WO2015192274A1 - 一种可铆接的变形低铜合金材料及其应用 - Google Patents

一种可铆接的变形低铜合金材料及其应用 Download PDF

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WO2015192274A1
WO2015192274A1 PCT/CN2014/000909 CN2014000909W WO2015192274A1 WO 2015192274 A1 WO2015192274 A1 WO 2015192274A1 CN 2014000909 W CN2014000909 W CN 2014000909W WO 2015192274 A1 WO2015192274 A1 WO 2015192274A1
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copper alloy
alloy material
low
alloy
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PCT/CN2014/000909
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孙文声
郜晓彬
余惺
杨澍
周宏渤
张明
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宁波博威合金材料股份有限公司
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C18/00—Alloys based on zinc
    • C22C18/04—Alloys based on zinc with aluminium as the next major constituent

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  • the invention relates to the low copper alloy material and the technical field thereof, and particularly relates to a rivetable deformed low copper alloy material and an application thereof, which can be applied to a power plug of a household appliance, etc., which need to be riveted and stamped. .
  • Copper and copper alloys are one of the most widely used and largest non-ferrous metals, accounting for more than half of the electronics and electrical industry. Although the demand for copper is strong, China's copper resources are in short supply, the domestic resource supply rate is less than 25%, and copper prices continue to remain high. Moreover, the copper content of copper alloy is relatively high, generally above 55%, and the price of copper raw materials usually accounts for 85-90% of the price of copper alloy. Therefore, the impact of copper price on the capital flow of copper processing enterprises and the relationship between market supply and demand is very serious. . The growing shortage of copper resources and the continuing high copper prices have forced people to accept the fact that copper and copper alloys have become scarce materials. Therefore, in order to cope with the complex and ever-changing world economic situation, the development of new low-cost alloy materials to replace copper alloys has become the future development trend of non-ferrous metals and processing industries.
  • Zinc-based alloy is another important non-ferrous metal alloy. It has the characteristics of low melting point, good fluidity, good electrical conductivity and low raw materials. It is generally used as a die casting and gravity casting product.
  • the alloy obtained by pressure and gravity casting is as-cast structure, often in the form of dendrites, the microstructure is coarse, and since zinc is a hexagonal crystal, the slip system is less at room temperature, the cast alloy is brittle, and the elongation is very low. Deep processing with large deformation such as riveting and crimping cannot be performed.
  • the power plug is a relatively common household appliance component, which is widely used and has a wide range of uses.
  • the raw materials for manufacturing power plugs are mostly brass alloys, such as H59 and H62, but the high cost and limited resources of copper will inevitably restrict the future development of household appliances.
  • the free fall under certain conditions shall not meet the damage and the temperature rise within the specified time after power-on shall not exceed 45K.
  • the material also needs to meet other machining requirements, such as proper strength, hardness and plasticity, to meet the processing requirements of riveting and stamping in the subsequent power plug manufacturing process. Cast zinc alloy can not meet the above requirements, and the use of wrought zinc alloy as a power plug has rarely been reported.
  • the most deformed zinc alloy at this stage is a Zn-Al alloy, but the alloy has the disadvantages of poor cutting performance, serious intergranular corrosion tendency, and low dimensional stability, which cannot meet the requirements of the power plug manufacturing industry for easy processing of materials. Riveting and other performance requirements.
  • JP-A-H10-168533A discloses a zinc alloy containing: 0.1-4.5% Mg, the balance being Zn and unavoidable impurities. If necessary, at least one element is selected from the group consisting of Cu, Ni, Mn, total amount ⁇ 7%, and/or ⁇ 10% Al, and/or at least one element selected from the group consisting of Ti, Zr, Cr, Co, Li, Be , Si and La series elements, the total amount ⁇ 2%, the alloy has excellent tensile strength and creep resistance at high temperatures, but the alloy is a cast zinc alloy, suitable for cold die casting, hot die casting, injection molding The casting method.
  • CN102277517A discloses a high-strength weldable zinc alloy having the following composition: aluminum 8-12%; copper 0.5-3%; titanium 0.05-0.5%; magnesium 0.02-0.2%; chromium 0.03-0.15%; rare earth 0.1-0.25 %; The balance is zinc and unavoidable impurities; the impurity content is ⁇ 0.05%.
