural part. Examples of this are cutting off the sprue or reworking the surface of the structural part. Forming processing steps that bring the material of the structural part into a different state do not follow. The finished construction part is therefore in the as-cast state. The copper alloys according to the invention have a higher strength than pure copper due to the solidification of the solid solution in the as-cast state. The electrical conductivity is relatively little reduced compared to pure copper. The alloys according to the invention also have good castability: they show only a slight tendency to absorb gas and are characterized by a good mold filling capacity. Through an appropriate selection of the alloying elements and the alloying composition, an alloy adapted to the respective application can be found. In particular, the Ag content can be limited to 0.15% by weight. The metal costs of the alloys according to the invention are increased by a maximum of 15% compared to pure copper. Construction parts produced by master molding processes are less expensive to manufacture than construction parts that are made from semi-finished products. The total cost of the construction parts according to the invention can consequently be cheaper than the total costs of other construction parts. The alloy according to the invention can optionally contain 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb. These elements result in grain refinement of the cast structure and thus increase the strength of the cast material. By deoxidizing the melt, they can also reduce gas absorption.
Ein weiterer Aspekt der Erfindung betrifft Käfigläufer mit mehreren Leiterstäben und zwei Kurzschlussringen, die aus einer Kupferlegierungen einstückig gegossen sind. Erfindungsgemäß weist die Kupferlegierung folgende Zusammensetzung in Gewichts-% auf: 0,05 bis 0,5 % Ag, jeweils 0,05 bis 0,5 % von mindestens zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht, Rest Cu sowie unvermeidbare Verunreinigungen, optional 0,01 bis 0,2 % von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Alternativ kann die Kupferlegierung des Käfigläufers folgende Zusammensetzung in Gewichts-% aufweisen:
Die Erfindung geht dabei von der Überlegung aus, Leiterstäbe und Kurzschlussringe von Käfigläufern einstückig zu gießen. Geeignete Gießverfahren hierfür können Druckguss, Feinguss, Vollformguss und andere Verfahren sein. Aufgrund ihrer hohen elektrischen Leitfähigkeit sind Kupferlegierungen für die Herstellung von Käfigläufern gut geeignet. Da aufgrund der hohen Drehzahlen der Asynchronmaschinen große Kräfte insbesondere auf die Leiterstäbe der Käfigläufer wirken, müssen die verwendeten Kupferlegierungen bereits im Gusszustand eine hohe Festigkeit aufweisen. Besonders geeignet sind deshalb Kupferlegierungen, die folgende Zusammensetzung in Gewichts-% aufweisen: 0,05 bis 0,5 % Ag, jeweils 0,05 bis 0,5 % von mindestens zwei Elementen aus der Gruppe, die aus Ni, Zn, Sn und Al besteht, Rest Cu sowie unvermeidbare Verunreinigungen. Die erfindungsgemäßen Kupferlegierungen weisen aufgrund der Mischkristallverfestigung im Gusszustand eine höhere Festigkeit auf als Reinkupfer. Die elektrische Leitfähigkeit ist gegenüber Reinkupfer verhältnismäßig wenig reduziert. Die erfindungsgemäßen Legierungen weisen ferner eine gute Gießbarkeit auf: Sie zeigen nur eine geringe Tendenz zur Gasaufnahme und sind durch ein gutes Formfüllvermögen gekennzeichnet. Optional kann die erfindungsgemäße Legierung 0,01 bis 0,2 Gew.-% von einem oder mehreren Elementen aus der Gruppe enthalten, die aus Mg, Ti, Zr, B, P, As, Sb besteht. Diese Elemente bewirken eine Kornfeinung des Gussgefüges und erhöhen so die Festigkeit des Gusswerkstoffs. Durch eine geeignete Auswahl der Legierungselemente und der Legierungszusammensetzung kann eine auf die jeweilige Anwendung angepasste Legierung gefunden werden. Insbesondere erweisen sich folgende Legierungen als vorteilhaft:
Kupferlegierung mit folgender Zusammensetzung in Gewichts-%:
Alternativ: Kupferlegierung mit folgender Zusammensetzung in Gewichts-%:
Alternativ: Kupferlegierung mit folgender Zusammensetzung in Gewichts-%:
Alternativ: Kupferlegierung mit folgender Zusammensetzung in Gewichts-%:
Copper alloy with the following composition in% by weight:
Alternatively: copper alloy with the following composition in% by weight:
Alternatively: copper alloy with the following composition in% by weight:
Alternatively: copper alloy with the following composition in% by weight:
Zu jeder der vorgenannten Legierungen kann optional 0,01 bis 0,2 Gew.-% von einem oder mehreren Elementen aus der Gruppe, die aus Mg, Ti, Zr, B, P, As, Sb besteht, hinzutreten. Die Metallkosten der erfindungsgemäßen Legierungen sind gegenüber Reinkupfer um maximal 15 % erhöht.Each of the aforementioned alloys can optionally have 0.01 to 0.2% by weight of one or more elements from the group consisting of Mg, Ti, Zr, B, P, As, Sb added. The metal costs of the alloys according to the invention are increased by a maximum of 15% compared to pure copper.
