WO2015046459A1 - 銅合金および銅合金板 - Google Patents
銅合金および銅合金板 Download PDFInfo
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- WO2015046459A1 WO2015046459A1 PCT/JP2014/075705 JP2014075705W WO2015046459A1 WO 2015046459 A1 WO2015046459 A1 WO 2015046459A1 JP 2014075705 W JP2014075705 W JP 2014075705W WO 2015046459 A1 WO2015046459 A1 WO 2015046459A1
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/002—Castings of light metals
- B22D21/005—Castings of light metals with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
- C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
- C21D8/0221—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips characterised by the working steps
- C21D8/0236—Cold rolling
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
- C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
- C21D8/0247—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips characterised by the heat treatment
- C21D8/0273—Final recrystallisation annealing
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/46—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
Definitions
- the present invention relates to a copper alloy that exhibits a brass color and has good stress corrosion cracking resistance and discoloration resistance and excellent stress relaxation characteristics, and a copper alloy plate made of this copper alloy.
- copper alloys such as Cu-Zn have been used for various applications such as connectors, terminals, relays, springs, switches, building materials, daily necessities, machine parts, etc., which are components of electrical and electronic equipment.
- Copper connectors may be used as they are for connectors, terminals, relays, springs, etc., but may be plated with Sn or Ni due to corrosion problems such as discoloration and stress corrosion cracking.
- Sn or Ni due to corrosion problems such as discoloration and stress corrosion cracking.
- the copper alloy surface is coated by plating treatment such as plating, resin, clear coating, or the like.
- the plating layer on the surface of the plated product peels off after long-term use.
- the surface of the plate is pre-plated with Sn, Ni, etc., and the plate material is punched and used. is there. Since the punched surface is not plated, discoloration and stress corrosion cracking are likely to occur.
- Sn or Ni is contained by plating or the like, it is difficult to recycle the copper alloy.
- the coated product has a problem that the color tone changes with the passage of time and the coating film peels off. And a plating product and a coating product will impair the antibacterial property (bactericidal property) which a copper alloy has. From the above, there is a demand for a copper alloy that is excellent in discoloration resistance and stress corrosion cracking resistance and can be used without forming a plating.
- Possible usage environments for terminals, connectors, handrails, etc. are, for example, high-temperature and humid indoor environments, stress corrosion cracking environments containing trace amounts of nitrogen compounds such as ammonia and amines, and close to automotive interiors and engine rooms under hot weather The high temperature environment etc. which reach about 100 degreeC when used in a part are mentioned. In order to withstand these environments, good discoloration resistance and stress corrosion cracking resistance are desired. The discoloration has a great influence not only on the appearance, but also on the antibacterial property and electrical conductivity of copper. Handrails, door handles, connectors / terminals that are not plated, connectors / terminals with exposed end faces, door handles, etc. are widely used and have excellent discoloration resistance and stress corrosion cracking resistance.
- a copper alloy material is required.
- high material strength is necessary when thinning of the material is required, and is necessary for obtaining a high contact pressure when used for terminals and connectors.
- the high material strength is utilized with stress below the elastic limit of the material at room temperature when used for terminals, connectors, relays, springs and the like.
- the temperature of the use environment increases, for example, when the temperature rises to 90 ° C. to 150 ° C., the copper alloy is permanently deformed, and a predetermined contact pressure cannot be obtained.
- it is desired that the permanent deformation is small at a high temperature, and it is desirable that the stress relaxation characteristic used as a scale of the permanent deformation at a high temperature is excellent.
- copper alloys with high conductivity and high strength are used as components for connectors, terminals, relays, springs, switches, etc. used in electrical, electronic, automotive parts, communications, electronic / electrical equipment, etc. .
- the constituent materials used for them are required to be able to cope with extremely severe characteristics improvements and various usage environments.
- Excellent cost performance is required.
- a thin plate is used for the spring contact portion of the connector.
- high strength and high strength and elongation or bending workability are required. It is required to have balance, discoloration resistance, stress corrosion cracking resistance, and stress relaxation characteristics to withstand the usage environment.
- it is required to have high productivity and particularly excellent cost performance by minimizing the use of copper as a noble metal.
- the high-strength copper alloy examples include Cu, phosphor bronze containing 5 mass% or more of Sn, and a small amount of P, and a white powder containing 10 to 18 mass% Ni in a Cu-Zn alloy.
- brass which is an alloy of Cu and Zn, is well known as a general-purpose high-conductivity and high-strength copper alloy with excellent cost performance.
- Patent Document 1 discloses a Cu—Zn—Sn alloy as an alloy for satisfying the demand for high strength.
- Phosphor bronze and white are generally manufactured by horizontal continuous casting because they have poor hot workability and are difficult to manufacture by hot rolling. Therefore, productivity is poor, energy costs are high, and yield is poor.
- high-strength representative varieties such as phosphor bronze and western white contain a large amount of precious metal copper, or a large amount of Sn, Ni, which is more expensive than copper, which is a problem in terms of economy. There is.
- the specific gravity of these alloys is as high as about 8.8, there is a problem in weight reduction.
- strength and electrical conductivity are contradictory characteristics, and as the strength increases, the electrical conductivity generally decreases.
- Western white containing 10 mass% or more of Ni or phosphor bronze containing 5 mass% or more of Sn without containing Zn has high strength.
- the electrical conductivity is less than 10% IACS in the white and phosphor bronze is less than 16% IACS, and the conductivity is low, which causes a problem in use.
- Zn which is the main element of brass alloy, is cheaper than Cu.
- the density decreases, and the strength, that is, tensile strength, proof stress or yield stress, spring limit value, and fatigue strength increase.
- the stress corrosion cracking resistance deteriorates, and when the Zn content exceeds 15 mass%, problems begin to occur, and over 20 mass%, the stress resistance increases as it exceeds 25 mass%.
- the corrosion cracking property deteriorates and reaches 30 mass%, the stress corrosion cracking sensitivity becomes very high, which is a serious problem.
- the stress relaxation property indicating heat resistance is once improved when the Zn addition amount is 5 to 15 mass%, but it deteriorates rapidly as the Zn content exceeds 20 mass%, and in particular, 25 mass% or more than 25 mass%. As a result, the stress relaxation characteristics are very poor. And as the Zn content increases, the strength improves, but the ductility and bending workability deteriorate, and the balance between strength and ductility deteriorates. Moreover, discoloration resistance is poor regardless of the Zn content, and when the usage environment is poor, the color changes to brown or red.
- conventional high-strength copper alloys such as phosphor bronze, white, and brass are superior in cost performance, adaptable to various usage environments, and can be partially omitted, resulting in smaller size, lighter weight, and higher performance.
- As a component component of various devices such as electronics / electricity and automobiles, and decorative / architectural members, which are tending to be apt to be developed, the development of new high-strength copper alloys is strongly demanded.
- the Cu—Zn—Sn alloy described in Patent Document 1 does not have sufficient properties including strength.
- the present invention has been made in order to solve such problems of the prior art, and has the advantages of conventional brass, such as excellent cost performance, low density, and conductivity higher than phosphor bronze and white.
- the present inventor has repeatedly studied from various angles and conducted various researches and experiments.
- the Cu—Zn alloy containing Zn at a high concentration of 18 mass% or more and 30 mass% or less First, appropriate amounts of Ni and Sn are added.
- the total content of Ni and Sn and the ratio of the content are within an appropriate range.
- f1 [Zn] + 5 ⁇ [Sn] ⁇ 2 ⁇ [Ni]
- f2 [Zn] ⁇ 0.5 ⁇ [Sn] ⁇ 3 ⁇ [Ni]
- f3 ⁇ f1 ⁇ (32 ⁇ f1) ⁇ 1/2 ⁇ Zn
- Ni, Sn are adjusted so that [Ni] is set to an appropriate value at the same time, and the P amount and the Ni amount The content ratio is within an appropriate range.
- the metal structure of the matrix is substantially a single phase of ⁇ phase, and the crystal grain size of ⁇ phase is appropriately adjusted.
- discoloration resistance, stress corrosion cracking resistance, and stress relaxation characteristics are improved. Further, in order to improve the strength without impairing ductility and bending workability, it is necessary to consider the interaction between elements from various viewpoints including the properties of each element of Zn, Ni and Sn. . In other words, discoloration resistance and stress corrosion cracking resistance can be achieved simply by adding each element within the range of 18-30 mass% Zn, 1-1.5 mass% Ni, and 0.2-1 mass% Sn. It is not always possible to obtain high strength without improving the stress relaxation characteristics and without impairing ductility and bending workability.
- the lower limit values of relational expressions f1 and f2 and the upper limit value of f3 are the minimum necessary values for obtaining high strength even when the interaction of each element of Zn, Ni, and Sn is taken into consideration.
- the relational expressions f1 and f2 exceed the upper limit value or fall below the lower limit value of f3, the strength increases, but the ductility and bending workability are impaired, and the stress relaxation characteristics or stress corrosion cracking resistance is poor. Become.
- the upper limit value of the relational expression f1: [Zn] + 5 ⁇ [Sn] ⁇ 2 ⁇ [Ni] is a value indicating whether or not the metal structure of the alloy of the present invention is substantially only the ⁇ phase. It is a boundary value with good workability.
- an alloy of Cu and 18-30 mass% Zn contains 1-1.5 mass% Ni and 0.2-1 mass% Sn, the ⁇ phase and ⁇ phase may exist in a non-equilibrium state. is there.
- the ⁇ phase and ⁇ phase are present, ductility and bending workability are impaired, and discoloration resistance, stress corrosion cracking resistance, and stress relaxation characteristics are deteriorated.
- the ⁇ single phase is substantially etched using a mixed solution of ammonia water and hydrogen peroxide, excluding non-metallic inclusions such as oxides generated during dissolution, and intermetallic compounds such as crystallized substances and precipitates.
- non-metallic inclusions such as oxides generated during dissolution
- intermetallic compounds such as crystallized substances and precipitates.
- substantially ⁇ single phase means that the metal structure was observed with a metal microscope at a magnification of 300 times except for intermetallic compounds such as non-metallic inclusions including oxides, precipitates and crystallized substances. Sometimes, the proportion of ⁇ phase in the metal structure is 100%.
- the upper limit value of the relational expression f2 [Zn] ⁇ 0.5 ⁇ [Sn] ⁇ 3 ⁇ [Ni] is a boundary value for obtaining good stress corrosion cracking resistance, ductility, and bending workability.
- a critical defect of the Cu—Zn alloy is the high sensitivity to stress corrosion cracking.
- the sensitivity to stress corrosion cracking depends on the Zn content. When the content exceeds 25 mass% or 26 mass%, the sensitivity to stress corrosion cracking is particularly high.
- the upper limit value of the relational expression f2 corresponds to a Zn content of 25 mass% or 26 mass%, is also a boundary value for stress corrosion cracking, and is also a boundary value for obtaining ductility and bending workability.
- the lower limit value of the relational expression f3: ⁇ f1 ⁇ (32 ⁇ f1) ⁇ 1/2 ⁇ [Ni] is a boundary value for obtaining good stress relaxation properties.
- the Cu—Zn alloy is an alloy having excellent cost performance.
- the stress relaxation property is poor, and even if it has a high strength, the high strength cannot be utilized.
- the first condition is to co-add 1 to 1.5 mass% of Ni and 0.2 to 1 mass% of Sn.
- the total content and the content ratio of Ni and Sn are important. Although details will be described later, at least three Ni atoms are required for one Sn atom.
- the copper alloy according to the first aspect of the present invention comprises 18-30 mass% Zn, 1-1.5 mass% Ni, 0.2-1 mass% Sn, and 0.003-0.06 mass%. P, with the balance being Cu and inevitable impurities, between Zn content [Zn] mass%, Sn content [Sn] mass%, and Ni content [Ni] mass%
- Sn content [Sn] mass% and the Ni content [Ni] mass% 1.3 ⁇ [Ni] + [Sn] ⁇ 2.4, 1.5 ⁇ [Ni] / [Sn] ⁇ 5.5, Between the Ni content [Ni] mass% and the P content [P
- the copper alloy according to the second aspect of the present invention comprises 19 to 29 mass% Zn, 1 to 1.5 mass% Ni, 0.3 to 1 mass% Sn, and 0.005 to 0.06 mass%. P, with the balance being Cu and inevitable impurities, between Zn content [Zn] mass%, Sn content [Sn] mass%, and Ni content [Ni] mass%
- 9 ⁇ f3 ⁇ f1 ⁇ (32 ⁇ f1) ⁇ 1/2 ⁇ [Ni] ⁇ 22,
- the copper alloy according to the third aspect of the present invention comprises 18-30 mass% Zn, 1-1.5 mass% Ni, 0.2-1 mass% Sn, and 0.003-0.06 mass%.
- P and at least one or two or more selected from Al, Fe, Co, Mg, Mn, Ti, Zr, Cr, Si, Sb, As, Pb, and rare earth elements are each 0.00.
- the copper alloy according to the fourth aspect of the present invention is the copper alloy according to the first to third aspects described above, wherein the conductivity is 18% IACS or more and 27% IACS or less, and the average crystal grain size is 2 to 12 ⁇ m.
- the conductivity is 18% IACS or more and 27% IACS or less
- the average crystal grain size is 2 to 12 ⁇ m.
- there are circular or elliptical precipitates and the average particle diameter of the precipitates is 3 to 180 nm, or the ratio of the number of precipitates having a particle diameter of 3 to 180 nm in the precipitates is 70% or more. It is.
- the copper alloy according to the fifth aspect of the present invention is used for electronic / electric equipment parts such as connectors, terminals, relays, switches, etc. in the copper alloys according to the first to fourth aspects described above.
- a copper alloy plate according to a sixth aspect of the present invention is composed of the copper alloy according to the first to fifth aspects described above, and a casting process for casting the copper alloy, a hot rolling process for hot rolling, Using a continuous heat treatment furnace, a cold rolling process in which the rolled material obtained in the hot rolling process is cold rolled at a cold working rate of 40% or more, and a rolled material obtained in the cold rolling process are continuously used.
- the maximum temperature of the rolled material is 560 to 790 ° C.
- the holding time in the high temperature region from the maximum temperature minus 50 ° C. to the maximum temperature is 0.04 to 1.0 minutes.
- a recrystallization heat treatment step for crystal treatment is performed Depending on the thickness of the copper alloy plate, a pair of cold rolling process and annealing process including batch annealing may be performed once or a plurality of times between the hot rolling process and the cold rolling process. Good.
- the copper alloy plate according to the seventh aspect of the present invention is composed of the copper alloy plate according to the sixth aspect described above, and the manufacturing step includes finish cold rolling the rolled material obtained in the recrystallization heat treatment step. It further includes a finish cold rolling step and a recovery heat treatment step for recovering and heat-treating the rolled material obtained in the finish cold rolling step.