  • the tensile strength of the alloy is above 360 MPa, and the elongation is only ⁇ 10%, which cannot meet the requirements of riveting processing for zinc alloys for power plugs.
  • the technical problem to be solved by the present invention is that, in view of the deficiencies of the prior art, a deformable low-copper alloy material that can be riveted is provided, and the alloy material can be applied to parts such as a power plug of a household appliance that need to be riveted and stamped.
  • a rivetable deformed low copper alloy material composed of Al, Cu, M, Zn and unavoidable impurities, wherein M is Ni, V At least one of Ti, Zr, La, Ce, Pr, Nd, Mo, Si, Be, Cr, Mn, Co, and Mg, and the impurity includes at least one of Fe, Pb, Sn, Sb, and Cd
  • the microstructure of the low copper alloy material contains an aluminum-rich aluminum-zinc-copper ternary eutectic structure
  • Al forms nascent alpha dendrites and eutectic ⁇ phases in the form of aluminum-rich ⁇ -Al solid solution.
  • a small amount of Al is dissolved in ⁇ -Zn solid solution, which mainly plays a strengthening role in the alloy.
  • the alloy Strength and hardness increase, but plasticity decreases.
  • the proper content of Al can improve the fluidity of alloy casting, prevent oxidation, and improve the press workability, the zinc-aluminum-based deformed zinc alloy is difficult to crack due to poor impact toughness during riveting and stamping. Not suitable for riveting.
  • the inventors have found through extensive experiments that a certain amount of copper is added to the zinc-aluminum-based alloy to form a network.
  • the aluminum-rich aluminum-zinc-copper ternary eutectic structure makes the riveting and stamping properties of the alloy greatly improved, and the cracking phenomenon is significantly reduced.
  • the formation of the networked ternary eutectic structure requires an appropriate ratio of aluminum to copper.
  • the content ratio of Al/Cu is controlled to 1-4, and the aluminum content is controlled to be 0.1-6.0 wt%.
  • Cu is mainly formed into an ⁇ phase (i.e., CuZn5) in addition to solid solution in the ⁇ phase and the ⁇ phase.
  • Cu inhibits the metastable ⁇ phase transition, providing high strength, hardness, corrosion resistance and flow properties of the alloy, and reducing the intergranular corrosion sensitivity of the alloy.
  • the maximum solid solubility of copper in zinc is 2.7wt%.
  • the ⁇ phase precipitates. In the case of low copper content, the amount of ⁇ phase precipitates is small and the size is small, and the alloy maintains a small intensity increase.
  • the elongation increases, the hardness remains basically unchanged, and the copper content is appropriately increased, which is advantageous for refining the matrix structure of the zinc-aluminum-based alloy, increasing the density, and reducing the tendency of shrinkage and shrinkage.
  • the ⁇ phase, the ⁇ phase, and the ⁇ phase are co-precipitated to form an aluminum-rich aluminum-zinc-copper ternary eutectic structure, and the precipitated structure contributes to the riveting of the subsequent material without significantly reducing the strength. , stamping processing, smooth rolling flat wire.
  • the copper content should not be too high, and a too high copper content will precipitate a large amount of ⁇ phase.
  • the present invention controls the copper content to be 0.1 to 5% by weight.
  • the low copper alloy material has a tensile strength of 290-400 MPa, a hardness of 90-110 HV5, and an elongation of ⁇ 15%.
  • the low copper alloy material of the invention is made into a round wire of ⁇ 4.8 or ⁇ 4.0, it is machined into a pin, and the power cord and the plug are connected together by a riveting device, thereby forming an AC/DC plug.
  • Power cord T2 copper is often used to achieve a better connection between the low copper alloy plug and the power cord.
  • the mechanical properties of the two copper alloys should be similar.
  • the tensile strength of the low copper alloy is 290-400 MPa and the hardness is 90-110 HV5. ⁇ 15% to achieve a better connection match between the low copper alloy plug and the power cord.
  • the content of Ni is 0.001 to 0.1% by weight
  • the content of Mg is 0.001 to 0.1% by weight
  • the content of Mn is 0.001 to 0.1% by weight.
