Copper C510 (Phosphor Bronze)
Introduction to Copper C510 (Phosphor Bronze)
Copper C510, commonly known as Phosphor Bronze, is a copper alloy incorporating small amounts of phosphorus and tin to enhance its strength, wear resistance, and fatigue properties. It retains excellent electrical conductivity while offering improved toughness and resistance to corrosion. This alloy is widely used in CNC machining services that demand high strength, durability, and excellent performance in challenging environments.
Copper C510 is ideal for precision CNC machined copper parts in the electronics, automotive, and manufacturing industries. Its properties make it perfect for use in electrical connectors, springs, and other mechanical components requiring high endurance and resistance to wear and fatigue.
Chemical, Physical, and Mechanical Properties of Copper C510 (Phosphor Bronze)
Chemical Composition (Typical)
Element | Composition Range (wt.%) | Key Role |
|---|---|---|
Copper (Cu) | 90.0% | Provides electrical conductivity and corrosion resistance |
Tin (Sn) | 4.0–6.0% | Improves strength, wear resistance, and corrosion protection |
Phosphorus (P) | 0.01–0.35% | Enhances strength, wear resistance, and reduces oxidation |
Other Elements | ≤0.5% | Residual elements with minimal impact on properties |
Physical Properties
Property | Value (Typical) | Test Standard/Condition |
|---|---|---|
Density | 8.73 g/cm³ | ASTM B311 |
Melting Point | 930°C | ASTM E29 |
Thermal Conductivity | 60 W/m·K at 20°C | ASTM E1952 |
Electrical Conductivity | 15–25% IACS at 20°C | ASTM B193 |
Coefficient of Expansion | 19.5 µm/m·°C | ASTM E228 |
Specific Heat Capacity | 380 J/kg·K | ASTM E1269 |
Elastic Modulus | 105 GPa | ASTM E111 |
Mechanical Properties (Annealed Temper)
Property | Value (Typical) | Test Standard |
|---|---|---|
Tensile Strength | 450–650 MPa | ASTM E8/E8M |
Yield Strength (0.2%) | 300–450 MPa | ASTM E8/E8M |
Elongation | 12–25% | ASTM E8/E8M |
Hardness | 85–130 HB | ASTM E10 |
Fatigue Strength | ~200 MPa | ASTM E466 |
Impact Resistance | Moderate | ASTM E23 |
Note: These values are typical for annealed Copper C510 and can vary based on specific processing conditions.
Key Characteristics of Copper C510 (Phosphor Bronze)
Excellent Strength and Durability
Copper C510 offers high tensile strength, making it ideal for mechanical applications requiring durability, such as springs, bearings, and bushings.
Moderate Electrical Conductivity
With 15–25% IACS conductivity, Copper C510 is used in electrical applications that demand high strength while maintaining good electrical conductivity.
High Resistance to Wear and Fatigue
The addition of phosphorus enhances wear resistance, making Copper C510 suitable for applications where components are exposed to repetitive motion or mechanical stress.
Corrosion Resistance
Copper C510 is highly corrosion-resistant, particularly in seawater and other mildly corrosive environments, making it ideal for marine and industrial applications.
Improved Machinability
The alloy’s composition provides excellent machinability while retaining strength, allowing for efficient and precise CNC machining.
CNC Machining Challenges and Solutions for Copper C510 (Phosphor Bronze)
Machining Challenges
Tool Wear
The high strength of Copper C510 can cause significant tool wear during machining, especially in high-speed operations.
Solution: Use carbide tools with TiN or TiAlN coatings, and monitor cutting speeds to reduce wear and extend tool life.
Chip Formation
The material’s strength and toughness can result in long, stringy chips affecting machining efficiency.
Solution: Employ chip breakers and optimize coolant flow to facilitate smooth chip removal.
Work Hardening
Copper C510 can work harden quickly during machining, leading to difficulties in further processing.
Solution: Use moderate cutting speeds, apply sufficient coolant, and use sharp, high-quality tools to minimize work hardening.
Optimized Machining Strategies
Tool Selection
Parameter | Recommendation | Rationale |
|---|---|---|
Tool Material | Carbide tools with TiN coating | Reduces wear and enhances tool life |
Geometry | Positive rake, sharp edges | Improves chip flow and reduces material buildup |
Cutting Speed | 80–150 m/min | Prevents excessive heating and reduces tool wear |
Feed Rate | 0.08–0.12 mm/rev | Ensures smooth cutting and reduces work hardening |
Coolant | Flood coolant or air blast | Reduces heat buildup and assists in chip removal |
Copper C510 Cutting Parameters (ISO 513 Compliance)
Operation | Speed (m/min) | Feed (mm/rev) | Depth of Cut (mm) | Coolant Pressure (bar) |
|---|---|---|---|---|
Roughing | 80–120 | 0.10–0.15 | 2.0–3.0 | 25–40 |
Finishing | 120–150 | 0.05–0.08 | 0.5–1.0 | 30–50 |
Key Features and Applications for Copper C510 (Phosphor Bronze)
Machining Process | Function and Benefit for Copper C510 (Phosphor Bronze) |
|---|---|
Achieves tight tolerances for high-strength mechanical components. | |
Ideal for producing complex parts such as gears, springs, and bearings. | |
Suitable for turning cylindrical parts with high dimensional accuracy. | |
Processes precise holes for connectors and high-performance mechanical parts. | |
Ideal for internal bore machining with tight tolerances and smooth finishes. | |
Provides fine surface finishes for mechanical and electrical components. | |
Ideal for producing complex parts with intricate geometries and precise features. | |
Delivers tight tolerances for parts exposed to high mechanical stress. | |
Used for creating intricate features and small-scale components in mechanical assemblies. |
Surface Treatment for Copper C510 CNC Parts
Electroplating: A nickel or gold coating is added for enhanced corrosion resistance and durability in marine environments.
Polishing: Achieves smooth, glossy finishes with Ra 0.2–0.4 µm for improved electrical conductivity and aesthetic appeal.
Brushing: Provides a uniform satin finish ideal for decorative parts and mechanical components.
PVD Coating: Adds a durable 2–5 µm coating to protect against wear and corrosion in heavy-duty applications.
Passivation: Enhances corrosion resistance, especially in industrial and marine environments, prolonging the life of the parts.
Powder Coating: Provides a uniform 50–100 µm protective coating for enhanced UV and weather resistance.
Teflon Coating: Adds a low friction, chemical-resistant layer ideal for sliding mechanical components.
Chrome Plating: Adds a 10–20 µm shiny, durable finish for high-load applications requiring corrosion resistance.
Industry Applications of Copper C510 (Phosphor Bronze)
Aerospace Industry: Copper C510 produces high-performance electrical connectors and switches in aerospace applications.
Electrical & Power: Ideal for power generation equipment, including electrical busbars, connectors, and switches.
Automotive Industry: Used in automotive systems for electrical contacts, terminals, and other components in high-current applications.
FAQs
What are the advantages of using Copper C510 in high-strength electrical applications?
How does Copper C510 compare to other copper alloys regarding machinability and wear resistance?
Can Copper C510 be used for automotive electrical connectors?
What are the best surface treatments for Copper C510 to improve its durability and performance?
How does Copper C510 perform in high-temperature and high-stress environments?
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