Die Erfindung wird anhand der folgenden Ausführungsbeispiele näher erläutert.The invention is explained in more detail using the following exemplary embodiments.
Tabelle 1 zeigt eine Zusammenstellung der untersuchten Legierungen. Es ist für jede Legierung die Zusammensetzung der Probe, die ermittelte Zugfestigkeit Rm im Gusszustand und die relative elektrische Leitfähigkeit, ausgedrückt durch den IACS-Wert, angegeben. Die Metallkosten, die sich aus der Legierungszusammensetzung rechnerisch ergeben, sind auf die Metallkosten von reinem Kupfer (Probe Nr. 1) normiert.
Probe Nr. 2 ist eine Referenzlegierung mit 99 % Kupfer und 1 % Silber. Diese Legierung hat hinsichtlich Festigkeit und Leitfähigkeit attraktive Eigenschaften, aufgrund der hohen Metallkosten ist sie jedoch nur in ganz speziellen Anwendungsfällen wirtschaftlich einsetzbar.Sample No. 2 is a reference alloy with 99% copper and 1% silver. This alloy has attractive properties in terms of strength and conductivity, but due to the high metal costs, it can only be used economically in very special applications.
Probe Nr. 3 ist eine Kupferlegierung mit ungefähr 0,5 % Silber, 0,5 % Nickel und 0,5 % Zink. Mit dieser Legierung wird eine Festigkeit erreicht, die ca. 35 % über der von Reinkupfer liegt. Die elektrische Leitfähigkeit beträgt 68 % IACS.Sample No. 3 is a copper alloy with approximately 0.5% silver, 0.5% nickel and 0.5% zinc. This alloy achieves a strength that is approx. 35% higher than that of pure copper. The electrical conductivity is 68% IACS.
Probe Nr. 4 ist eine Kupferlegierung mit ungefähr 0,1 % Silber, 0,1 % Nickel und 0,1 % Zink. Mit dieser Legierung wird eine Festigkeit erreicht, die ca. 20 % über der von Reinkupfer liegt. Die elektrische Leitfähigkeit beträgt 91 % IACS. Die relative Steigerung der Festigkeit ist damit deutlich größer als die relative Abnahme der elektrischen Leitfähigkeit. Diese überraschende Eigenschaftskombination der Legierung ist aus den individuellen Beiträgen der einzelnen Legierungselemente nicht zu erwarten. Die relative Steigerung der Metallkosten ist geringer als die relative Steigerung der Festigkeit und kann somit beispielsweise durch eine Reduktion des Querschnitts der Leiterstäbe kompensiert werden. Damit bietet diese Legierung eine sehr attraktive Kombination von Eigenschaften für die Verwendung in gegossenen Käfigläufern von Asynchronmaschinen.Sample No. 4 is a copper alloy with approximately 0.1% silver, 0.1% nickel and 0.1% zinc. This alloy achieves a strength that is approx. 20% higher than that of pure copper. The electrical conductivity is 91% IACS. The relative increase in strength is thus significantly greater than the relative Decrease in electrical conductivity. This surprising combination of properties of the alloy is not to be expected from the individual contributions of the individual alloy elements. The relative increase in metal costs is less than the relative increase in strength and can therefore be compensated for, for example, by reducing the cross section of the conductor bars. This alloy thus offers a very attractive combination of properties for use in cast squirrel cage rotors.