  • Ni and Mg have a small amount of solid solubility in zinc, and are dissolved in the ⁇ phase and the ⁇ phase to inhibit the transformation of the ⁇ phase.
  • the addition amount of the two in the low copper alloy is more than 0.001%, the strength is increased. Function, and can improve the intergranular corrosion resistance of the alloy, but with the increase of the content of the two, although the strength and hardness of the alloy are improved, at the same time the plasticity is reduced, the thermal cracking and cold cracking properties are increased, and the riveting and punching properties are changed. difference.
  • the contents of Ni, Mg and Mn in the present invention are controlled to be 0.001 to 0.1% by weight, respectively.
  • the V content is 0.001-0.1 wt%
  • the Ti content is 0.001-0.1 wt%
  • the Zr content is 0.001-0.1 wt%.
  • the solubility of Zr, V and Ti in low copper alloy is very low.
  • the three will combine with Zn, Cu and Al to form fine dispersed particles, which can refine the grain of the alloy and increase the strength, such as Ti and Zn.
  • TiZn 3 can refine the grain of the alloy, thereby improving the mechanical properties and recrystallization temperature of the alloy, but the excessive content tends to cause the brittleness of the alloy, which is not conducive to the subsequent riveting process, so the addition amount is controlled at 0.001-0.1wt%, respectively. .
  • the content of La is 0.001-0.1 wt%
  • the content of Ce is 0.001-0.1 wt%
  • the content of Pr is 0.001-0.1 wt%
  • the content of Nd is 0.001.
  • the content of Mo is 0.001-0.1wt%
  • the content of Si is 0.001-0.1wt%
  • the content of Cr is 0.001-0.1wt%
  • the content of Co It is 0.001 to 0.1% by weight.
  • the rare earth elements La, Ce, Pr and Nd can play a good role in refining grains and degassing. After addition, the mechanical properties, riveting and stamping properties of the alloy can be significantly improved, but the excessive addition will cause the matrix to be brittle.
  • the content of Be is from 0.001 to 0.1% by weight.
  • 0.001-0.1 wt% of Be is dissolved in the zinc matrix to act as a solid solution strengthening.
  • the low copper alloy of the present invention has strong sensitivity to impurities such as Fe, Pb, Sn, Sb and Cd.
  • impurities such as Fe, Pb, Sn, Sb and Cd.
  • the FeAl 3 and FeZn 7 phases formed when the impurity contains Fe will reduce the fluidity of the alloy, and the formed hard spots are not conducive to the subsequent deep processing, especially for the subsequent electroplating performance, and it is easy to form a black surface on the surface after electroplating. point.
  • Pb is distributed between fine grain and dendrites, which is easy to cause intergranular corrosion.
  • Sn and zinc form a low-melting eutectic, making the material easy to become brittle, which is not conducive to subsequent processing.
  • Sb and Cd are present in the solid solution to form hot brittleness and reduce corrosion resistance.
  • elements such as Fe, Pb, Sn, Sb, and Cd are controlled as impurities in the alloy of the present invention, and the total amount is controlled to be 0.1 wt% or less.
  • the content of the impurity Pb should be controlled to be 0.005 wt% or less
  • the content of the impurity Cd should be controlled to be 0.001 wt% or less.
  • the riveted deformed low copper alloy material of the present invention is applied to a power plug.
  • the low copper alloy of the invention has good riveting and stamping processing properties, and can be applied to parts such as power plugs of household appliances that need to be riveted and stamped.
  • the alloy of the present invention has appropriate strength, hardness and elongation as compared with the conventional Zn-Cu, Zn-Al-based deformed zinc alloy, and the tensile strength is maintained between 290 and 400 MPa, and the hardness is between 90 and 110 HV5.
  • the elongation is ⁇ 15%, which can achieve riveting and stamping processing performance.
  • the ordinary wrought zinc alloy has a low recrystallization temperature, dynamic recrystallization occurs during the stretching process, and processing softening occurs when the processing rate reaches 30%, but the present invention overcomes the above-mentioned failure of the ordinary deformed zinc alloy.