- the recovery heat treatment step a continuous heat treatment furnace is used and the maximum temperature of the rolled material is 150. The recovery heat treatment is performed under the condition that the temperature is ⁇ 580 ° C. and the holding time in the high temperature region from the highest temperature minus ⁇ 50 ° C. to the highest temperature is 0.02 to 100 minutes.
- a method for producing a copper alloy sheet according to an eighth aspect of the present invention is a copper alloy sheet made of the copper alloy according to the first to fifth aspects described above, comprising a casting step, a cold rolling step as a pair,
- the cold rolling process includes an annealing process, a cold rolling process, a recrystallization heat treatment process, a finish cold rolling process, and a recovery heat treatment process, and does not include a process of hot working a copper alloy or a rolled material.
- a combination of a process and the recrystallization treatment process, and a combination of the finish cold rolling process and the recovery heat treatment process, or both, and the recrystallization heat treatment process Using a continuous heat treatment furnace, the maximum temperature of the rolled material is 560 to 790 ° C, and the holding time in the high temperature region from the maximum temperature minus 50 ° C to the maximum temperature is 0.04 to 1.0 minutes.
- the recovery heat treatment step is performed, Using a continuous heat treatment furnace, the maximum temperature of the rolled material is 150 to 580 ° C and the holding time in the high temperature region from the maximum temperature of minus 50 ° C to the maximum temperature is 0. Recovery heat treatment is performed under the condition of 02 to 100 minutes.
- the cost performance is excellent, the density is small, the conductivity is higher than that of phosphor bronze and white, the balance between high strength, elongation / bending workability and conductivity, and the stress relaxation characteristics are excellent. It is possible to provide a copper alloy excellent in stress corrosion cracking resistance, discoloration resistance, and antibacterial properties, and a copper alloy plate made of this copper alloy corresponding to various usage environments.
- Compositional relation f1 [Zn] + 5 ⁇ [Sn] ⁇ 2 ⁇ [Ni]
- Compositional relation f2 [Zn] ⁇ 0.5 ⁇ [Sn] ⁇ 3 ⁇ [Ni]
- Compositional relation f3 ⁇ f1 ⁇ (32 ⁇ f1) ⁇ 1/2 ⁇ [Ni]
- Composition relation f4 [Ni] + [Sn]
- Compositional relation f5 [Ni] / [Sn]
- Composition relation f6 [Ni] / [P]
- the copper alloy according to the first embodiment of the present invention includes 18 to 30 mass% Zn, 1 to 1.5 mass% Ni, 0.2 to 1 mass% Sn, and 0.003 to 0.06 mass%. And the balance consists of Cu and inevitable impurities, the composition relational expression f1 is in the range of 17 ⁇ f1 ⁇ 30, the compositional relational expression f2 is in the range of 14 ⁇ f2 ⁇ 26, and the compositional relational expression f3 is Within the range of 8 ⁇ f3 ⁇ 23, the composition relational expression f4 is within the range of 1.3 ⁇ f4 ⁇ 2.4, the compositional relational expression f5 is within the range of 1.5 ⁇ f5 ⁇ 5.5, and the compositional relational expression f6 is The range is 20 ⁇ f6 ⁇ 400.
- the copper alloy according to the second embodiment of the present invention includes 19 to 29 mass% Zn, 1 to 1.5 mass% Ni, 0.3 to 1 mass% Sn, and 0.005 to 0.06 mass%. And the balance is Cu and inevitable impurities, the composition relational expression f1 is in the range of 18 ⁇ f1 ⁇ 30, the compositional relational expression f2 is in the range of 15 ⁇ f2 ⁇ 25.5, and the compositional relational expression f3 is in the range of 9 ⁇ f3 ⁇ 22, the composition relational expression f4 is in the range of 1.4 ⁇ f4 ⁇ 2.4, the compositional relational expression f5 is in the range of 1.7 ⁇ f5 ⁇ 4.5, the compositional relational expression f6 is in the range of 22 ⁇ f6 ⁇ 220.
- the copper alloy according to the third embodiment of the present invention includes 18-30 mass% Zn, 1-1.5 mass% Ni, 0.2-1 mass% Sn, 0.003-0.06 mass%. And at least one or more selected from Al, Fe, Co, Mg, Mn, Ti, Zr, Cr, Si, Sb, As, Pb and rare earth elements, .0005 mass% or more and 0.05 mass% or less, and 0.0005 mass% or more and 0.2 mass% or less in total, the balance is made of Cu and inevitable impurities, and the compositional relational expression f1 is within the range of 17 ⁇ f1 ⁇ 30.
- composition relational expression f2 is in the range of 14 ⁇ f2 ⁇ 26
- compositional relational expression f3 is in the range of 8 ⁇ f3 ⁇ 23
- compositional relational expression f4 is in the range of 1.3 ⁇ f4 ⁇ 2.4
- compositional relational expression f5 Is 1.5 ⁇
- the composition relational expression f6 is in the range of 20 ⁇ f6 ⁇ 400 within the range of f5 ⁇ 5.5.
- the copper alloys according to the first to third embodiments of the present invention described above have a metal structure that is an ⁇ single phase.
- the average crystal grain size is 2 to 12 ⁇ m, and there are circular or elliptical precipitates.
- the ratio of the number of precipitates having a diameter of 3 to 180 nm or the number of precipitates having a particle diameter of 3 to 180 nm in the precipitates is 70% or more.
- the electrical conductivity is preferably 18% IACS or more and 27% IACS or less.
- the strength and stress relaxation characteristics are preferably defined as described later.
- (Zn) Zn is a main element of the present alloy, and at least 18 mass% or more is necessary to overcome the problems of the present invention.
- the density of the alloy of the present invention is made about 3% or more lower than that of pure copper, and the density of the alloy of the present invention is made about 2% or more lower than phosphor bronze or white.
- Zn content is required to be 18 mass% or more in order to improve tensile strength, yield strength, yield stress, springiness, fatigue strength, etc., improve discoloration resistance, and obtain fine crystal grains. It is.
- the lower limit of the Zn content is preferably 19 mass% or more, or 20 mass% or more, and more preferably 23 mass% or more.
- the Zn content exceeds 30 mass%, good stress relaxation properties and stress corrosion cracking properties cannot be obtained even if Ni, Sn, or the like is contained within the composition range of the present application described later, and the conductivity is increased. The ductility and bending workability also deteriorate, and the improvement in strength is saturated. More preferably, the upper limit of the Zn content is 29 mass% or less, and more preferably 28.5 mass% or less. Conventionally, there is no copper alloy containing 19 mass% or more or 23 mass% or more of Zn, which is excellent in stress relaxation characteristics and discoloration resistance and excellent in strength, corrosion resistance, and conductivity.
- Ni is contained in order to improve the balance between discoloration resistance, stress corrosion cracking resistance, stress relaxation characteristics, heat resistance, ductility, bending workability, strength and ductility, and bending workability of the alloy of the present invention.
- Zn content is a high concentration of 19 mass% or more or 23 mass% or more, the above-described characteristics work more effectively.
- Ni needs to be contained in an amount of 1 mass% or more, preferably 1.1 mass% or more, the composition ratio relationship with Sn and P, and six compositional relational expressions (f1 , F2, f3, f4, f5, f6).
- Ni is necessary to make use of the features of Sn described later, to make use of the features of Sn more than the content of single Sn, and to overcome problems in the metal structure of Sn.
- the Ni content exceeding 1.5 mass% leads to an increase in cost and the electrical conductivity is lowered, so the content is set to 1.5 mass% or less.
- Sn improves the balance of discoloration resistance, stress corrosion cracking resistance, stress relaxation characteristics, strength and ductility / bending workability by co-addition with the strength of the alloy of the present invention and Ni, P. Included to make crystal grains fine. In order to exert these effects, it is necessary to contain 0.2 mass% or more of Sn, and at the same time, the contents of Ni and P, and six relational expressions (f1, f2, f3, f4, f5, f6) It is necessary to satisfy. As a result, the characteristics of Sn can be fully utilized. In order to make those effects more prominent, the lower limit of the Sn content is preferably 0.25 mass% or more, more preferably 0.3 mass% or more.
- the upper limit of Sn content is 0.9 mass% or less.
- the P content needs to be at least 0.003 mass%.
- an appropriate amount of P in a solid solution state and an appropriate amount of Ni and P precipitates are required.
- the lower limit of the P content is preferably 0.005 mass% or more, more preferably 0.008 mass% or more, and still more preferably 0.01 mass% or more.
- the precipitates mainly composed of P and Ni increase, the particle size of the precipitates increases, and the bending workability decreases.
- the upper limit of the P content is preferably 0.05 mass% or less. Note that the ratio of Ni and P (composition relational expression f6), which will be described later, is important for improving the stress relaxation characteristics and reducing the susceptibility to stress corrosion cracking. The balance of the precipitate is also important.
- the copper alloy according to the third embodiment contains these elements.
- Fe, Co, Al, Mg, Mn, Ti, Zr, Cr, Si, Sb, As, Pb, and rare earth elements make the crystal grains of the alloy fine.
- Fe, Co, Al, Mg, Mn, Ti, and Zr form a compound together with P or Ni, suppress the growth of recrystallized grains during annealing, and have a large effect of crystal grain refinement.
- Fe and Co have a large effect, and form a compound of Ni and P containing Fe or Co, thereby reducing the particle size of the compound.
- the fine compound further refines the size of recrystallized grains during annealing and improves the strength. However, if the effect becomes excessive, bending workability and stress relaxation characteristics are impaired.
- Al, Sb and As have the effect of improving the discoloration resistance of the alloy, and Pb has the effect of improving the press formability.
- each element of Fe, Co, Al, Mg, Mn, Ti, Zr, Cr, Si, Sb, and As needs to contain 0.0005 mass% or more.
- the upper limit of the content of these elements is 0.03 mass% or less for any element.
- the upper limit of the total content of these elements is 0.15 mass% or less, more preferably 0.1 mass% or less.
- the copper alloy contains unavoidable elements such as oxygen, hydrogen, carbon, sulfur, and water vapor in the production process including the raw material including the return material and mainly when dissolved in the atmosphere. Therefore, naturally these inevitable impurities are included.
- elements other than the specified component elements may be treated as inevitable impurities, and the content of inevitable impurities is preferably 0.1 mass% or less.
- composition relational expression f1 [Zn] + 5 ⁇ [Sn] ⁇ 2 ⁇ [Ni] is 30, it is a boundary value of whether or not the metal structure of the alloy of the present invention is substantially only ⁇ phase, and at the same time, good It is also a boundary value for obtaining excellent stress relaxation characteristics, ductility, and bending workability.
- the content of the main element Zn is 30 mass% or less, and at the same time, this relational expression must be satisfied.
- the low melting point metal Sn is contained in the Cu-Zn alloy in an amount of 0.2 mass% or 0.3 mass% or more, Sn segregation occurs in the final solidified portion and crystal grain boundary during casting.
- ⁇ phase and ⁇ phase with high Sn concentration are formed.
- the ⁇ phase and ⁇ phase that exist in a non-equilibrium state can be eliminated by casting, hot working, annealing / heat treatment, brazing of product processing, or devising heat treatment conditions. When the value of the formula exceeds 30, it is difficult.
- Sn is given a coefficient “+5”.
- the coefficient “5” is larger than the coefficient “1” of Zn which is a main element.
- Ni has the property of reducing the segregation of Sn and inhibiting the formation of ⁇ phase and ⁇ phase within the composition range of the present application, and is given a coefficient “ ⁇ 2”.
- the alloy of the present invention includes the crystal grain boundary, and the alloy of the present invention includes the processing method of the product.
- the ⁇ phase and ⁇ phase are completely absent.
- the absence of ⁇ and ⁇ phases in the metal structure improves the ductility and bending workability of the alloy of the present invention, and at the same time improves the stress relaxation characteristics.
- the strength is low and the discoloration resistance is deteriorated, so that it is preferably 18 or more, more preferably Is 20 or more, more preferably 23 or more.
- compositional relational expression f2 [Zn] ⁇ 0.5 ⁇ [Sn] ⁇ 3 ⁇ [Ni] is 26, the boundary value for obtaining good stress corrosion cracking resistance, ductility and bending workability of the alloy of the present invention It is.
- a critical defect of the Cu—Zn alloy is high sensitivity to stress corrosion cracking.
- the sensitivity to stress corrosion cracking depends on the Zn content.
- the stress corrosion cracking susceptibility can be particularly lowered by containing Ni.
- the upper limit of the composition relational expression f2 is 25.5 or less.
- f2 [Zn] ⁇ 0.5 ⁇ [Sn] ⁇ 3 ⁇ [Ni] is less than 14
- the strength is low and the discoloration resistance is deteriorated.
- it is 18 or more.
- the lower limit value of the compositional relational expression f3 is 9 or more, more preferably 10 or more.
- the upper limit value of the composition relational expression f3 is 22 or less.
- compositional relational expression f5 [Ni] / [Sn] is further important in the stress relaxation characteristics of a Cu—Zn alloy containing a high concentration of Zn co-doped with Ni, Sn, and P in the composition range of the present application.
- Abundance, or balance is important.
- the value of [Ni] / [Sn] by mass ratio is 1.5 or more. It has been found that the stress relaxation characteristics are improved.
- the effect becomes more remarkable in the alloy of the present invention that has been subjected to a recovery treatment after finish rolling.
- the value of [Ni] / [Sn] is 1.5 or more, 1.7 or more, or 2.0 or more, in combination with other conditions such as when the Zn content is large or when the value of f1 is large. Precipitation of ⁇ phase and ⁇ phase in the metal structure can be suppressed.
- the compositional relational expression f6 [Ni] / [P] exceeds 400, the amount of the compound formed by Ni and P and the amount of P in solid solution are reduced, so that the stress relaxation property is deteriorated.
- the upper limit value of the compositional relational expression f6 is 220 or less, more preferably 150 or less, and still more preferably 100 or less.
- the effect of making the crystal grains finer is reduced, and the strength of the alloy is reduced.
- the ⁇ phase structure means that when the metal structure is observed with a metal microscope having a magnification of 300 times, the characteristics are significantly affected, and the ⁇ phase and ⁇ phase are clearly recognized.
- the target is.
- the fact that it is substantially a single phase means that the metal structure is observed with a metal microscope with a magnification of 300 times (field of view: 89 ⁇ 127 mm), excluding non-metallic inclusions including oxides, intermetallic compounds such as precipitates and crystallized substances. When observed, the proportion of ⁇ phase in the metal structure is 100%.
- the average crystal grain size is preferably 2 to 12 ⁇ m, particularly when used for applications such as terminals and connectors, for the following reasons.