Probe Nr. 5 ist eine Kupferlegierung mit ungefähr 0,1 % Silber, 0,13 % Zinn und 0,1 % Nickel. Mit dieser Legierung wird eine Festigkeit erreicht, die ca. 20 % über der von Reinkupfer liegt. Die elektrische Leitfähigkeit beträgt 84 % IACS. Die relative Steigerung der Festigkeit ist damit größer als die relative Abnahme der elektrischen Leitfähigkeit. Diese überraschende Eigenschaftskombination der Legierung ist aus den individuellen Beiträgen der einzelnen Legierungselemente nicht zu erwarten. Die relative Steigerung der Metallkosten ist geringer als die relative Steigerung der Festigkeit.Sample No. 5 is a copper alloy with approximately 0.1% silver, 0.13% tin and 0.1% nickel. This alloy achieves a strength that is approx. 20% higher than that of pure copper. The electrical conductivity is 84% IACS. The relative increase in strength is therefore greater than the relative decrease in electrical conductivity. This surprising combination of properties of the alloy is not to be expected from the individual contributions of the individual alloy elements. The relative increase in metal costs is less than the relative increase in strength.
Probe Nr. 6 ist eine Kupferlegierung mit ungefähr 0,1 % Silber, 0,1 % Zink und 0,1 % Aluminium. Mit dieser Legierung wird eine Festigkeit erreicht, die ca. 6 % über der von Reinkupfer liegt. Die elektrische Leitfähigkeit beträgt 84 % IACS. Aufgrund der Elemente Zn und Al stellt diese Legierung eine kostengünstige Alternative dar.Sample No. 6 is a copper alloy with approximately 0.1% silver, 0.1% zinc and 0.1% aluminum. This alloy achieves a strength that is approx. 6% higher than that of pure copper. The electrical conductivity is 84% IACS. Due to the elements Zn and Al, this alloy is an inexpensive alternative.
Probe Nr. 7 ist eine Kupferlegierung mit ungefähr 0,1 % Zinn, 0,1 % Zink und 0,1 % Aluminium. Mit dieser Legierung wird eine Festigkeit erreicht, die ca. 8 % über der von Reinkupfer liegt. Die elektrische Leitfähigkeit beträgt 78 % IACS. Da diese Legierung kein Silber enthält, stellt sie eine besonders kostengünstige Alternative dar.Sample No. 7 is a copper alloy with approximately 0.1% tin, 0.1% zinc and 0.1% aluminum. This alloy achieves a strength that is approx. 8% higher than that of pure copper. The electrical conductivity is 78% IACS. Since this alloy does not contain silver, it is a particularly inexpensive alternative.
Claims (13)
- Copper alloy having the following composition [in % by weight] :from 0.05 to 0.5% Ag,in each case from 0.05 to 0.5% of at least two elements from the group which comprises Ni, Zn, Sn and Al,balance Cu and inevitable impurities,optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb.
- Copper alloy according to claim 1 having the following composition [in % by weight]:in each case from 0.05 to 0.5% of two elements from the group which comprises Ni, Zn, Sn and Al,balance Cu and inevitable impurities,optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb.
- Copper alloy according to claim 2 having the following composition [in % by weight]:from 0.06 to 0.3% Ag,in each case from 0.06 to 0.3% of two elements from the group which comprises Ni, Zn, Sn and Al,balance Cu and inevitable impurities,optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb.
- Copper alloy according to claim 3 having the following composition [in % by weight]:from 0.06 to 0.15% Ag,in each case from 0.06 to 0.15% of two elements from the group which comprises Ni, Zn, Sn and Al,balance Cu and inevitable impurities,optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb.