  • the process softening phenomenon occurs when the processing rate of the low copper alloy of the invention reaches 85%, so that the low copper alloy of the invention has good deformation performance and can smoothly produce round and flat wires.
  • the alloy of the invention satisfies the requirements of the power plug for the temperature rise performance of the material, and the temperature rise after 1 h is generally 15-34 K, which meets the performance requirements of the temperature rise of the power plug according to IEC 60884-1.
  • the alloy is mainly used as an alternative to ordinary brass power plugs, which can save cost, and can also be applied to other copper alloy parts that need riveting and stamping processing.
  • Example 1 is a SEM picture of the microstructure of the low copper alloy of Example 1;
  • Figure 2 is the result of the energy spectrum analysis indicated by the arrow in Figure 1.
  • Example alloys and two comparative alloys were selected (Comparative Example 1 was alloyed according to JP-A-10-168533A, and Comparative Example 2 was alloyed according to CN102277517A), and processed into AC by the same process.
  • Round wire required for /DC plug ⁇ 100- ⁇ 200mm ingot is produced by semi-continuous casting or horizontal continuous casting. The ingot is sawn and cut to a length of 400-700mm, heated to 200-300 °C, and passed through the positive direction. Extrusion machine or reverse extrusion machine extrudes round wire blank ⁇ 6-12, after multiple stretching and at least two annealing, it is processed into finished products with specifications of ⁇ 4.8 and ⁇ 4.0, and then it is corrected. straight. The round wire is machined into a pin, and then the power cord and the plug are connected together by a riveting device to form an AC/DC finished plug. The composition and performance test results of the examples, comparative examples are shown in Table 1.
  • the SEM image of the microstructure of the low copper alloy of Example 1 is shown in Fig. 1.