- the crystal grain size is preferably slightly larger, and is 3 ⁇ m or more, and further 4 ⁇ m or more.
- the average crystal grain size exceeds 12 ⁇ m, high strength cannot be obtained and the susceptibility to stress corrosion cracking may be increased. Since the stress relaxation characteristic is saturated at about 7 to 9 ⁇ m, the upper limit of the average crystal grain size is preferably 9 ⁇ m or less, more preferably 8 ⁇ m or less.
- the size and number of precipitates for the following reasons.
- the presence of circular or elliptical precipitates mainly composed of Ni and P suppresses the growth of recrystallized grains, obtains fine crystal grains, and improves stress relaxation characteristics.
- the recrystallization generated during annealing is to replace a crystal that has been significantly strained by processing with a new crystal having almost no strain.
- recrystallization does not instantly replace the processed crystal grains with recrystallized grains, and requires a longer time or higher temperature. That is, time and temperature are required from the start of recrystallization generation to the end of recrystallization. Until the recrystallization is completed, the recrystallized grains that are initially generated grow and become large, but the growth can be suppressed by the precipitates.
- the average particle diameter of the precipitates is 3 to 180 nm, or the ratio of the number of precipitates having a particle diameter of 3 to 180 nm in the precipitates is 70% or more and 100% or less.
- the average particle diameter is 5 nm or more, further 7 nm or more, or 150 nm or less, and further 100 nm or less.
- the ratio of the number of precipitates having a particle size of 3 to 180 nm in the precipitates is more preferably 80% or more and 100% or less.
- the upper limit of the electrical conductivity is not particularly required to exceed 27% IACS or 26% IACS for the target member in this case, and stress relaxation characteristics, stress corrosion cracking resistance, Those having excellent discoloration resistance and strength are most useful in the present application. Moreover, there are some which carry out spot welding on use, and if the electrical conductivity is too high, problems may occur. On the other hand, since it exceeds the conductivity of expensive bronze and white and is intended for conductive applications such as connectors and terminals, the lower limit of the conductivity is preferably 18% IACS or more and 19% IACS or more.
- both the tensile strength indicating the breaking strength and the yield strength indicating the initial deformation strength are both high. And it is better that the ratio of proof stress / tensile strength is large, and it is preferable that the difference between the strength in the direction parallel to the rolling direction of the plate and the strength in the direction perpendicular to the rolling direction is small.
- the tensile strength of TS P when taken parallel to the test piece in the rolling direction, the yield strength and YS P the tensile strength when taken specimen perpendicular to the rolling direction TS O, the yield strength YS
- O the above relationship can be expressed as follows.
- Strength / Tensile strength (parallel to the rolling direction, perpendicular to the rolling direction) is 0.9 or more and 1 or less, more preferably, 0.92 or more, 1.0 or less 0.9 ⁇ YS P / TS P ⁇ 1.0 0.9 ⁇ YS 2 O / TS 2 O ⁇ 1.0
- Tensile strength when a test piece is taken in parallel to the rolling direction /
- Tensile strength when a test piece is taken perpendicular to the rolling direction is 0.9 or more and 1.1 or less, More preferably, it is 0.92 or more and 1.05 or less 0.9 ⁇ TS P / TS O ⁇ 1.1
- Yield strength when collecting test pieces parallel to the rolling direction / yield strength when collecting test pieces perpendicular to the rolling direction is 0.9 or more and 1.1 or less, more preferably 0.92 or more, 1.05 or less 0.9 ⁇ YS P / YS 2 O ⁇ 1.1
- the final cold working rate is less than 5%, high strength cannot be obtained, and the ratio of proof stress / tensile strength is small.
- the lower limit of the cold working rate is 10% or more.
- the upper limit of the cold working rate is 35% or less.
- the ratio of proof stress / tensile strength can be increased, that is, close to 1.0, and the difference in proof stress between the parallel direction and the orthogonal direction can be reduced.
- Copper alloys are used as terminals, connectors, and relays in an environment of about 100 ° C. or 100 ° C. or higher, for example, in a car under the hot sun or in an environment close to an engine room.
- One of the main functions required for terminals and connectors is to have a high contact pressure.
- the maximum contact pressure is 80% of the stress or proof stress of the elastic limit when the material is subjected to a tensile test. Therefore, a stress corresponding to 80% of the elastic limit stress or the proof stress cannot be used as the contact pressure.
- the stress relaxation test is a test for examining how much the stress has been relaxed after being held at 120 ° C. or 150 ° C.
- the target strength of the material is as described above, it is brass with a high Zn concentration if the stress relaxation rate is 30% or less, particularly 25% or less in a test under severe conditions at 150 ° C. for 1000 hours. Considering this, it can be said that the level is very high. Further, if the stress relaxation rate exceeds 30% and 40% or less, it is good, and if it exceeds 40% and 50% or less, there is a problem in use, and if it exceeds 50%, the heat is substantially severe. It is difficult to use in the environment. On the other hand, in a slightly mild condition test at 120 ° C. for 1000 hours, higher performance is required, and if the stress relaxation rate is 14% or less, it is said to be a high level, exceeding 14% and 21% or less. If it exceeds 40%, there is a problem in use. If it exceeds 40%, it can be said that it is difficult to use in a mild heat environment.
- an ingot having the above component composition is prepared, and this ingot is hot worked.
- the starting temperature of hot rolling is 760 ° C. in order to make each element into a solid solution state, to further reduce the segregation of Sn, and from the viewpoint of hot ductility.
- the temperature is 890 ° C. or lower.
- the hot rolling processing rate is preferably set to at least 50% in order to reduce the destruction of the coarse cast structure of the ingot and segregation of elements such as Sn.
- the temperature at the end of the final rolling or the temperature range from 650 ° C. to 350 ° C. is set to 1 ° C. so that the compound of Ni and P as these precipitates does not become coarse. It is preferable to cool at an average cooling rate of at least / sec.
- the process proceeds to a recrystallization heat treatment, that is, an annealing process.
- the cold rolling rate depends on the final product thickness, but is preferably at least 40% or more, preferably 55% or more and 97% or less.
- the lower limit of the cold rolling rate is preferably 40% or more and 55% or more, and is terminated before the material strain deteriorates due to strong processing at room temperature.
- the crystal grain size is preferably 3-30 ⁇ m in the annealing step.
- the temperature condition is 400 to 650 ° C., and the condition is maintained for 1 to 10 hours.
- a method of continuous annealing which is performed in a short time and at a high temperature, is often used.
- the maximum temperature of the material is 560 to 790 ° C, and the high temperature state of "the maximum temperature reached minus 50 ° C" Then, the high temperature region from the maximum temperature of minus 50 ° C. to the maximum temperature is held for 0.04 to 1.0 minutes.
- the continuous annealing method is also used in the recovery treatment heat treatment described later.
- the annealing process and the cold rolling process can be omitted depending on the final product thickness, or may be performed a plurality of times.
- the metal structure if it is a mixed grain state in which large crystal grains and small crystal grains are mixed, stress relaxation characteristics, bending workability, and stress corrosion cracking resistance deteriorate, and mechanical properties parallel to and perpendicular to the rolling direction are deteriorated. Anisotropy occurs.
- the precipitate containing Ni and P as main components keeps the recrystallized grains fine by annealing during the annealing.
- pinning which is a growth inhibiting action
- the cold rolling rate is desirably 40% to 96%.
- a processing rate of 40% or more is necessary in order to obtain finer and uniform crystal grains. Is 90% or less.
- the crystal grain size after the annealing process which is the heat treatment before the final annealing, and cold rolling before finishing are processed. It is desirable to prescribe the relationship between rates.
- the crystal grain size after the final annealing is D1
- the crystal grain size after the previous annealing step is D0
- the cold working rate of cold rolling before finishing is RE (%)
- RE is 40 to 96.
- D0 ⁇ D1 ⁇ 6 ⁇ (RE / 100) is satisfied.
- the crystal grain size after the annealing process should be within 6 times the crystal grain size after the final annealing and RE / 100. Is preferred.
- the higher the cold working rate the more nucleation sites of recrystallized nuclei. Therefore, even if the crystal grain size after the annealing process is more than three times the crystal grain size after the final annealing, it is fine and uniform. Recrystallized grains are obtained.
- the final annealing is a heat treatment to obtain the target crystal grain size.
- the target average crystal grain size is 2 to 12 ⁇ m.
- the annealing conditions are as follows: in the case of a batch type, hold at 350 ° C. to 550 ° C. for 1 to 10 hours. The maximum temperature reached is 560 to 790 ° C., and the temperature is kept at the maximum temperature reached minus 50 ° C. for 0.04 to 1.0 minutes.
- the average crystal grain size is preferably 3 ⁇ m or more, 12 ⁇ m or less, or 5 ⁇ m to 9 ⁇ m. Therefore, continuous annealing at high temperature and short time is preferable in order to avoid mixed grains. . Similarly, continuous annealing at a high temperature for a short time is preferable in order to ensure the coarsening of precipitates and the solid solution amount of P in the matrix.
- the recrystallization heat treatment in the pre-finishing rolling is preferably a high temperature-short time continuous heat treatment or a continuous annealing.
- a heating step for heating the copper alloy material to a predetermined temperature a holding step for holding the copper alloy material at a predetermined temperature for a predetermined time after the heating step, and the copper alloy material after the holding step.
- a cooling step for cooling to a predetermined temperature is provided.
- the maximum reached temperature of the copper alloy material is Tmax (° C.), and the time during which heat is maintained in the temperature range from the temperature 50 ° C. lower than the maximum reached temperature of the copper alloy material to the maximum reached temperature is tm (min).
- the stress relaxation characteristics are deteriorated, the stress corrosion cracking resistance is deteriorated, the strength is lowered, and the bending workability is deteriorated. Further, there is a risk that anisotropy of mechanical properties such as tensile strength, proof stress, and elongation in the direction parallel to and perpendicular to the rolling direction may occur.
- the upper limit of Tmax is 760 ° C. or lower, and the upper limit of It1 is 670 or lower.
- Tmax is lower than 560 ° C. or when It1 is less than 500, it is not recrystallized or is ultrafine even when recrystallized, and becomes smaller than 2 ⁇ m, and has bending workability and stress relaxation characteristics.
- the lower limit of Tmax is 580 ° C. or higher, and the lower limit of It1 is 520 or higher.
- the high-temperature and short-time continuous heat treatment method has different heating and cooling steps due to the structure of the apparatus, and the conditions may slightly deviate.
- the objective and target of this application can be achieved also by batch type annealing, when it heats for a long time by batch type annealing, the particle size of a precipitate will become large easily.
- the cooling rate is slow, so the amount of dissolved P decreases, and the balance between the Ni amount in the solid solution state and the precipitated Ni—P amount deteriorates, so the stress relaxation characteristics are slightly worse. Become.
- the temperature conditions of “the highest temperature” and “the temperature that is 50 ° C. lower than the highest temperature” in continuous heat treatment for a short time at a high temperature are higher than the annealing temperature of batch annealing. Therefore, even if the annealing prior to the final annealing is batch annealing, by performing the final annealing by a high-temperature and short-time continuous heat treatment method, the amount of P dissolved in the previous batch annealing, the solid solution state A certain amount of Ni and the amount of precipitated Ni—P can be almost canceled.
- the final annealing method including the problem of mixed grains, is performed by a high-temperature and short-time continuous heat treatment method.
- the finish rolling rate varies depending on the crystal grain size, target strength, and bending workability, the finish rolling rate is preferably 5 to 50% because the balance between the bending workability and strength targeted by the present application is good. If it is less than 5%, it is difficult to obtain high strength, particularly high yield strength, even if the crystal grain size is 2 to 3 ⁇ m, and the rolling rate is preferably 10% or more. On the other hand, as the rolling rate increases, the strength increases due to work hardening, but the ductility and bending workability deteriorate. Even when the size of the crystal grains is large, if the rolling rate exceeds 50%, ductility and bending workability deteriorate.
- the rolling rate is preferably 40% or less, more preferably 35% or less.
- the tension leveler may be used to correct the strain.
- the recovery heat treatment step is preferably produced by a high temperature-short time continuous heat treatment, a heating step for heating the copper alloy material to a predetermined temperature, and holding the copper alloy material at a predetermined temperature for a predetermined time after the heating step. And a cooling step for cooling the copper alloy material to a predetermined temperature after the holding step.
- the maximum temperature reached of the copper alloy material is Tmax2 (° C.), and the time for heating and holding in the temperature range from the temperature lower than the maximum temperature reached 50 ° C.
- the upper limit of Tmax2 is 540 ° C. or lower, or the lower limit of It2 is 380 or lower.
- the lower limit of Tmax2 is 250 ° C. or higher, or the lower limit of It2 is 240 or higher.
- the high-temperature and short-time continuous heat treatment method has different heating and cooling steps due to the structure of the apparatus, and the conditions may slightly deviate.
- the maximum temperature achieved for the rolled material is 150 to 580 ° C, and the maximum recovery temperature minus 50 ° C is recovered for 0.02 to 100 minutes without recrystallization.
- Apply heat treatment This low-temperature heat treatment improves stress relaxation characteristics, elastic limit, electrical conductivity, and mechanical properties.
- recovery heat treatment can also be abbreviate
- the alloy of the present invention is an ingot produced by a continuous casting method or the like without performing hot working, specifically by omitting hot rolling, and in some cases at about 700 ° C. for 1 hour or more. It can also be obtained by homogenization annealing at a high temperature and cold rolling and repeated annealing including batch type, final annealing, finish rolling, and recovery heat treatment. Between the casting process and the final annealing, the paired cold rolling process and annealing process may be performed one or more times or a plurality of times depending on the thickness or the like.
- the final annealing is preferably a continuous heat treatment method at a high temperature for a short time as described above.
- processing performed at a temperature lower than the recrystallization temperature of the copper alloy material to be processed is referred to as cold processing
- processing performed at a temperature higher than the recrystallization temperature is referred to as hot processing.
- the forming processes are defined as cold rolling and hot rolling, respectively.
- recrystallization is defined as a change from one crystal structure to another crystal structure or the formation of a strain having a strain caused by processing into a new, unstrained crystal structure.
- the stress relaxation characteristics are improved by maintaining the temperature of the rolled material at 150 to 580 ° C. for substantially 0.02 to 100 minutes after final finish rolling.
- the recovery heat treatment can be omitted if there is a plan to perform an Sn plating process to which a thermal condition corresponding to the above conditions is applied after finishing rolling, after forming the plate material or product. Moreover, you may Sn-plat the copper alloy plate which gave recovery heat processing.
- This recovery heat treatment process improves the elastic limit, stress relaxation characteristics, spring limit value, and elongation of the material by low-temperature or short-time recovery heat treatment without recrystallization, and decreases the conductivity by cold rolling. It is a heat treatment for recovering.