- Copper alloy according to any one of claims 1 to 4, characterised in that the ratio of the weight proportions in each case of two alloy elements from the group which comprises Ag, Ni, Zn, Sn and Al is a maximum of 1.5.
- Copper alloy according to either claim 2 or claim 5, having the following composition [in % by weight]:
Ag: 0.06 to 0.5% Ni: 0.06 to 0.5% Zn: 0.06 to 0.5%
optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb. - Copper alloy according claim 6 having the following composition [in % by weight]:
Ag: 0.06 to 0.15% Ni: 0.06 to 0.15% Zn: 0.06 to 0.15%
optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb. - Copper alloy according to either claim 4 or claim 5 having the following composition [in % by weight]:
Ag: 0.06 to 0.15% Sn: 0.06 to 0.15% Ni: 0.06 to 0.15%
optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb. - Copper alloy according to either claim 4 or claim 5 having the following composition [in % by weight]:
Ag: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15%
optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb. - Current-carrying construction component comprising a copper alloy according to any one of the preceding claims, characterised in that the construction component is produced by means of a technical original forming method.
- Cage rotor comprising a copper alloy according to any one of claims 1 to 9, wherein the cage rotor comprises a plurality of conductor rods and two short-circuit rings, characterised in that the conductor rods and the short-circuit rings are cast integrally.
- Current-carrying construction component comprising a copper alloy having the following composition [in % by weight] :
Sn: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15%
optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb, characterised in that the construction component is produced by means of a technical original forming method. - Cage rotor comprising a copper alloy having the following composition [in % by weight]:
Sn: 0.06 to 0.15% Zn: 0.06 to 0.15% Al: 0.06 to 0.15%
optionally from 0.01 to 0.2% of one or more elements from the group which comprises Mg, Ti, Zr, B, P, As, Sb,
wherein the cage rotor comprises a plurality of conductor rods and two short-circuit rings, characterised in that the conductor rods and the short-circuit rings are cast integrally.
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DE102013007274.3A DE102013007274B4 (en) | 2013-04-26 | 2013-04-26 | Construction part made of a cast copper alloy |
PCT/EP2014/000957 WO2014173498A1 (en) | 2013-04-26 | 2014-04-10 | Cast copper alloy for asynchronous machines |
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EP2989224B1 true EP2989224B1 (en) | 2020-07-22 |
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EP (1) | EP2989224B1 (en) |
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CN106521232B (en) * | 2016-11-22 | 2018-05-18 | 陕西斯瑞新材料股份有限公司 | It is a kind of it is high-strength, in lead Novel copper alloy Cu-Zn-Cr-RE conducting bars and preparation method |
CN107511469A (en) * | 2017-10-13 | 2017-12-26 | 安阳恒安电机有限公司 | A kind of squirrel cage motor rotor low pressure cast copper equipment, cast copper and its cast copper method |
RU2709909C1 (en) * | 2018-11-26 | 2019-12-23 | Федеральное государственное автономное образовательное учреждение высшего образования "Белгородский государственный национальный исследовательский университет" (НИУ "БелГУ") | Low-alloyed copper alloy |
US20230243018A1 (en) * | 2020-06-30 | 2023-08-03 | Mitsubishi Materials Corporation | Copper alloy, copper alloy plastic working material, component for electronic/electrical devices, terminal, bus bar, lead frame and heat dissipation substrate |
CN113234955A (en) * | 2021-04-30 | 2021-08-10 | 浙江利丰电器股份有限公司 | Silver-copper alloy material for manufacturing commutator copper sheet |
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WO2014173498A1 (en) | 2014-10-30 |
JP6254679B2 (en) | 2017-12-27 |
EP2989224A1 (en) | 2016-03-02 |
DE102013007274A1 (en) | 2014-10-30 |
DE102013007274B4 (en) | 2020-01-16 |
US20160056698A1 (en) | 2016-02-25 |
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