  • the results of the energy spectrum analysis indicated by the arrows in Fig. 1 are shown in Fig. 2. It is apparent that the alloy of the present invention has aluminum-zinc-rich copper and copper.
  • a ternary eutectic structure, the ternary eutectic structure is a network.
  • Free fall and temperature rise test according to IEC60884-1 standard, IEC60884-1 standard: The plug processed into the finished product is energized for 1 hour by alternating current, and the temperature rise cannot exceed 45K. The drum is dropped. According to the weight of the plug, the plug should be subjected to 100-1000 roller drop test. The plug cannot be broken or bent during the test. . Free fall and temperature rise tests were performed on the examples and comparative alloys. The sample of the free drop test does not have a flexible cable, and the weight does not exceed 100 g. After dropping 1000 times, the surface of the sample is observed to be cracked, and the degree of integrity is judged. The results of the free fall and temperature rise test are shown in Table 1.

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Abstract

本发明公开的低铜合金材料由Al、Cu、M、Zn和不可避免的杂质组成，M为Ni、V、Ti、Zr、La、Ce、Pr、Nd、Mo、Si、Be、Cr、Mn、Co和Mg中的至少一种元素，杂质包括Fe、Pb、Sn、Sb和Cd中的至少一种元素；该低铜合金材料的重量百分比组成中：Al的含量x=0.1-6.0 wt%，Cu的含量y=0.1-4.0 wt%，M的含量z=0.001-1.0 wt%，杂质的总量≤0.1 wt%，余量为Zn；Al与Cu的含量之和满足：0.5 wt%≤x+y≤9.0 wt%，Al与Cu的含量之比满足：1≤x/y≤4。该合金可应用于家用电器的电源插头等需要进行铆接、冲压加工的零部件。

Description

一种可铆接的变形低铜合金材料及其应用 技术领域
本发明涉及低铜合金材料及其应用技术领域，具体涉及一种可铆接的变形低铜合金材料及其应用，该合金材料可应用于家用电器的电源插头等需要进行铆接、冲压加工的零部件。
背景技术
铜及铜合金是应用最广、用量最大的有色金属之一，在电子电器工业中的用量占一半以上。虽然对铜的需求旺盛，但我国铜资源严重短缺，国内资源供给率不足25％，铜价也持续保持高位。并且，铜合金的含铜量较高，一般在55％以上，而铜原料价格通常占铜合金售价的85-90％，因此铜价对铜加工企业的资金流动和市场供求关系的影响十分严重。铜资源的日益短缺和持续的高铜价使人们不得不接受这一事实：铜及铜合金已成为稀缺材料。因此，为应对复杂多变的世界经济形势，开发新型的低成本合金材料替代铜合金已成为有色金属及加工等行业的未来发展趋势。
锌基合金是另一种重要的有色金属合金，具有熔点低、流动性好、导电性能好、原料低廉等特点，一般作为压铸和重力铸造产品使用。压力和重力铸造得到的合金为铸态组织，常以枝晶形式存在，组织形貌粗大，并且由于锌是六方结构晶体，室温时滑移系较少，铸造合金呈脆性，延伸率很低，不能进行铆接、压接等变形量较大的深加工。