- the strength is slightly increased by low-temperature annealing hardening.
- holding at about 300 ° C. for 10 minutes returns to the strength of the original rolled material and improves ductility.
- the degree of hardening by low temperature annealing is large, the material becomes brittle like the Cu—Zn alloy.
- the upper limit of the finish rolling ratio is preferably 50% or less, preferably 40% or less, and more preferably 35% or less.
- the lower limit of the rolling rate is at least 5% or more, preferably 10% or more.
- the crystal grain size is preferably 2 ⁇ m or more, more preferably 3 ⁇ m or more. In order to improve the balance between high strength and strength and ductility, the crystal grain size should be 12 ⁇ m or less.
- the proof stress in the direction orthogonal to the rolling direction is low when the material is in the rolled state, but the proof stress can be improved without impairing the ductility by this recovery heat treatment.
- the difference between the tensile strength and the proof stress in the direction orthogonal to the rolling direction is 10% or less, and is within 10%.
- the difference in tensile strength or proof stress between the direction parallel to the rolling direction and the direction perpendicular to the rolling direction is 10% or more, and both are within 10%, generally 5%. Become.
- the copper alloy plate which is this embodiment is manufactured.
- the copper alloys and copper alloy plates according to the first to third embodiments of the present invention have excellent discoloration resistance, high strength, good bending workability, excellent discoloration resistance, and stress relaxation. Excellent properties and stress corrosion cracking resistance. From these characteristics, it is excellent in cost performance such as low metal cost and low alloy density, etc.
- it because it has good discoloration resistance, it is possible to omit plating in some areas. For applications such as handrails, door handles, interior wall materials for elevators, metal fittings and members for construction, and medical equipment, copper You can take advantage of the antibacterial action.
- the average crystal grain size is 2 to 12 ⁇ m
- the electrical conductivity is 18% IACS or more and 27% IACS or less
- a circular or elliptical precipitate is present
- the average particle diameter of the precipitate is 3 to 180 nm. If there is, the balance of strength, strength and bending workability is further improved.
- the stress relaxation property particularly the effective stress at 150 ° C., is high, it is a suitable material for electronic / electric equipment parts such as connectors, terminals, relays, switches, and automobile parts, which are used in harsh environments.
- the raw material is melted in a low-frequency melting furnace with an internal volume of 5 tons, and the casting is a semi-continuous casting having a thickness of 190 mm and a width of 630 mm.
- a lump was produced.
- the ingots were each cut to a length of 1.5 m, and then subjected to a hot rolling step (plate thickness 13 mm) -cooling step-milling step (plate thickness 12 mm) -cold rolling step.
- the hot rolling start temperature in the hot rolling process was 820 ° C., hot rolled to a plate thickness of 13 mm, and then shower water cooled in the cooling process.
- the average cooling rate in the cooling step is the rolling material temperature after the final hot rolling, or the cooling rate in the temperature region from when the temperature of the rolling material is 650 ° C. to 350 ° C., and at the rear end of the rolled plate It was measured.
- the measured average cooling rate was 3 ° C./second.
- Steps A1-1 to A1-4 are cold rolling (plate thickness 2.5 mm) -annealing step (580 ° C., held for 4 hours) -cold rolling (plate thickness 0.8 mm) -annealing step (500 ° C., 4 mm
- Pre-finishing rolling process sheet thickness 0.36 mm, cold working rate 55%)-Final annealing process-Finishing cold rolling process (sheet thickness 0.3 mm, cold working rate 17%)-Recovery heat treatment process Went.
- Steps A2-1 to A2-6 are:-cold rolling (sheet thickness: 1 mm)-annealing process (510 ° C, held for 4 hours)-pre-finishing rolling process (sheet thickness: 0.36 mm, cold working rate: 64%)- The final annealing step-finish cold rolling step (sheet thickness 0.3 mm, cold working rate 17%)-recovery heat treatment step was performed.
- Steps A2-7 to A2-8 are:-cold rolling (sheet thickness 1 mm)-annealing process (510 ° C, hold for 4 hours)-pre-finishing rolling process (sheet thickness 0.4 mm, cold working rate 60%)-
- a final annealing step-finish cold rolling step sheet thickness 0.3 mm, cold working rate 25%)-recovery heat treatment step was performed.
- Steps A2-9 to A2-10 are:-cold rolling (sheet thickness 1 mm)-annealing step (high temperature short time annealing (maximum reached temperature Tmax (° C)-holding time tm (min)), (660 ° C-0. 24 minutes))-Pre-finishing rolling process (sheet thickness 0.4 mm, cold working rate 60%)-Final annealing process-Finishing cold rolling process (sheet thickness 0.3 mm, cold working rate 25%)-Recovery heat treatment The process was performed.
- Step A2-11 includes:-cold rolling (sheet thickness: 1 mm)-annealing step (high temperature short time annealing (maximum reached temperature Tmax (° C)-holding time tm (min)), (660 ° C-0.24 minutes)) -Pre-finishing rolling process (sheet thickness 0.36 mm, cold working rate 64%)-Final annealing process-Finishing cold rolling process (sheet thickness 0.3 mm, cold working rate 17%)-Recovery heat treatment process .
- the final annealing in the steps A1-1 to A1-3 was performed by batch annealing (410 ° C., maintained for 4 hours).
- Step A1-1 the recovery heat treatment was performed in a laboratory in a batch manner (300 ° C., held for 30 minutes).
- step A1-2 the recovery heat treatment was performed by a continuous high-temperature short-time annealing method in the actual operation line.
- the maximum temperature Tmax (° C) of the rolled material and the holding time tm (min) in the temperature range from the temperature 50 ° C lower than the maximum temperature of the rolled material to the maximum temperature are expressed as (maximum temperature Tmax (° C)- (Retention time tm (min)), (450 ° C.-0.05 minutes).
- step A1-3 recovery heat treatment was performed in the laboratory under the conditions of (300 ° C.-0.07 minutes), which will be described later.
- step A1-4 the final annealing is carried out by the continuous high temperature short time annealing method of the actual operation line (maximum attained temperature Tmax (° C.) ⁇ Holding time tm (min)), (690 ° C. ⁇ 0.12 minutes).
- the recovery heat treatment was performed under the conditions of (450 ° C.-0.05 minutes).
- the final annealing in step A2-1 was performed by batch annealing (at 425 ° C. for 4 hours).
- the final annealing in the steps A2-5 and A2-6 was performed at (390 ° C., 4 hours hold) and (550 ° C., 4 hours hold), respectively.
- Step A2-2, Step A2-3, and Step A2-4 were performed by the continuous high-temperature short-time annealing method (680 ° C.-0.06 minutes).
- Step A2-11 was performed under the conditions of a continuous high temperature short time annealing method (620 ° C.-0.05 minutes).
- Steps A2-7 to A2-10 are performed by a continuous high-temperature short-time annealing method.
- Steps A2-7 and A2-8 are performed under the conditions of (690 ° C.-0.12 minutes), and steps A2-9 are ( 710 ° C.-0.15 minutes) and step A2-10 (750 ° C.-0.3 minutes).
- the recovery heat treatment in Step A2-1, Step A2-2, Step A2-5 to Step A2-7, and Step A2-9 to Step A2-11 is performed by continuous high-temperature short-time annealing (450 ° C.-0.05 minutes). ).
- the recovery heat treatment in step A2-3 and step A2-8 was performed in the process A2-4 performed in the laboratory under the conditions of (300 ° C.-0.07 min) and (250 ° C.-0.15 min), respectively. Not implemented.
- the high-temperature short-time annealing conditions (300 ° C.-0.07 min) and (250 ° C.-0.15 min) in the steps A2-3 and A2-8 correspond to a molten Sn plating step instead of the recovery heat treatment step.
- the finished rolled material is immersed for 0.07 minutes and 0.15 minutes in a 2 liter oil bath heated to 300 ° C. and 250 ° C. in the heat-treated oil specified in JIS K 2242: 2012, JIS 3 types. The method was carried out. The cooling was air cooling.
- the manufacturing process B was performed as follows.
- a laboratory ingot having a thickness of 30 mm, a width of 120 mm, and a length of 190 mm was cut out from the ingot of production process A.
- the ingot is subjected to hot rolling process (sheet thickness 6 mm)-cooling process (air cooling)-pickling process-rolling process-annealing process-rolling process before finishing (thickness 0.36 mm)-recrystallization heat treatment process-finishing cold Rolling step (plate thickness 0.3 mm, processing rate 17%)-recovery heat treatment step was performed.
- the hot rolling step the ingot was heated to 830 ° C. and hot rolled to a thickness of 6 mm.
- the cooling rate in the cooling step (the temperature of the rolled material after hot rolling or the cooling rate from when the temperature of the rolled material is 650 ° C. to 350 ° C.) is 5 ° C./second, and the surface is acid after the cooling step. Washed.
- the annealing process is one time, cold rolling is performed to 0.9 mm in the rolling process, and the annealing process is performed at 510 ° C. for 4 hours. And cold rolled to 0.36 mm.
- Final annealing was performed in Step B1-1 (at 425 ° C. for 4 hours), in Step B1-2 and Step B1-3 (at 680 ° C.-0.06 minutes), and finish-rolled to 0.3 mm.
- the recovery heat treatment was performed in Step B1-1 (450 ° C.-0.05 minutes), in Step B1-2 (300 ° C.-0.07 min), and in Step B1-3 (held at 300 ° C. for 30 minutes).
- Process B1-4 is cold-rolled to 0.72 mm in the rolling process (working rate 88%), and the annealing process is performed at (600 ° C., held for 4 hours). Cold rolling (processing rate 50%), final annealing (680 ° C.-0.07 minutes) was performed, and finish rolling was performed to 0.3 mm. Then, a recovery heat treatment was performed (300 ° C., 30 minutes hold).
- step B2-1 the annealing step was omitted.
- a 6 mm thick plate after pickling is cold-rolled to 0.36 mm in the pre-finishing rolling process (processing rate 94%), final annealing (at 425 ° C. for 4 hours), and finished to 0.3 mm. Further, a recovery heat treatment was performed (300 ° C., hold for 30 minutes).
- Step B3-1 and Step B3-2 hot rolling was not performed, and cold rolling and annealing were repeated. That is, a 30 mm thick ingot is homogenized and annealed at 720 ° C.
- the annealing process corresponding to the short-time heat treatment performed in the continuous annealing line of the actual operation in the manufacturing process A was substituted by immersing the rolled material in a salt bath. The maximum temperature reached was the bath bath liquid temperature, the time during which the rolled material was completely immersed was the holding time, and air cooling was performed after the immersion.
- a salt (solution) a mixture of BaCl, KCl, and NaCl was used.
- the process C (C1) and the process CA (C1A) were performed as follows. It melt
- the surface was pickled and cold-rolled to 0.9 mm in a rolling process.
- the annealing process was performed at 510 ° C. for 4 hours, and then cold rolled to 0.36 mm in the next rolling process.
- the final annealing conditions are 425 ° C. for 4 hours in the process C (C1), and in the process CA (C1A) with a salt bath (680 ° C.-0.06 minutes) and 0.3 mm by finish cold rolling. Then, cold rolling (cold working rate: 17%) and recovery heat treatment (300 ° C., hold for 30 minutes) were performed.
- the process C2 is a process for a comparative material, and was performed by changing the thickness and heat treatment conditions from the characteristics of the material.
- cold rolling to 1 mm and annealing are performed under conditions of 430 ° C. and 4 hours, cold rolling to 0.4 mm in the rolling process, final annealing conditions are 380 ° C. and holding for 4 hours, finish cold rolling Then, cold rolling to 0.3 mm (cold working rate: 25%) and recovery heat treatment (230 ° C., hold for 30 minutes) were performed.
- phosphor bronze alloy No. 124
- JIS H 3110C5191R-H having a thickness of 0.3 mm was used.
- the bending workability was evaluated by the W-bending specified by JIS H 3110.
- Evaluation A indicates that no crack was generated when the bending radius was 0.5 times the thickness of the material
- evaluation B indicates that no crack occurred when the bending radius was 1 time that of the material
- evaluation C was a crack that occurred when the bending radius was one time the material thickness.
- the stress relaxation rate was measured in accordance with JCBA T309: 2004 as follows.
- a cantilever screw type jig was used for the stress relaxation test of the specimen. Samples were taken from two parallel and perpendicular to the rolling direction, and the shape of the test piece was 0.3 mm thick ⁇ 10 mm wide ⁇ 60 mm long.
- the stress applied to the specimen was 80% of the 0.2% proof stress, and the specimen was exposed to an atmosphere at 150 ° C. and 120 ° C. for 1000 hours.
- the present invention aims to have excellent stress relaxation properties even for a Cu—Zn alloy containing Zn at a high concentration. Therefore, if the stress relaxation rate at 150 ° C. is 30% or less, particularly 25% or less is excellent in stress relaxation characteristics, and if it exceeds 30% and 40% or less, the stress relaxation characteristics are good and can be used. is there. Further, when the stress relaxation property exceeds 40% and 50% or less, there is a problem in use, and when it exceeds 50%, it is difficult to use and is “impossible”. In the present application, those having stress relaxation characteristics exceeding 40% were determined to be “unsuitable”.
- the alloy of the present invention not only has a high yield strength at normal temperature or a low stress relaxation rate, but also requires a high value of the previous formula. If the proof stress x 80% x (100%-stress relaxation rate (%)) is 240 N / mm 2 or more in a test at 150 ° C, it can be used in a high temperature state, and at 270 N / mm 2 or more, “Appropriate”, and “300” / mm 2 or more is “optimal”. Yield strength and stress relaxation characteristics may not be collected from the relationship between the slitter width after slitting, that is, when the width is smaller than 60 mm, the direction is 90 degrees (perpendicular) to the rolling direction.
- test piece shall be evaluated only in the 0 degree (parallel) direction to the rolling direction for evaluating the stress relaxation characteristics and the effective maximum contact pressure.
- the effective stress calculated from the result of the stress relaxation test in the direction of 90 degrees (perpendicular) in the rolling direction and 0 degrees (parallel) in the rolling direction, and 0 in the rolling direction There is no significant difference between the effective stress calculated from the result of stress relaxation test in only the degree (parallel) direction and the effective stress calculated from the result of stress relaxation test in only 90 degree (perpendicular) direction in the rolling direction. confirmed.
- the alloy of the present invention it is preferable to achieve the above three criteria.
- Stress corrosion cracking The stress corrosion cracking property was measured by adjusting the pH to 10.1 ⁇ 0.1 by adding sodium hydroxide to the test container specified in ASTM B858-01 and the test solution, that is, 107 g / 500 ml of ammonium chloride. The room air conditioning was controlled at 1 ° C.