由于锌基合金的成本优势，近年来在某些铜合金占主导地位的应用领域中，铸造锌合金已逐步替代了一些铜合金。但是采用压铸工艺生产的锌合金不能进行后续加工变形，且压铸锌合金产品的外形受限于模具，往往存在合模线等缺陷，影响后续加工，因此采用铸造锌合金替代铜合金的推广应用受到较大限制， 对于变形锌合金而言更是如此。
电源插头是较为常见的家用电器零部件，其使用量大，使用范围广。目前制造电源插头的原料以黄铜合金居多，如H59、H62等，但是成本较高，加上铜的资源有限，必然会对家用电器的未来发展造成制约。
作为电源插头的材料需满足一定条件下的自由跌落不得出现损坏和通电后规定时间内的温升不得超过45K。围际电工委员会(IEC)的IEC60884-1《家用和类似用途插头插座第1部分：通用要求》标准规定：如果样品不带软缆时，重量不超过100g，自由跌落1000次，表面不得出现损害；通电1小时后，插销的温升不得超过45K。除了自由跌落和温升的要求外，材料还需满足其他机加工方面的要求，例如适当的强度、硬度和塑性，以满足后续电源插头制造过程中的铆接、冲压等加工要求。铸造锌合金无法满足以上要求，采用变形锌合金作为电源插头目前也鲜有报道。
现阶段研究最多的变形锌合金是Zn-Al系合金，但该合金存在切削性能较差、晶间腐蚀倾向严重、尺寸稳定性低等缺点，不能满足电源插头制造行业对材料的易加工和可铆接等性能要求。
JP特开平10-168533A公开了一种锌合金，该锌合金含有：0.1-4.5％Mg，其余为Zn和不可避免的杂质。如有必要，至少一种元素选自Cu，Ni，Mn，总量≤7％，和/或≤10％Al，和/或至少一种元素选自Ti，Zr，Cr，Co，Li，Be，Si和La系列元素，总量≤2％，该合金在高温下具有优异的拉伸强度和抗蠕变性能，但该合金为铸造锌合金，适用于冷模铸造、热模铸造、注射成型等铸造方法。
CN102277517A公开了一种高强可焊锌合金，该合金组成为：铝8～12％；铜0.5～3％；钛0.05～0.5％；镁0.02～0.2％；铬0.03～0.15％；稀土0.1～0.25％； 余量为锌和不可避免的杂质；杂质含量≤0.05％。作为一种Zn-Al基变形锌合金，该合金的抗拉强度在360MPa以上，而延伸率只有≤10％，不能满足电源插头用锌合金对铆接加工的要求。
发明内容
本发明所要解决的技术问题是，针对现有技术的不足，提供一种可铆接的变形低铜合金材料，该合金材料可应用于家用电器的电源插头等需要进行铆接、冲压加工的零部件。
本发明解决上述技术问题所采用的技术方案为：一种可铆接的变形低铜合金材料，该低铜合金材料由Al、Cu、M、Zn和不可避免的杂质组成，其中M为Ni、V、Ti、Zr、La、Ce、Pr、Nd、Mo、Si、Be、Cr、Mn、Co和Mg中的至少一种元素，杂质包括Fe、Pb、Sn、Sb和Cd中的至少一种元素，该低铜合金材料的微观结构中含有富含铝的铝锌铜三元共晶组织；
该低铜合金材料的重量百分比组成中：Al的含量x＝0.1-6.0wt％，Cu的含量y＝0.1-5.0wt％，M的含量z＝0.001-1.0wt％，杂质的总量≤0.1wt％，余量为Zn；Al与Cu的含量之和满足：0.5wt％≤x+y≤9.0wt％，Al与Cu的含量之比满足：1≤x/y≤4。
Al以富含铝的α-Al固溶体形式形成初生α枝晶和共晶α相，少量Al固溶于η-Zn固溶体中，在合金中主要起强化作用，随着Al含量的提高，合金的强度、硬度提高，但塑性降低。虽然适当含量的Al可以改善合金铸造的流动性，防止氧化，并且改善压力加工性能，但锌铝基变形锌合金在进行铆接和冲压加工时，由于冲击韧性较差，容易开裂，所以该类合金不适合用于铆接加工。但本发明人通过大量试验发现，在锌铝基合金中添加一定量的铜，可形成网状的 富含铝的铝锌铜三元共晶组织，该三元共晶组织使得合金的铆接和冲压加工性能得到较大改善，开裂现象明显降低。而该网状的三元共晶组织的形成需要适当的铝、铜配比，本发明中，Al/Cu的含量比控制在1-4，铝含量控制在0.1-6.0wt％。
本发明中加入Cu除了固溶于α相和η相外，主要形成ε相(即CuZn5)。Cu对亚稳态的β相转变起到抑制作用，提供合金高的强度、硬度、耐蚀性和合金液的流动性能，降低合金的晶间腐蚀敏感性。铜在锌中的最大固溶度是2.7wt％，随着温度的降低，析出ε相，在铜含量较低的情况下，ε相析出的数量少、尺寸小，合金在保持较小强度增幅下，伸长率增加，硬度基本保持不变，适当地提高铜含量，有利于细化锌铝基合金的基体组织，提高致密度，减少缩孔缩松倾向。在本发明中，η相、α相、ε相三者共同析出，形成富含铝的铝锌铜三元共晶组织，该析出组织在不明显降低强度的同时，有助于后续材料的铆接、冲压加工、顺利轧制扁线。但铜含量不宜过高，过高的铜含量会析出大量的ε相，虽然强度、硬度增高，但延伸率大大下降，因此本发明将铜含量控制在0.1-5wt％。
优选地，该低铜合金材料的重量百分比组成中：x＝0.5-4.5wt％，y＝0.5-3.0wt％，1≤x/y≤2.5。
优选地，该低铜合金材料的重量百分比组成中：x＝4.6-6.0wt％，y＝0.3-3.5wt％，1≤x/y≤3。
优选地，该低铜合金材料的抗拉强度为290-400MPa，硬度为90-110HV5，延伸率≥15％。本发明低铜合金材料制成Φ4.8或Φ4.0的圆线后，经机加工成插针，通过铆接设备将电源线和插头连接在一起，即制成AC/DC插头。电源线通 常采用T2铜，为实现低铜合金插头与电源线更好的连接，两者的机械性能应相近，本方面控制低铜合金的抗拉强度为290-400MPa，硬度为90-110HV5，延伸率≥15％，以实现低铜合金插头与电源线的更好的连接匹配。
优选地，所述的Ni的含量为0.001-0.1wt％，所述的Mg的含量为0.001-0.1wt％，所述的Mn的含量为0.001-0.1wt％。Ni、Mg在锌中有少量的固溶度，固溶于η相和β相中，可抑制β相的转变，当两者在低铜合金中的添加量大于0.001％时就有提高强度的作用，并且可提高合金的耐晶间腐蚀性能，但随着两者含量的增加，虽然合金的强度、硬度提高，但同时塑性降低，增大热裂和冷裂性能，使铆接和冲压性能变差。综合考虑两者对合金性能的影响，本发明中Ni、Mg和Mn的含量分别控制在0.001-0.1wt％。
优选地，所述的V的含量为0.001-0.1wt％，所述的Ti的含量为0.001-0.1wt％，所述的Zr的含量为0.001-0.1wt％。Zr、V、Ti在低铜合金中的溶解度很低，三者会与Zn、Cu、Al结合生成细小弥散的质点，起到细化合金晶粒、提高强度的作用，如Ti与Zn形成的TiZn3能够细化合金的晶粒，从而提高合金的力学性能和再结晶温度，但过高的含量易造成合金的脆性，不利于后续的铆接加工，因此添加量分别控制在0.001-0.1wt％。
优选地，所述的La的含量为0.001-0.1wt％，所述的Ce的含量为0.001-0.1wt％，所述的Pr的含量为0.001-0.1wt％，所述的Nd的含量为0.001-0.1wt％；所述的Mo的含量为0.001-0.1wt％，所述的Si的含量为0.001-0.1wt％，所述的Cr的含量为0.001-0.1wt％，所述的Co的含量为0.001-0.1wt％。稀土元素La、Ce、Pr、Nd能够起到良好的细化晶粒和除气作用，添加后可明显改善合金的力学性能、铆接加工和冲压加工性能，但添加量过高会造成基体脆性，延伸率大 大降低。Mo、Si、Cr、Co的添加量分别控制在0.001-0.1wt％，Mo、Si、Cr、Co与锌生成第二相，均匀分散于锌基体中，起到第二相强化作用。
优选地，所述的Be的含量为0.001-0.1wt％。0.001-0.1wt％的Be固溶于锌基体中，起到固溶强化的作用。
本发明低铜合金对于Fe、Pb、Sn、Sb和Cd等杂质具有较强的敏感性。含有杂质Fe时形成的FeAl3和FeZn7相会降低合金的流动性，且形成的硬质点不利于后续的深加工，特别是对后续的电镀性能影响很大，易在电镀后产品表面形成黑点。Pb呈细小颗粒分布于晶界和枝晶间，容易造成晶间腐蚀。Sn与锌会形成低熔点的共晶体，使得材料容易变脆，不利于后续的加工。Sb和Cd存在于固溶体中，形成热脆性，降低耐蚀性能。因此Fe、Pb、Sn、Sb和Cd等元素在本发明合金中，都是作为杂质元索来控制，总量控制在0.1wt％以下。为进一步限制Pb、Cd等有害元素含量，满足环保的要求，本发明合金中，杂质Pb的含量应控制在0.005wt％以下，杂质Cd的含量应控制在0.001wt％以下。
优选地，本发明可铆接的变形低铜合金材料在电源插头上的应用。本发明低铜合金的铆接和冲压加工性能好，可应用于家用电器的电源插头等需要进行铆接、冲压加工的零部件。
与现有技术相比，本发明的优点在于：
(1)本发明合金与普通的Zn-Cu、Zn-Al基变形锌合金相比，具有适当的强度、硬度和延伸率，抗拉强度保持在290-400MPa之间，硬度在90-110HV5、延伸率≥15％，可以实现铆接、冲压加工性能。
(2)普通变形锌合金再结晶温度低，拉伸过程中会发生动态再结晶，当加工率达到30％时就会产生加工软化，但本发明克服了普通变形锌合金的上述不 足，本发明低铜合金的加工率达到85％时才会出现加工软化现象，从而本发明低铜合金具有良好的变形性能，能够顺利生产出圆线和扁线。
(3)该发明合金满足电源插头对材料温升性能的要求，1h后的温升一般为15-34K，符合IEC60884-1对电源插头温升方面的性能要求。
(4)该合金主要应用于普通黄铜电源插头的替代，可以节省成本，也可应用于其他需要进行铆接、冲压加工的铜合金零部件的替代。
附图说明