- a resin cantilever screw jig was used in order to examine the sensitivity of stress corrosion cracking in a state where stress was applied.
- the stress corrosion cracking property was evaluated. That is, if fine cracks are generated, the original state is not restored, and as the degree of cracks increases, the stress relaxation rate increases, so the stress corrosion cracking resistance can be evaluated.
- a material with a stress relaxation rate of 15% or less after 24 hours exposure is designated as “Evaluation A” as having excellent stress corrosion cracking resistance, and the stress relaxation rate exceeds 15% and 30% or less is stress corrosion cracking resistance.
- “Evaluation B” was rated as good, and those exceeding 30% were evaluated as “Evaluation C” because they were difficult to use in severe stress corrosion cracking environments.
- the sample was extract
- the average grain size of the crystal grains is measured by a metal micrograph of 300 times, 600 times, 150 times, etc., according to the size of the crystal grains, and an appropriate magnification is selected, and the copper grain size test method in JIS H 0501 Measured according to the quadrature method. Twins are not regarded as crystal grains.
- One crystal grain is elongated by rolling, but the volume of the crystal grain hardly changes by rolling.
- the cross section obtained by cutting the plate material in parallel with the rolling direction it is possible to estimate the average crystal grain size in the recrystallization stage from the average crystal grain size measured by the quadrature method.
- the ⁇ phase ratio of each alloy was judged by a 300-fold metal micrograph (field of view: 89 ⁇ 127 mm). As described above, the ⁇ , ⁇ , and ⁇ phases can be easily distinguished including non-metallic inclusions.
- the observed metal structure is subjected to binarization processing for the ⁇ phase and ⁇ phase by using the image processing software “WinROOF”, and ⁇ with respect to the area of the entire metal structure
- the area ratio of the phase and ⁇ phase was defined as the area ratio, and the total area ratio of ⁇ phase and ⁇ phase was divided from 100% to obtain the ⁇ phase ratio.
- the metal structure measured 3 visual fields, and calculated the average value of each area ratio.
- the average particle size of the precipitate was determined as follows.
- the transmission electron image by TEM of 150,000 times (detection limit is 2 nm) is elliptically approximated with the image analysis software “Win ROOF”, and the geometric mean value of the major axis and minor axis is within the field of view. It calculated
- ⁇ Discoloration resistance test High temperature and high humidity atmosphere test>
- each sample was exposed to an atmosphere at a temperature of 60 ° C. and a relative humidity of 95% using a thermostatic chamber (HIFLEX FX2050, Enomoto Kasei Co., Ltd.).
- the test time was 24 hours, a sample was taken out after the test, the surface color of the material before and after exposure was measured with a spectrocolorimeter, L * a * b * was measured, and the color difference before and after exposure was calculated and evaluated.
- the discoloration becomes reddish brown and red.
- the difference in a * before and after the test that is, the changed value is less than “A”: 1, “ B ”: 1 or more and less than 2,“ C ”: 2 or more.
- the color difference represents the difference between the respective measured values before and after the test, and it was judged that the color change resistance was inferior as the numerical value was large, which was in good agreement with the visual evaluation.
- At least one or two or more selected from Al, Fe, Co, Mg, Mn, Ti, Zr, Cr, Si, Sb, As, Pb and rare earth elements are each 0.0005 mass% or more, 0 When contained in a total of 0.0005 mass% or less and 0.2 mass% or less in total, the crystal grains became fine and the strength was slightly increased (see Test Nos. 114 to 123). (12) When Fe or Co is contained in an amount exceeding 0.05 mass%, the average particle size of the precipitate is smaller than 3 nm and the strength is increased, but the bending workability is deteriorated and the stress relaxation property is deteriorated (test). No. 218, 219).
- the final annealing method is continuous annealing method, batch method Even in the case where the recovery heat treatment is performed in a laboratory or in a continuous annealing method (step A1-1, step A1-2 and step A2-2) A1-3, etc.) If the maximum temperature Tmax is appropriate and the value of the index It is within the appropriate range, the target strength, bending workability, discoloration resistance, stress relaxation characteristics, stress corrosion cracking resistance in this application Sex was obtained.
- step B1-1 and step B1-3 Even if the final annealing or the recovery heat treatment is a continuous annealing method or a batch method in the laboratory test of small pieces (step B1-1 and step B1-3), the strength and bending work targeted in the present application , Discoloration resistance, stress relaxation characteristics, and stress corrosion cracking resistance were obtained.
- the high temperature short time type is slightly better with respect to stress relaxation characteristics. Almost the same characteristics were obtained.
- the crystal grain size after the final annealing is D1
- the crystal grain size after the previous annealing step is D0
- the cold working rate of the cold rolling before finishing is RE (%)
- 6 ⁇ (RE / 100) is not satisfied, the strength is low, the proof stress / tensile strength is low, the ratio between the tensile strength and the proof stress in the direction parallel to and perpendicular to the rolling direction is small, bending workability, stress The relaxation characteristics deteriorated.
- the target process was B1-4, the crystal grain size after annealing before final was 40 ⁇ m, and the crystal grain size after final annealing was a mixed grain state of 6 ⁇ m and 7 ⁇ m, respectively, and did not satisfy the relational expression. .
- the crystal grain size after annealing before final is 10 ⁇ m, and the crystal grain size after final annealing is 4 ⁇ m, satisfying the relational expressions, so it has excellent strength and bending workability, and yield strength / tensile strength Strength increased and stress relaxation properties were excellent.
- steps A2-7, A2-8 and A2-9 with an average crystal grain size of 5 to 9 ⁇ m have a final processing rate of 25%, but the strength is slightly higher, but bending workability Also, the stress relaxation characteristics and stress corrosion cracking resistance were good.
- the precipitated particle size was smaller than 3 nm or larger than 180 nm, the stress relaxation property and bending workability deteriorated (Test Nos. 10, 30, 50, 218, 219, etc.).
- the color fastness was excellent, the strength was high, the bending workability was good, the stress relaxation property was excellent, and the stress corrosion cracking resistance was good.
- the copper alloy of the present invention and the copper alloy plate made of this copper alloy, it has excellent cost performance, small density, and conductivity higher than phosphor bronze and western white, as well as high strength, elongation / bending workability and conductivity. Excellent balance of rate and stress relaxation properties, and excellent stress corrosion cracking resistance, discoloration resistance, and antibacterial properties can be used in various usage environments.
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Abstract
Description
本願は、2013年9月26日に、日本に出願された特願2013-199475号、及び2014年2月28日に、日本に出願された特願2014-039678号に基づき優先権を主張し、その内容をここに援用する。
また、例えば特許文献1には、高強度の要請を満たすための合金として、Cu-Zn-Sn合金が開示されている。
一方、黄銅は、Zn含有量を増すに従って、耐応力腐食割れ性が悪くなり、Zn含有量が、15mass%を超えると問題が生じ始め、20mass%を超え、25mass%を超えるにしたがって、耐応力腐食割れ性が悪くなり、30mass%にもなると、応力腐食割れ感受性が非常に高くなり、深刻な問題となる。耐熱性を示す応力緩和特性は、Zn添加量を5~15mass%にすると一旦向上するが、Zn含有量が20mass%を超えるにしたがって急激に悪くなり、特に、25mass%、または、25mass%以上になると、応力緩和特性は非常に乏しいものとなる。そして、Zn含有量が増すに従って、強度は向上するものの、延性、曲げ加工性が悪くなり、強度と延性のバランスが悪くなる。また、耐変色性は、Zn含有量に関わらず乏しく、使用環境が悪いと、褐色、或いは赤色に変色する。
以上から、従来の黄銅は、コストパフォーマンスに優れるものの、耐応力腐食割れ性、応力緩和特性、強度・延性バランス、耐変色性の観点から、小型化,高性能化を図る電子・電気機器、自動車の構成材、ドアハンドル等の装飾部材や建築部材として、適切な銅合金とは言い難い。
また、特許文献1に記載されたCu-Zn-Sn合金においても、強度を含む諸特性は十分でなかった。
そこで、17≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30と、14≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦26と、8≦f3={f1×(32-f1)}1/2×〔Ni〕≦23と、の3つの関係式を満たすことが必要である。
なお、実質的にα単相は、溶解時に生じる酸化物などの非金属介在物、晶出物、析出物などの金属間化合物を除いて、アンモニア水と過酸化水素の混合液を用いてエッチングし、倍率300倍の金属顕微鏡で金属組織を観察した時、マトリックス中にβ相、γ相が明瞭に観察されないことである。なお、金属顕微鏡で観察した時、α相は薄い黄色、β相はα相より濃い黄色、γ相は水色、酸化物、非金属介在物は灰色、金属化合物はγ相より青みを帯びた水色、若しくは青色に見える。本発明において、実質的にα単相であることは、酸化物を含む非金属介在物、析出物や晶出物等の金属間化合物を除き、倍率300倍の金属顕微鏡で金属組織を観察した時、金属組織中に、α相の占める割合が100%であることを示す。
Cu-Zn合金の耐変色性を向上させるためには、前記のNiとSnの含有量比率とともに、NiとSnの合計含有量が所定以上で発揮することを見出した。
17≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30、
14≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦26、
8≦f3={f1×(32-f1)}1/2×〔Ni〕≦23、
の関係を有するとともに、Snの含有量〔Sn〕mass%と、Niの含有量〔Ni〕mass%との間に、
1.3≦〔Ni〕+〔Sn〕≦2.4、
1.5≦〔Ni〕/〔Sn〕≦5.5、
の関係を有し、Niの含有量〔Ni〕mass%と、Pの含有量〔P〕mass%との間に、
20≦〔Ni〕/〔P〕≦400、
の関係を有しており、α単相である金属組織を有している。
18≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30、
15≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦25.5、
9≦f3={f1×(32-f1)}1/2×〔Ni〕≦22、
の関係を有するとともに、Snの含有量〔Sn〕mass%と、Niの含有量〔Ni〕mass%との間に、
1.4≦〔Ni〕+〔Sn〕≦2.4、
1.7≦〔Ni〕/〔Sn〕≦4.5、
の関係を有し、Niの含有量〔Ni〕mass%と、Pの含有量〔P〕mass%との間に、
22≦〔Ni〕/〔P〕≦220、
の関係を有しており、α単相である金属組織を有している。
17≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30、
14≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦26、
8≦f3={f1×(32-f1)}1/2×〔Ni〕≦23、
の関係を有するとともに、Snの含有量〔Sn〕mass%と、Niの含有量〔Ni〕mass%との間に、
1.3≦〔Ni〕+〔Sn〕≦2.4、
1.5≦〔Ni〕/〔Sn〕≦5.5、
の関係を有し、Niの含有量〔Ni〕mass%と、Pの含有量〔P〕mass%との間に、
20≦〔Ni〕/〔P〕≦400、
の関係を有しており、α単相である金属組織を有している。
そして、本実施形態では、この含有量の表示方法を用いて、以下のように、複数の組成関係式を規定している。
組成関係式f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕
組成関係式f3={f1×(32-f1)}1/2×〔Ni〕
組成関係式f4=〔Ni〕+〔Sn〕
組成関係式f5=〔Ni〕/〔Sn〕
組成関係式f6=〔Ni〕/〔P〕
また、本発明の第1~3の実施形態に係る銅合金においては、好ましくは、平均結晶粒径が2~12μmとされ、円形又は楕円形の析出物が存在し、該析出物の平均粒子径が3~180nm、又は、該析出物の内で粒子径が3~180nmの析出物が占める個数の割合が70%以上とされている。
また、本発明の第1~3の実施形態に係る銅合金においては、強度、応力緩和特性について後述するように規定されることが好ましい。
Znは、本合金の主要元素であり、本発明の課題を克服するためには、少なくとも18mass%以上必要である。コストを低くするために、純銅より本発明合金の密度を約3%以上、りん青銅や洋白より本発明合金の密度を約2%以上小さくする。また、引張強さ、耐力、降伏応力、ばね性、疲労強度などの強度を向上させ、かつ、耐変色性を向上させ、そして、微細な結晶粒を得るためにZn含有量は18mass%以上必要である。より効果的なものにするためには、Zn含有量の下限が好ましくは、19mass%以上、または20mass%以上であり、更に好ましくは、23mass%以上である。
一方、Zn含有量が、30mass%を超えると、後述する本願組成範囲内で、Ni、Sn等を含有させても、良好な応力緩和特性、応力腐食割れ性を得ることができず、導電性も悪くなり、延性、曲げ加工性も悪くなり、強度の向上も飽和する。より好ましくは、Zn含有量の上限が29mass%以下であり、更に好ましくは28.5mass%以下である。
なお、従来から、19mass%以上或いは23mass%以上のZnを含有した銅合金であって、応力緩和特性、耐変色性に優れ、かつ強度、耐食性、導電性が良好な銅合金は見当たらない。
Niは、本発明合金の耐変色性、耐応力腐食割れ性、応力緩和特性、耐熱性、延性や曲げ加工性、強度と延性、曲げ加工性のバランスを向上させるために含有させる。特にZn含有量が19mass%以上或いは23mass%以上の高濃度の時、上述の特性はより効果的に働く。これらの効果を発揮させるためには、Niは1mass%以上の含有が必要であり、好ましくは1.1mass%以上であり、Sn、Pとの組成比の関係、及び6つの組成関係式(f1、f2、f3、f4、f5、f6)を少なくとも満たすことが必要である。特にNiは、後述するSnの特長を活かし、さらに単独のSnの含有以上にSnの特長を活かし、かつ、Snの金属組織上の問題点を克服するために必要である。一方、1.5mass%を超えるNiの含有は、コストアップに繋がり、導電率も低くなるので、1.5mass%以下とした。
Snは、本発明合金の強度、そしてNi,Pとの共添加により、耐変色性、耐応力腐食割れ性、応力緩和特性、強度と延性・曲げ加工性のバランスを向上させ、再結晶時の結晶粒を微細にするために含有させる。これらの効果を発揮させるためには、0.2mass%以上のSnの含有が必要であり、同時にNi,Pの含有、及び、6つの関係式(f1、f2、f3、f4、f5、f6)を満たすことが必要である。これらにより、Snの特徴を最大限に活かすことができる。それらの効果をより顕著なものにするためには、Sn含有量の下限が好ましくは0.25mass%以上であり、より好ましくは0.3mass%以上である。一方、Snを1mass%以上含有しても、耐応力腐食割れ性、応力緩和特性の効果が飽和するどころか悪くなり、延性・曲げ加工性が悪くなる。特に、Zn濃度が25mass%以上の高濃度の時、実施上、β相やγ相が残留し易くなる。好ましくは、Sn含有量の上限が0.9mass%以下である。
Pは、Niの含有と相まって、応力緩和特性を向上させ、応力腐食割れ感受性を低くし、耐変色性の向上に効果があり、結晶粒を細かくすることができる。そのためには、P含有量は少なくとも0.003mass%以上必要である。応力緩和特性を向上させ、応力腐食割れ感受性を低くし、耐変色性の向上させるために、固溶状態にあるPの適切な量、適切な量のNiとPの析出物が必要なことから、P含有量の下限は、0.005mass%以上が好ましく、より好ましくは0.008mass%以上、さらに好ましくは0.01mass%以上である。一方、0.06mass%を超えても、上記効果は飽和し、PとNiを主体とする析出物が多くなり、析出物の粒径も大きくなり、曲げ加工性が低下する。P含有量の上限は、0.05mass%以下が好ましい。なお、後述するNiとPの比(組成関係式f6)が、応力緩和特性を向上させ、応力腐食割れ感受性低くするために重要であり、固溶状態にあるNi、Pと、NiとPの析出物のバランスも、重要である。
Al、Fe、Co、Mg、Mn、Ti、Zr、Cr、Si、Sb、As、Pb及び希土類元素といった元素は、各種特性を向上させる作用効果を有する。そこで、第3の実施形態の銅合金においては、これらの元素を含有するものとされている。
ここで、Fe、Co、Al、Mg、Mn、Ti、Zr、Cr、Si、Sb、As、Pb及び希土類元素は、合金の結晶粒を微細にする。Fe、Co、Al、Mg、Mn、Ti、Zrは、PまたはNiともに化合物を形成し、焼鈍時の再結晶粒の成長を抑制し、結晶粒微細化の効果が大きい。特にFe、Coは、その効果が大きく、FeまたはCoを含有したNiとPの化合物を形成し、化合物の粒径を微細にする。微細な化合物は、焼鈍時の再結晶粒の大きさを一層微細にし、強度を向上させる。ただし、その効果が過剰になると、曲げ加工性、応力緩和特性を損なう。さらにAl、Sb、Asは、合金の耐変色性を向上させる効果を有し、Pbは、プレス成形性を向上させる効果を有する。
これらの効果を発揮するには、Fe、Co、Al、Mg、Mn、Ti、Zr、Cr、Si、Sb、Asのいずれの元素も、各々0.0005mass%以上の含有が必要である。一方、いずれの元素も、0.05mass%を超えると効果が飽和するどころか、却って、曲げ加工性を阻害する。好ましくはこれら元素の含有量の上限がいずれの元素も0.03mass%以下である。さらに、これら元素の合計含有量も、0.2mass%を超えると、効果が飽和するどころか、却って、曲げ加工性を阻害する。好ましくは、これら元素の合計含有量の上限が0.15mass%以下であり、より好ましくは0.1mass%以下である。
銅合金には、リターン材を含む原料、および、主として大気での溶解時を含む製造工程で、微量であるが、酸素、水素、炭素、硫黄、水蒸気等の元素が、不可避的に含有されるため、当然これらの不可避不純物を含む。
ここで、本実施形態である銅合金においては、規定した成分元素以外の元素は不可避不純物として扱ってもよく、不可避不純物の含有量は0.1mass%以下とすることが好ましい。
組成関係式f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕が30のとき、本発明合金の金属組織が、実質的にα相だけになるかどうかの境界値であり、同時に良好な応力緩和特性、延性、曲げ加工性を得るための境界値でもある。主要元素Znの含有量が、30mass%以下であると同時に本関係式を満たさなければならない。Cu-Zn合金に、低融点金属のSnを0.2mass%、或いは0.3mass%以上含有すると、鋳造時の最終の凝固部、結晶粒界にSnの偏析が生じる。その結果、Sn濃度の高い、γ相、β相が形成される。非平衡状態で存在するγ相、β相は、鋳造、熱間加工、焼鈍・熱処理、或いは、製品加工のろう付けを経ても、或いは、熱処理条件等を工夫しても、消滅させることが上式の値が30を超えると困難である。組成関係式f1において、本発明の組成範囲内で、Snは、係数「+5」が与えられる。係数「5」は、主要元素であるZnの係数「1」に比べ大きい。一方、Niは、本願の組成範囲内で、Snの偏析を少なくし、γ相、β相の形成を阻害する性質を持ち、係数「-2」が与えられる。組成関係式f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕が30以下であれば、本発明合金は結晶粒界を含め、また、本発明合金は、製品の加工方法を含めても、γ相、β相が皆無になる。金属組織中に、γ相、β相が皆無になることにより、本発明合金の延性、曲げ加工性が良好となり、同時に応力緩和特性がよくなる。より好ましくは、f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕の値が、29.5以下で、さらに好ましくは29以下である。一方、f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕の値が、17未満であると、強度が低く、耐変色性も悪くなるため、好ましくは、18以上であり、より好ましくは、20以上であり、更に好ましくは23以上である。
組成関係式f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕が26のとき、本発明合金が良好な耐応力腐食割れ性と延性、曲げ加工性を得るための境界値である。前記のとおり、Cu-Zn合金の致命的な欠点として、応力腐食割れの感受性が高いことが挙げられる。Cu-Zn合金の場合、応力腐食割れの感受性は、Znの含有量に依存し、Zn含有量が25mass%或いは26mass%を超えると、特に応力腐食割れの感受性が高くなる。組成関係式f2=26は、Zn含有量が25mass%或いは26mass%に相当する。本願のNi、Snが共添加される組成範囲内で、Niの含有によって、特に応力腐食割れ感受性を低くできる。好ましくは、組成関係式f2の上限値が25.5以下である。一方、f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕が、14未満であると、強度が低く、また耐変色性が悪くなるため、好ましくは15以上であり、より好ましくは18以上である。
組成関係式f3={f1×(32-f1)}1/2×〔Ni〕は、Ni、Snを共添加し、f1が30以下であって、さらに、本組成関係式f3={f1×(32-f1)}1/2×〔Ni〕の値が8以上であるとき、高濃度のZnを含むにもかかわらず、優れた応力緩和特性を発揮する。好ましくは、組成関係式f3の下限値が9以上であり、より好ましくは10以上である。一方、f3={f1×(32-f1)}1/2×〔Ni〕が23を超えても、その効果が飽和する。好ましくは、組成関係式f3の上限値が22以下である。
本願の組成範囲内で、合金の耐変色性を良くするためには、NiとSnの合計含有量である組成関係式f4=〔Ni〕+〔Sn〕が、1.3以上であることが必要であり、より好ましくは1.4以上である。応力緩和特性を向上させるためにも、そして、より高い強度を得るためにも、組成関係式f4=〔Ni〕+〔Sn〕が、1.3以上であることが好ましい。一方、組成関係式f4=〔Ni〕+〔Sn〕が、2.4を超えると、合金のコストが上がり、導電性も悪くなることから、2.4以下が好ましい。
本願組成範囲のNi、Sn、Pを共添加した高濃度のZnを含有するCu-Zn合金の応力緩和特性においては、さらに組成関係式f5=〔Ni〕/〔Sn〕が重要である。潜在的に応力緩和特性を良くし、強度を高める作用を有する一方で、金属組織上の問題点を抱え、高い原子価を持つSnを最大限に活用するためにも、2価のNiとの存在比、すなわちバランスが重要である。マトリックスに存在する4価のSn原子1つに対し、2価のNi原子が少なくとも3つ以上であると、質量比で〔Ni〕/〔Sn〕の値が1.5以上であるとより一層応力緩和特性が向上することを見出した。特に、仕上げ圧延後の回復処理した本願発明合金において、その効果はより顕著になる。より好ましくは、組成関係式f5=〔Ni〕/〔Sn〕の値が1.7以上であり、より好ましくは2.0以上である。〔Ni〕/〔Sn〕の値が1.5以上、1.7以上、或いは2.0以上であると、Zn含有量が多い場合や、f1の値が大きいときなど、他の条件と相まって金属組織中のβ相やγ相の析出を抑えることができる。また、組成関係式f5=〔Ni〕/〔Sn〕の値が4.5以下まで良好な応力緩和特性を示し、5.5を超えると悪くなる。