图1为实施例1低铜合金微观结构的SEM图片；
图2为图1中箭头所指处的能谱分析结果。
具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
选取了20个实施例合金和2个对比例合金(对比例1按照JP特开平10-168533A进行合金配比，对比例2按照CN102277517A进行合金配比)，采用相同的工艺方法分别加工成制造AC/DC插头所需的圆线：通过半连铸或水平连铸生产成Φ100-Φ200mm铸锭，铸锭经过挤压后锯切至400-700mm的长度，加热至200-300℃，通过正向挤压机或反向挤压机挤压出圆线坯Φ6-12，经过多次拉伸和至少两次退火后加工成规格为Φ4.8、Φ4.0圆线成品，然后对其进行矫直。圆线经过机加工后成插针，然后通过铆接设备把电源线和插头连接在一起，制成AC/DC成品插头。实施例、对比例的成分及性能测试结果见表1。
实施例1低铜合金微观结构的SEM图片如图1所示，图1中箭头所指处的能谱分析结果如图2所示，可明显看出本发明合金具有富含铝的铝锌铜三元共晶组织，该三元共晶组织为网状。
根据IEC60884-1标准进行自由跌落和温升测试，IEC60884-1标准规定：对 加工成成品的插头进行交流电通电1h，升温不能超过45K为合格；滚筒跌落检测，根据插头的重量不同要对插头进行100-1000次的滚筒跌落试验，在试验的过程中插头不能有断裂、弯曲。对于实施例和对比例合金进行自由跌落和温升测试。自由跌落测试的样品不带软缆，重量不超过100g，跌落1000次后观察样品表面是否有裂纹，判断其完好程度。自由跌落和温升测试的结果见表1。
Figure PCTCN2014000909-appb-000001

Claims (10)

  1. 一种可铆接的变形低铜合金材料，其特征在于，该低铜合金材料由Al、Cu、M、Zn和不可避免的杂质组成，其中M为Ni、V、Ti、Zr、La、Ce、Pr、Nd、Mo、Si、Be、Cr、Mn、Co和Mg中的至少一种元素，杂质包括Fe、Pb、Sn、Sb和Cd中的至少一种元素，该低铜合金材料的微观结构中含有富含铝的铝锌铜三元共晶组织；
    该低铜合金材料的重量百分比组成中：Al的含量x＝0.1-6.0wt％，Cu的含量y＝0.1-4.0wt％，M的含量z＝0.001-1.0wt％，杂质的总量≤0.1wt％，余量为Zn；Al与Cu的含量之和满足：0.5wt％≤x+y≤9.0wt％，Al与Cu的含量之比满足：1≤x/y≤4。
  2. 根据权利要求1所述的一种可铆接的变形低铜合金材料，其特征在于该低铜合金材料的重量百分比组成中：x＝0.5-4.5wt％，y＝0.5-3.0wt％，1≤x/y≤2.5。
  3. 根据权利要求1所述的一种可铆接的变形低铜合金材料，其特征在于该低铜合金材料的重量百分比组成中：x＝4.6-6.0wt％，y＝0.3-3.5wt％，1≤x/y≤3。
  4. 根据权利要求1所述的一种可铆接的变形低铜合金材料，其特征在于该低铜合金材料的抗拉强度为290-400MPa，硬度为90-110HV5，延伸率≥15％。
  5. 根据权利要求1-4中任一项所述的一种可铆接的变形低铜合金材料，其特征在于所述的Ni的含量为0.001-0.1wt％，所述的Mg的含量为0.001-0.1wt％，所述的Mn的含量为0.001-0.1wt％。
  6. 根据权利要求1-4中任一项所述的一种可铆接的变形低铜合金材料，其特征在于所述的V的含量为0.001-0.1wt％，所述的Ti的含量为0.001-0.1wt％，所述的Zr的含量为0.001-0.1wt％。
  7. 根据权利要求1-4中任一项所述的一种可铆接的变形低铜合金材料，其特征在于所述的La的含量为0.001-0.1wt％，所述的Ce的含量为0.001-0.1wt％，所述的Pr的含量为0.001-0.1wt％，所述的Nd的含量为0.001-0.1wt％；所述的Mo的含量为0.001-0.1wt％，所述的Si的含量为0.001-0.1wt％，所述的Cr的含量为0.001-0.1wt％，所述的Co的含量为0.001-0.1wt％。
  8. 根据权利要求1-4中任一项所述的一种可铆接的变形低铜合金材料，其特征在于所述的Be的含量为0.001-0.1wt％。
  9. 根据权利要求1-4中任一项所述的一种可铆接的变形低铜合金材料，其特征在于该低铜合金材料中所述的杂质Pb的含量为0.005wt％以下，所述的杂质Cd的含量为0.001wt％以下。
  10. 权利要求1-4中任一项所述的一种可铆接的变形低铜合金材料在电源插头上的应用。
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