さらに、応力緩和特性は、固溶状態にあるNiと、Pと、そしてNiとPの化合物に影響を受ける。ここで、組成関係式f6=〔Ni〕/〔P〕が20未満であると、固溶状態にあるNiに対するNiとPの化合物の割合が多くなるので、応力緩和特性が悪くなり、曲げ加工性も悪くなる。すなわち、組成関係式f6=〔Ni〕/〔P〕が20以上、好ましくは22以上であると、応力緩和特性、および曲げ加工性が良くなる。一方で、組成関係式f6=〔Ni〕/〔P〕が400を超えると、NiとPで形成される化合物の量、固溶するPの量が少なくなるので、応力緩和特性が悪くなる。好ましくは、組成関係式f6の上限値が220以下であり、より好ましくは150以下で、さらに好ましくは、100以下である。また、結晶粒を細かくする作用も小さくなり、合金の強度が低くなる。
β相、γ相が存在すると、特に延性、曲げ加工性を損ない、応力緩和特性、耐応力腐食割れ性、耐変色性を悪くする。ただし、本実施形態において、α相組織であるとは、倍率300倍の金属顕微鏡で金属組織を観察した時、前記特性に影響を顕著に与える、明瞭にβ相、γ相が認められる大きさのものを対象とする。実質的にα単相であることは、酸化物を含む非金属介在物、析出物や晶出物等の金属間化合物を除き、倍率300倍(視野89×127mm)の金属顕微鏡で金属組織を観察した時、金属組織中に、α相の占める割合が100%であることを示す。
本実施形態である銅合金においては、以下の理由から、特に、端子、コネクタ等の用途に使用される場合、平均結晶粒径を2~12μmとすることが好ましい。
本実施形態である銅合金では、製造プロセスによるが、最小で1μmの結晶粒を得ることができるが、平均結晶粒径が2μm未満であると、応力緩和特性が悪くなり、強度は高くなるものの延性、曲げ加工性が悪くなるおそれがある。特に応力緩和特性から好ましくは、結晶粒度は少し大きいほうがよく、3μm以上、更には、4μm以上である。一方、端子、コネクタ等の用途においては、平均結晶粒径が12μmを超えると、高い強度が得られず、応力腐食割れの感受性も高くなるおそれがある。応力緩和特性も約7~9μmで飽和するので、平均結晶粒径の上限は、好ましくは9μm以下であり、より好ましくは8μm以下である。
本実施形態である銅合金においては、以下の理由から、析出物の大きさや個数を規定することが好ましい。
NiとPを主とする円形又は楕円形の析出物が存在することにより、再結晶粒の成長を抑制し、微細な結晶粒を得るとともに応力緩和特性を向上させる。焼鈍時に生成する再結晶は、加工により著しくひずみを受けた結晶を、ひずみのほとんど無い、新たな結晶として、置き換えることである。しかしながら、再結晶は加工を受けた結晶粒が瞬時に再結晶粒に置き換わるものではなく、長い時間、或いはより高い温度を必要とする。すなわち、再結晶の生成開始から、再結晶の終了まで、時間と温度を要する。再結晶が完全に終了するまで、初めに生成した再結晶粒は、成長して大きくなるが、該析出物により、その成長を抑制することができる。
導電率の上限は、本件で対象とする部材は、27%IACS、或いは、26%IACSを超えることは特に必要とせず、従来の黄銅の欠点であった応力緩和特性、耐応力腐食割れ性、耐変色性、強度の優れたものが、本願で最も有益である。また、用途上、スポット溶接を施すものもあり、導電率が高すぎると不具合が生じることもある。一方、高価なりん青銅や洋白の導電率を上回り、コネクタ、端子用途等の導電性用途を対象としているので、導電率の下限は18%IACS以上、19%IACS以上が好ましい。
本実施形態である銅合金においては、強度について特に規定はないが、端子、コネクタ等の用途に使用される場合、延性、曲げ加工性が良好であることを前提に、圧延方向に対して、0度方向、90度方向から試験片を採取した試料において、常温の強度は、引張強さで少なくとも500N/mm2以上、好ましくは、550N/mm2以上、より好ましくは、575N/mm2以上、さらに好ましくは600N/mm2以上、耐力で少なくとも450N/mm2以上、好ましくは、500N/mm2以上、より好ましくは、525N/mm2以上、更に好ましくは、550N/mm2以上である。また、好ましい常温の強度の上限は、引張強さで800N/mm2以下、耐力で750N/mm2以下である。
(1)耐力/引張強さ(圧延方向に対して平行、圧延方向に対して直交)が0.9以上1以下、より好ましくは、0.92以上、1.0以下
0.9≦YSP/TSP≦1.0
0.9≦YSO/TSO≦1.0
(2)圧延方向に対して平行に試験片を採取したときの引張強さ/圧延方向に対して直交に試験片を採取したときの引張強さが、0.9以上、1.1以下、より好ましくは、0.92以上、1.05以下
0.9≦TSP/TSO≦1.1
(3)圧延方向に対して平行に試験片を採取したときの耐力/圧延方向に対して直交に試験片を採取したときの耐力が、0.9以上、1.1以下、より好ましくは、0.92以上、1.05以下
0.9≦YSP/YSO≦1.1
銅合金は、約100℃、或いは100℃以上の環境、例えば、自動車の炎天下の室内、エンジンルームに近い環境で、端子、コネクタ、リレーとして使用される。端子、コネクタに求められる主要な機能の1つに、高い接触圧力を有することが挙げられる。常温であれば、最大の接触圧は、材料の引張試験を行ったときの弾性限界の応力、或いは耐力の80%であるが、100℃以上の環境で長時間使用すると、材料は、永久変形するので、弾性限界の応力、または耐力の80%に相当する応力では、接触圧力として、使用できない。応力緩和試験は、耐力の80%の応力を材料に加えた状態で、120℃、または、150℃で1000時間保持後、応力がどれだけ緩和されたかを調べるための試験である。すなわち、約100℃または、100℃以上の環境で使用される場合の、実効の最大の接触圧は、耐力×80%×(100%-応力緩和率(%))で表され、単に常温の耐力が高いだけでなく、前式の値が高いことが望まれる。150℃の試験で耐力×80%×(100%-応力緩和率(%))が、240N/mm2以上あれば、高温状態での使用が、少し問題あるが可能であり、270N/mm2以上であれば、高温状態での使用に適しており、300N/mm2以上であれば最適である。例えば、耐力が500N/mm2である黄銅の代表的な合金70%Cu-30%Znの場合、150℃で、耐力×80%×(100%-応力緩和率(%))の値が約70N/mm2、同様に耐力が550N/mm2である94%Cu-6%Snのりん青銅で、約180N/mm2であり、現行の実用合金では、到底満足できない。
なお、最終の目的とする結晶粒の大きさを細かくし、且つ均一にするためには、最終焼鈍の1つ前の熱処理である焼鈍工程後の結晶粒径と、仕上げ前冷間圧延の加工率の関係を規定しておくことが望ましい。すなわち、最終焼鈍後の結晶粒径をD1とし、その前の焼鈍工程後の結晶粒径をD0とし、仕上げ前冷間圧延の冷間加工率をRE(%)とすると、REが40~96において、D0≦D1×6×(RE/100)を満たすことが好ましい。最終焼鈍後の再結晶粒を細かく、均一なものにするために、焼鈍工程後の結晶粒径を、最終焼鈍後の結晶粒径の6倍と、RE/100との積以内にしておくことが好ましい。冷間加工率が高いほど、再結晶核の核生成サイトが増えるので、焼鈍工程後の結晶粒径が、最終焼鈍後の結晶粒径より3倍以上の大きさであっても細かく、均一な再結晶粒が得られる。
なお、本発明合金は、熱間加工を行うことなく、具体的には熱間圧延を省略して、連続鋳造法等によって作られる鋳塊を、場合によっては、約700℃で、1時間以上の高温で均質化焼鈍し、そして冷間圧延と、バッチ式を含む焼鈍の繰り返し、最終焼鈍、仕上げ圧延、および回復熱処理により、得ることもできる。鋳造工程と最終焼鈍の間に、対となる冷間圧延工程と焼鈍工程は、厚み等により、1回以上、複数回実施してよい。また最終焼鈍は、前記のとおり高温短時間の連続熱処理方法が好ましい。なお、本明細書においては、加工される銅合金材料の再結晶温度より低い温度で行われる加工を冷間加工、再結晶温度より高い温度で行われる加工を熱間加工とし、それらがロールによって成形される加工を各々、冷間圧延、熱間圧延と定義する。また、再結晶は、一つの結晶組織から別の結晶組織への変化あるいは、加工によって生じるひずみの存在する組織から、新しい、歪みのない結晶組織へ形成されることと定義される。
この回復熱処理工程は、再結晶を伴わず、低温又は短時間の回復熱処理により、材料の弾性限、応力緩和特性、ばね限界値、及び伸びを向上させ、また、冷間圧延により低下した導電率を回復させるため、の熱処理である。
このようにして、本実施形態である銅合金板が製造される。
上述した本発明の第1~3の実施形態に係る銅合金及び比較用の組成の銅合金を用い、製造工程を変えて試料を作製した。銅合金の組成を表1-4に示す。また、製造工程を表5に示す。なお、表1-4には、上述した実施形態に示す組成関係式f1、f2、f3、f4、f5、f6を示している。
熱間圧延工程での熱間圧延開始温度は820℃とし、板厚13mmまで熱間圧延した後、冷却工程でシャワー水冷した。冷却工程での平均冷却速度は、最終の熱間圧延後の圧延材温度、又は、圧延材の温度が650℃のときから350℃までの温度領域での冷却速度とし、圧延板の後端において測定した。測定した平均冷却速度は3℃/秒であった。
工程A2-1~A2-6は、―冷間圧延(板厚1mm)―焼鈍工程(510℃、4時間保持)―仕上げ前圧延工程(板厚0.36mm、冷間加工率64%)―最終焼鈍工程-仕上げ冷間圧延工程(板厚0.3mm、冷間加工率17%)-回復熱処理工程を行った。
工程A2-7~A2-8は、―冷間圧延(板厚1mm)―焼鈍工程(510℃、4時間保持)―仕上げ前圧延工程(板厚0.4mm、冷間加工率60%)―最終焼鈍工程-仕上げ冷間圧延工程(板厚0.3mm、冷間加工率25%)-回復熱処理工程を行った。
工程A2-9~A2-10は、―冷間圧延(板厚1mm)―焼鈍工程(高温短時間焼鈍(最高到達温度Tmax(℃)-保持時間tm(min))、(660℃-0.24分))―仕上げ前圧延工程(板厚0.4mm、冷間加工率60%)―最終焼鈍工程-仕上げ冷間圧延工程(板厚0.3mm、冷間加工率25%)-回復熱処理工程を行った。
工程A2-11は、―冷間圧延(板厚1mm)―焼鈍工程(高温短時間焼鈍(最高到達温度Tmax(℃)-保持時間tm(min))、(660℃-0.24分))―仕上げ前圧延工程(板厚0.36mm、冷間加工率64%)―最終焼鈍工程-仕上げ冷間圧延工程(板厚0.3mm、冷間加工率17%)-回復熱処理工程を行った。
工程A1-4では、最終焼鈍を、実操業ラインの連続の高温短時間焼鈍方法により、(最高到達温度Tmax(℃)-保持時間tm(min))、(690℃-0.12分)の条件で実施し、回復熱処理を(450℃-0.05分)の条件で実施した。
結晶粒の影響を調べるために工程A2-5、工程A2-6の最終焼鈍は、各々、(390℃、4時間保持)、(550℃、4時間保持)で行った。
工程A2-2、工程A2-3、工程A2-4は、連続の高温短時間焼鈍方法により(680℃‐0.06分)の条件で行った。工程A2-11は、連続の高温短時間焼鈍方法により(620℃‐0.05分)の条件で行った。
工程A2-7から工程A2-10は、連続の高温短時間焼鈍方法により、工程A2-7と工程A2-8は、(690℃-0.12分)の条件、工程A2-9は、(710℃-0.15分)の条件、工程A2-10(750℃-0.3分)の条件で実施した。
工程A2-3、工程A2-8の回復熱処理は、各々、実験室で(300℃-0.07min)、(250℃-0.15min)の条件で行った
工程A2-4では、回復熱処理を実施しなかった。
なお、前記工程A2-3、工程A2-8の高温短時間焼鈍条件(300℃-0.07min)、(250℃-0.15min)は、回復熱処理工程の代わりに溶融Snめっき工程に相当する条件として、JIS K 2242:2012、JIS 3種に規定される熱処理油を300℃、250℃に加熱した2リットルの油浴槽中に、仕上げ圧延材を0.07分、0.15分間浸漬する方法で実施した。なお、冷却は空冷とした。
製造工程Aの鋳塊から厚み30mm、幅120mm、長さ190mmの実験室用の鋳塊を切り出した。その鋳塊を、熱間圧延工程(板厚6mm)―冷却工程(空冷)-酸洗工程―圧延工程―焼鈍工程―仕上げ前圧延工程(厚み0.36mm)―再結晶熱処理工程-仕上げ冷間圧延工程(板厚0.3mm、加工率17%)-回復熱処理工程を行った。
熱間圧延工程は、830℃に鋳塊を加熱し、厚み6mmにまで熱間圧延した。冷却工程での冷却速度(熱間圧延後の圧延材温度、又は、圧延材の温度が650℃のときから350℃までの冷却速度)は、5℃/秒であり、冷却工程後に表面を酸洗した。
工程B1-4は、圧延工程で0.72mmまで冷間圧延し(加工率88%)、焼鈍工程の条件を(600℃、4時間保持)で行い、仕上げ前圧延工程で、0.36mmまで冷間圧延し(加工率50%)、最終焼鈍を(680℃-0.07分)で行い、0.3mmに仕上げ圧延を行った。そして回復熱処理を(300℃、30分保持)で行った。
工程B3-1、工程B3-2では、熱間圧延を行わず、冷間圧延と焼鈍の繰り返しで実施した。すなわち、厚み30mmの鋳塊を720℃、4時間で均質化焼鈍し、6mmまで冷間圧延し、焼鈍(620℃、4時間保持)、0.9mmまで冷間圧延、焼鈍(510℃、4時間保持)、0.36mmまで冷間圧延した。最終焼鈍を工程B3-1では、(425℃、4時間保持)、工程B3-2では、(680℃-0.06分)とし、0.3mmまで仕上げ冷間圧延を行った。そして、回復熱処理を(300℃、30分保持)で行った。
製造工程Bにおいて、製造工程Aでの実操業の連続焼鈍ライン等で行う短時間の熱処理に相当する焼鈍工程は、ソルトバスに圧延材を浸漬することにより代用した。最高到達温度をソルトバスの液温度とし、圧延材が完全に浸漬した時間を保持時間とし、浸漬後空冷した。なお、ソルト(溶液)は、BaCl、KCl、NaClの混合物を使用した。
なお、工程C2は、比較材の工程であり、材料の特性から、厚みおよび熱処理条件を変更して行った。酸洗後、1mmに冷間圧延、焼鈍工程を430℃、4時間の条件で行い、圧延工程で0.4mmに冷間圧延、最終焼鈍条件は、380℃、4時間保持、仕上げ冷間圧延で0.3mmに冷間圧延(冷間加工率:25%)し、回復熱処理を(230℃、30分保持)で行った。比較材のりん青銅(合金No.124)については、市販の厚みが0.3mmのJIS H 3110C5191R-Hを用いた。
また、金属組織を観察して平均結晶粒径、β相、γ相の占める割合を測定した。さらに、析出物の平均粒径と、全ての大きさの析出物の中で粒径が所定の値以下の析出物の個数の割合を測定した。
引張強度、耐力、及び伸びの測定は、JIS Z 2201、JIS Z 2241に規定される方法に従い、試験片の形状は、5号試験片で実施した。なお、試料は圧延方向に平行と直交の2つの方向から採取した。但し、工程B、工程Cで試験した材料は、幅が120mmであったので、5号試験片に準じた試験片で実施した。
導電率の測定は、日本フェルスター株式会社製の導電率測定装置(SIGMATEST D2.068)を用いた。なお、本明細書においては、「電気伝導」と「導電」の言葉を同一の意味に使用している。また、熱伝導性と電気伝導性は強い相関があるので、導電率が高い程、熱伝導性が良いことを示す。
曲げ加工性は、JIS H 3110で規定されているW曲げで評価した。曲げ試験(W曲げ)は、次のように行った。曲げ半径は、材料の厚さの1倍(曲げ半径=0.3mm、1t)、及び、0.5倍(曲げ半径=0.15mm、0.5t)とした。サンプルは、バッドウェイ(Bad Way)と言われる方向で圧延方向に対して90度をなす方向、及びグッドウェイ(Good Way)と言われる方向で圧延方向に0度をなす方向に行った。曲げ加工性の判定は、50倍の実体顕微鏡で観察してクラックの有無で判定した。曲げ半径が材料の厚さの0.5倍の条件でクラックが生じなかったものを「評価A」、曲げ半径が材料の厚さの1倍の条件でクラックが生じなかったものを「評価B」、曲げ半径が材料の厚さの1倍の条件でクラックが生じたものを「評価C」とした。
応力緩和率の測定は、JCBA T309:2004に従って、次のように行った。供試材の応力緩和試験には片持ち梁ねじ式治具を使用した。圧延方向に対して、平行および直交の2つから採取し、試験片の形状は、板厚0.3mm×幅10mm×長さ60mmとした。供試材への負荷応力は0.2%耐力の80%とし、150℃および120℃の雰囲気中に1000時間暴露した。応力緩和率は、応力緩和率=(開放後の変位/応力負荷時の変位)×100(%)として求め、圧延方向に対して、平行および直交の2つから採取した試験片の平均値を採用した。本発明は、Znを高濃度に含有するCu-Zn合金であっても、応力緩和性に優れることを目指している。そのため、150℃での応力緩和率が30%以下であれば、特に、25%以下は、応力緩和特性に優れ、30%を超え40%以下は、応力緩和特性が良好であり、使用可能である。また、応力緩和特性が40%を超え50%以下は、使用に問題があり、50%を超えるものは、使用に困難なレベルであり、「不可」である。本願において、応力緩和特性が、40%を超えるものは、「不適」とした。
また、実効の最大の接触圧は、耐力×80%×(100%-応力緩和率(%))で現される。本発明合金では、単に常温の耐力が高い、または、応力緩和率が低いだけでなく、前式の値が高いことが必要である。150℃の試験で耐力×80%×(100%-応力緩和率(%))が、240N/mm2以上あれば、高温状態での使用が「可」であり、270N/mm2以上で「適」であり、300N/mm2以上であれば「最適」である。耐力、および応力緩和特性は、スリッター後のスリッター幅の関係から、つまり、幅が60mmより小さい場合、圧延方向に90度(垂直)をなす方向から採取できない場合がある。その場合、試験片は圧延方向に0度(平行)方向のみで、応力緩和特性、および実効の最大の接触圧を評価するものとする。
なお、試験No.22、26、31(合金No.2)、及び試験No.44、45(合金No.3)において、圧延方向に90度(垂直)をなす方向及び圧延方向に0度(平行)方向での応力緩和試験の結果から算出した実効応力と、圧延方向に0度(平行)方向のみでの応力緩和試験の結果から算出した実効応力と、圧延方向に90度(垂直)方向のみでの応力緩和試験の結果から算出した実効応力とで大きな差がないことを確認した。
本発明合金では、以上の3つの判断基準を達成することが好ましい。
応力腐食割れ性の測定は、ASTMB858-01に規定された試験容器と、試験液すなわち107g/500mlの塩化アンモニウムに水酸化ナトリウムを加えてPHを10.1±0.1に調整し、22±1℃に室内の空調を制御して行った。
応力腐食割れ試験は、応力を付加した状態での応力腐食割れの感受性を調べるため、樹脂製の片持ち梁ねじ式治具を用いた。前記の応力緩和試験と同様、耐力の80%の曲げ応力、すなわち材料の弾性限界の応力を加えた状態にある圧延材を、上記の応力腐食割れ雰囲気中に暴露し、応力緩和率から、耐応力腐食割れ性の評価を行った。つまり、微細なクラックが発生しておれば、元の状態には戻らず、そのクラックの度合いが大きくなると応力緩和率が大きくなるので、耐応力腐食割れ性を評価できる。24時間暴露で応力緩和率が15%以下のものを、耐応力腐食割れ性に優れるものとして「評価A」とし、応力緩和率が、15%を超え、30%以下を耐応力腐食割れ性が良好として「評価B」とし、30%を超えるものは、過酷な応力腐食割れ環境での使用は困難であるとして、「評価C」とした。なお、試料は、圧延方向に対して平行方向から採取して実施した。
結晶粒の平均粒径の測定は、300倍、600倍、及び150倍等の金属顕微鏡写真で結晶粒の大きさに応じ、適宜倍率を選定し、JIS H 0501における伸銅品結晶粒度試験方法の求積法に準じて測定した。なお、双晶は結晶粒とはみなさない。
各合金のα相率は、300倍の金属顕微鏡写真(視野89×127mm)で判断した。前記のとおり、α、β、γ各相の区別は、非金属介在物等も含め容易である。β相又はγ相が存在する合金、試料については、その観察した金属組織を画像処理ソフト「WinROOF」を用い、β相およびγ相について2値化の処理を行ない、金属組織全体の面積に対するβ相、およびγ相の面積の割合を面積率とし、100%から合計のβ相、γ相の面積率を除し、α相率とした。なお、金属組織は3視野の測定を行い、それぞれの面積率の平均値を算出した。
析出物の平均粒径は次のようにして求めた。150,000倍(検出限界は、2nm)のTEMによる透過電子像を画像解析ソフト「Win ROOF」を用いて析出物のコントラストを楕円近似し、長軸と短軸の相乗平均値を視野内の中の全ての析出粒子に対して求め、その平均値を平均粒子径とした。析出物の平均粒径が約5nmより小さいものについては、750,000倍(検出限界は、0.5nm)で、析出物の平均粒径が約100nmより大きいものについては、50,000倍(検出限界は、6nm)で行った。透過型電子顕微鏡の場合、冷間加工材では転位密度が高いので析出物の情報を正確に把握することは難しい。また、析出物の大きさは、冷間加工によっては変化しないので、今回の観察は、仕上げ冷間圧延工程前の再結晶熱処理工程後の再結晶部分を観察した。測定位置は、圧延材の表面、裏面の両面から板厚の1/4の長さの2箇所とし、2箇所の測定値を平均した。
材料の耐変色性を評価する耐変色性試験は、恒温恒湿槽(楠本化成株式会社HIFLEX FX2050)を用いて温度60℃、相対湿度95%の雰囲気中に各サンプルを暴露した。試験時間は24時間とし、試験後に試料を取り出し、暴露前後の材料の表面色を分光測色計によりL*a*b*を測定し、暴露前後の色差を算出し評価した。高い濃度のZnを含有するCu-Zn合金では、変色が、赤褐色、赤色になることから、耐食性評価として、試験前後でのa*の差、すなわち変化した値が「A」:1未満、「B」:1以上2未満、「C」:2以上とした。色差は試験前後でのそれぞれの測定値の違いを表し、数値が大きいほど耐変色性が劣ると判断でき、目視での評価ともよく一致していた。
上述の耐変色性試験において評価する銅合金の表面色(色調)については、JIS Z 8722-2009(色の測定方法-反射及び透過物体色)に準拠した物体色の測定方法を実施し、JIS Z 8729-2004(色の表示方法─L*a*b*表色系及びL*u*v*表色系)で規定されているL*a*b*表色系で示した。
具体的には、コニカミノルタ社製の分光測色計「CM-700d」を使用して、SCI(正反射光込み)方式で、試験前後のL、a、b値を測定し、評価した。なお、試験前後のL*a*b*測定は3点測定し、その平均値を用いた。
(2)Ni量が、1mass%より少ないと、応力緩和特性、耐応力腐食割れ性、耐変色性が悪くなった。Ni量が、1.1mass%より多いと、応力緩和特性、耐応力腐食割れ性、耐変色性がより良くなった。(試験No.210、211、13等参照)
(4)P量が、0.003mass%より少ないと、応力緩和特性、耐応力腐食割れ性が悪くなった。結晶粒成長抑制作用が、効かなくなるので、結晶粒が大きくなり、強度が低くなる。P量が0.06mass%より多いと、曲げ加工性が悪くなった。(試験No.217、207、33等参照)
(7)関係式f3={f1×(32-f1)}1/2×〔Ni〕が8より小さいと、応力緩和特性が悪くなった。10以上であると、応力緩和特性が更によくなった(試験No.115、206、101、23等参照)。
(9)関係式f5=〔Ni〕/〔Sn〕の値が、1.5より小さいと、または、5.5より大きいと応力緩和特性が悪くなった。1.7以上であると、4.5より小さいと、さらに、応力緩和特性が良くなった(試験No.209、214、204、216、220、221、108、109,73、53等参照)。関係式f5=〔Ni〕/〔Sn〕の値が、1.5より小さいと、β相または、γ相が存在しやすくなり、曲げ加工性が悪くなり、応力緩和特性、耐応力腐食割れ性が悪くなった(試験No.220、221、204、209、220A、221A等参照)。
(10)関係式f6=〔Ni〕/〔P〕の値が、20より小さいと、または、400より大きいと応力緩和特性が悪くなった。25以上であると、または、250以下、更には100以下であると、さらに、応力緩和特性が良くなった。また、f6の値が、20より小さいと、曲げ加工性が悪くなった(試験No.207、208、217、101等参照)。
(12)FeまたはCoを0.05mass%を超えて含有すると、析出物の平均粒径が3nmより小さくなり、強度は高くなるが、曲げ加工性悪くなり、応力緩和特性が悪くなった(試験No.218、219参照)。
(13)Snが1mass%より多い、Pが0.06mass%より多い、f6=〔Ni〕/〔P〕の値が20より小さい、または、f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕が30より大きいと、圧延方向と直交方向の耐力/引張強さが0.9より小さくなった(試験No.204~207、215、101等参照)。
(1)実生産設備において、焼鈍回数が、最終焼鈍を含み、2、3回であっても(工程A1-2と工程A2-1等)、また、最終焼鈍方法が連続焼鈍法、バッチ法であっても(工程A2-1と工程A2-2等)、回復熱処理が実験室で実施したバッチであっても、連続焼鈍法であっても(工程A1-1、工程A1-2と工程A1-3等)、最高到達温度Tmaxが適正で、指数Itの数値が適正範囲内であれば、本願において目標とする、強度、曲げ加工性、耐変色性、応力緩和特性、耐応力腐食割れ性が得られた。回復熱処理を行うと、耐力/引張強さが大きくなった(工程A2-2と工程A2-4等)。
(2)実生産設備から得た前記諸特性と、小片にした工程Bで試作した諸特性は、同等であった(工程A2-1と工程B1-1等)。特に実生産設備の連続焼鈍法の結果とソルトバスで代用した実験で得た諸特性は、ほぼ同等であった(工程A2-3と工程B1-2等)。
(4)工程Bの小片サンプルで、1回焼鈍、焼鈍無しで仕上げ焼鈍のみ、または、熱間圧延工程無しで、焼鈍と冷間圧延を繰り返し試作した発明合金は、いずれも本願において、実生産設備から得た前記諸特性と同様、目標とする諸特性の銅合金板が得られた(工程B1-1と工程B2-1と工程B3-1と工程A1-1と工程A2-1)。
熱間圧延を経ない工程B3-1と工程B3-2では、最終焼鈍が、バッチ式、高温短時間式であっても、本願発明合金では、高温短時間式が応力緩和特性に関し少しよかったが、ほぼ同等の諸特性が得られた。
(6)溶融Snめっきを想定した回復熱処理(300℃-0.07分)、(250℃-0.15分)は、他の回復熱処理条件に比べ、少し強度が高く、伸び値が低く、応力緩和特性の150℃での実効の応力値が少し悪くなったが、目標とする特性を達成することができた(工程A1-1、工程A1-2と工程A1-3等)。
(7)最終焼鈍温度が低い場合、結晶粒の大きさが細かくなり、平均結晶粒径が2μmより小さいと、強度(引張強さ、耐力)は向上するが、曲げ加工性が悪くなり、少し応力緩和特性も悪くなった(工程A2-1と工程A2-5、工程2-11とA2-2等)。
(8)最終焼鈍温度が高い場合、結晶粒の大きさが大きくなり、平均結晶粒径が12μmより大きいと、強度が低くなり、少し応力緩和特性も悪くなり、150℃での実効応力が低くなった。また、バッチ式で実施したため、金属組織が混粒状態になり、機械的性質の異方性が大きくなり、曲げ加工性、耐応力腐食割れ性が悪くなった(工程A2-6)。
(9)最終焼鈍を連続焼鈍法で行うと、平均結晶粒径が5~9μmの少し大きめであっても、混粒もなく、均一な再結晶粒で構成されているので、応力緩和特性、曲げ加工性がよかった(工程A1-4、工程A2-7と工程A2-9等)。
(10)Zn量、Sn量が多い、f1の値が大きい、f5の値が小さいと金属組織中に、β相、γ相が残留しやすく、応力緩和特性、曲げ加工性、耐応力腐食割れ性が悪くなった(試験No.201、204、205、213、215、220等)。
(11)最終焼鈍を連続焼鈍法で行う場合、Zn量、Sn量が多い、f1の値が大きい、f5の値が小さいと、金属組織中に、β相、γ相がより多く存在し易くなり、応力緩和特性、曲げ加工性、耐応力腐食割れ性、耐変色性が悪くなった(試験No.201A、220A、221A等)。
(13)平均結晶粒径が5~9μmの少し大きめの工程A2-7、A2-8、A2-9は、最終の加工率が25%であるが、少し強度が高くなるが、曲げ加工性、応力緩和特性、耐応力腐食割れ性も良好であった。
析出粒子径が、3nmより小さいと、または180nmより大きいと、応力緩和特性、曲げ加工性が悪くなった(試験No.10、30、50、218、219等)。
Claims (8)
- 18~30mass%のZnと、1~1.5mass%のNiと、0.2~1mass%のSnと、0.003~0.06mass%のPと、を含有し、残部がCu及び不可避不純物からなり、
Znの含有量〔Zn〕mass%と、Snの含有量〔Sn〕mass%と、Niの含有量[Ni]mass%との間に、
17≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30、
14≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦26、
8≦f3={f1×(32-f1)}1/2×〔Ni〕≦23、
の関係を有するとともに、
Snの含有量〔Sn〕mass%と、Niの含有量〔Ni〕mass%との間に、
1.3≦〔Ni〕+〔Sn〕≦2.4、
1.5≦〔Ni〕/〔Sn〕≦5.5、
の関係を有し、
Niの含有量〔Ni〕mass%と、Pの含有量〔P〕mass%との間に、
20≦〔Ni〕/〔P〕≦400、
の関係を有しており、
α単相である金属組織を有している銅合金。 - 19~29mass%のZnと、1~1.5mass%のNiと、0.3~1mass%のSnと、0.005~0.06mass%のPと、を含有し、残部がCu及び不可避不純物からなり、
Znの含有量〔Zn〕mass%と、Snの含有量〔Sn〕mass%と、Niの含有量[Ni]mass%との間に、
18≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30、
15≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦25.5、
9≦f3={f1×(32-f1)}1/2×〔Ni〕≦22、
の関係を有するとともに、
Snの含有量〔Sn〕mass%と、Niの含有量〔Ni〕mass%との間に、
1.4≦〔Ni〕+〔Sn〕≦2.4、
1.7≦〔Ni〕/〔Sn〕≦4.5、
の関係を有し、
Niの含有量〔Ni〕mass%と、Pの含有量〔P〕mass%との間に、
22≦〔Ni〕/〔P〕≦220、
の関係を有しており、
α単相である金属組織を有している銅合金。 - 18~30mass%のZnと、1~1.5mass%のNiと、0.2~1mass%のSnと、0.003~0.06mass%のPと、を含有するとともに、Al、Fe、Co、Mg、Mn、Ti、Zr、Cr、Si、Sb、As、Pb及び希土類元素から選択される少なくとも1種または2種以上を、各々0.0005mass%以上0.05mass%以下、かつ、合計で0.0005mass%以上0.2mass%以下含有し、残部がCu及び不可避不純物からなり、
Znの含有量〔Zn〕mass%と、Snの含有量〔Sn〕mass%と、Niの含有量[Ni]mass%との間に、
17≦f1=〔Zn〕+5×〔Sn〕-2×〔Ni〕≦30、
14≦f2=〔Zn〕-0.5×〔Sn〕-3×〔Ni〕≦26、
8≦f3={f1×(32-f1)}1/2×〔Ni〕≦23、
の関係を有するとともに、
Snの含有量〔Sn〕mass%と、Niの含有量〔Ni〕mass%との間に、
1.3≦〔Ni〕+〔Sn〕≦2.4、
1.5≦〔Ni〕/〔Sn〕≦5.5、
の関係を有し、
Niの含有量〔Ni〕mass%と、Pの含有量〔P〕mass%との間に、
20≦〔Ni〕/〔P〕≦400、
の関係を有しており、
α単相である金属組織を有している銅合金。 - 請求項1から請求項3のいずれか一項に記載の銅合金であって、
導電率が18%IACS以上27%IACS以下であり、平均結晶粒径が2~12μmとされ、円形又は楕円形の析出物が存在し、該析出物の平均粒子径が3~180nm、又は、該析出物の内で粒子径が3~180nmの析出物が占める個数の割合が70%以上である銅合金。 - 請求項1から請求項4のいずれか一項に記載の銅合金であって、
コネクタ、端子、リレー、スイッチ等電子・電気機器部品に用いられる銅合金。 - 請求項1から請求項5のいずれか一項に記載の銅合金からなる銅合金板であって、
前記銅合金を熱間圧延加工する熱間圧延工程と、
前記熱間圧延工程で得られる圧延材を、冷間加工率40%以上で冷間圧延加工する冷間圧延工程と、
前記冷間圧延工程で得られる圧延材を、連続熱処理炉を用い、連続焼鈍法で、圧延材の最高到達温度が560~790℃であり、最高到達温度マイナス50℃から最高到達温度までの高温領域の保持時間が0.04~1.0分間である条件で、再結晶処理する再結晶熱処理工程と、を含む製造工程によって製造される銅合金板。 - 請求項6記載の銅合金板であって、
前記製造工程は、前記再結晶熱処理工程で得られる圧延材を仕上げ冷間圧延加工する仕上げ冷間圧延工程と、前記仕上げ冷間圧延工程で得られる圧延材を回復熱処理する回復熱処理工程をさらに有し、
前記回復熱処理工程では、連続熱処理炉を用い、圧延材の最高到達温度が150~580℃であり、最高到達温度マイナス50℃から最高到達温度までの高温領域の保持時間が0.02~100分間である条件で、回復熱処理を行う銅合金板。 - 請求項1から請求項5のいずれか一項に記載の銅合金からなる銅合金板の製造方法であって、
鋳造工程と、対となる冷間圧延工程と焼鈍工程と、冷間圧延工程と、再結晶熱処理工程と、仕上げ冷間圧延工程と、回復熱処理工程と、を含み、
銅合金または圧延材を熱間加工する工程を含まず、
前記冷間圧延工程と前記再結晶処理工程との組み合わせ、及び、前記仕上げ冷間圧延工程と前記回復熱処理工程との組み合わせ、のいずれか一方又は両方を行う構成とされており、
前記再結晶熱処理工程は、連続熱処理炉を用い、延材の最高到達温度が560~790℃であり、最高到達温度マイナス50℃から最高到達温度までの高温領域の保持時間が0.04~1.0分間である条件で行われ、
前記回復熱処理工程は、仕上げ冷間圧延後の銅合金材料を、連続熱処理炉を用い、圧延材の最高到達温度が150~580℃であり、最高到達温度マイナス50℃から最高到達温度までの高温領域の保持時間が0.02~100分間である条件で回復熱処理する銅合金板の製造方法。
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