CuSn5Zn5Pb5C (CC491K) EN 1982 bronze Bearings
85-5-5-5 Bronze Bearing Material: Detailed Analysis of H5111 (CAC406/B30-92/C83600/DIN1705/G-Cu5n5ZnPb/2.1096)
Oilless Die Components CuSn5Zn5Pb5-C (CC491K) EN 1982
CuSn5Pb5Zn5 is a bronze alloy of copper, tin, lead, and zinc, known for its use in casting. It offers excellent wear resistance and load capacity, making it ideal for producing high-quality bearings and valves.
Bronze, mainly composed of copper, is ideal for bearings because of its high load capacity, wear resistance, and anti-friction properties. The 85-5-5-5 bronze alloy, widely recognized by standards such as H5111, CAC406, B30-92, C83600, DIN1705, and G-Cu5n5ZnPb/2.1096, offers unique qualities for specific bearing uses. Let’s explore the characteristics, applications, and benefits of bearings made from this distinctive bronze alloy.
CuSn5Pb5Zn5 is a cast copper alloy known for its excellent wear and corrosion resistance.
Material Name: Cast Copper Alloy (85-5-5-5 Tin Bronze, Sand and Metal Casting)
Grade: CuSn5Pb5Zn5
Characteristics and Applications:
The CuSn5Pb5Zn5 cast copper alloy features good wear resistance and corrosion resistance, is easy to process, and exhibits favorable casting properties and air tightness. It is suitable for use in wear-resistant and corrosion-resistant components that operate under high loads and medium sliding speeds. Typical applications include bearing shells, bushings, cylinder liners, piston clutches, pump covers, and worm gears.
Chemical Composition:
Copper (Cu): Balance
Tin (Sn): 4.0 – 6.0%
Zinc (Zn): 4.0 – 6.0%
Lead (Pb): 4.0 – 6.0%
Phosphorus (P): ≤0.05% (impurity)
Nickel (Ni): ≤2.5% (not included in total impurities)
Aluminum (Al): ≤0.01% (impurity)
Iron (Fe): ≤0.3% (impurity)
Silicon (Si): ≤0.01% (impurity)
Antimony (Sb): ≤0.25% (impurity)
Sulfur (S): ≤0.10% (impurity)
Note: Total impurities ≤1.0%
Mechanical Properties:
Tensile Strength σb (MPa): ≥200
Yield Strength σ (MPa): ≥90
Elongation δ5 (%): ≥13
Hardness: ≥590 HB (reference value)
Heat Treatment Specifications:
Heating Temperature: 1188 – 1220°C
Pouring Temperature: 1150 – 1200°C
Casting Methods:
The alloy can be produced using sand casting or metal mold casting techniques.
Chemical Composition
| Element | Min. (%) | Max. (%) |
|---|---|---|
| Cu | 83.0 | 87.0 |
| Ni | – | 2.0 |
| P | – | 0.10 |
| Pb | 4.0 | 6.0 |
| Sn | 4.0 | 6.0 |
| Zn | 4.0 | 6.0 |
| Al | – | 0.01 |
| Fe | – | 0.3 |
| S | – | 0.10 |
| Sb | – | 0.25 |
| Si | – | 0.01 |
Mechanical Properties (Min. Values)
| Casting Process | Tensile Strength Rm (MPa) | Yield Strength 0.2% Rp0.2 (MPa) | Elongation 5D A (%) | HBW (10-1000) |
|---|---|---|---|---|
| Continuous (GC) | 250 | 110 | 13 | 65 |
| Centrifugal (GZ) | 250 | 110 | 13 | 65 |
Note: The mechanical property requirements apply to sizes up to and including 300 mm external diameter for continuous castings. For larger continuous castings, the requirements should be agreed between the supplier and the purchaser.
Equivalent Specifications
| Standard | Alloy | Status |
|---|---|---|
| BS 1400 | LG2 | |
| DIN 1705 | CuSn5ZnPb (Rg5) | |
| NFA 53707 | UE5 | |
| ASTM B505 | C83600 (SAE 40) | Active |
| ASTM B271 | C83600 (SAE 40) | Active |
| AS 1565 | C83600A | Active |
| JIS H5121 | CAC406C (BC6) | Active |
| JIS H5120 | CAC406 | Active |
| ISO 1338 | CuSn5Pb5Zn5 | – |
Optional Heat Treatments
- Stress Relieve (at customers’ request)
Technical Characteristics
- Good machining properties
- Good self-lubricating properties
- Corrosion resistant
- Working temperature should not exceed 200 °C / 392 °F
Material Grades and Characteristics for Bearings
Base Alloy Grades
| Indian | Grade | Equivalent Foreign Grade | Applicable Conditions |
|---|---|---|---|
| IS 318 | Others | Japan | USA |
| LTB2 | CuZn25Al6FeMn3 (Soft) | CuZn25Al6FeMn3 (Soft) | H5102 |
| 85-5-5-5 | CuZn25Al6FeMn3 (Hard) | CuZn25Al6FeMn3 (Hard) | H3102 |
| - | CuZn25Al6FeMn3 (Very Hard) | CuZn25Al6FeMn3 (Very Hard) | H3102 |
| – | CuAl10Fe3 | CuAl10Fe3 | H5114 |
| – | CuSn5Pb5Zn5 | QSn5-5-5 | H5111 |
This table provides a structured overview of the material grades and their equivalent standards in different countries, as well as specific characteristics and applications of solid lubricants used in bearings. Always ensure to validate and confirm material properties and specifications with detailed material data sheets or through consultation with materials specialists for accurate application in engineering designs and manufacturing.
Characteristics of 85-5-5-5 Bronze Bearings
Material Composition
- Tin (Sn): Offers enhanced wear resistance and reduces friction.
- Phosphorus (P): Improves strength and hardness.
- Zinc (Zn): Augments the alloy’s mechanical properties.
- Lead (Pb): Provides improved machinability and wear resistance.
Tin, phosphorus, and lead, among other elements, are alloyed with copper to create 85-5-5-5, providing a blend that exhibits enhanced mechanical properties and improved machinability.
Mechanical Properties
- Wear Resistance: Tin provides wear resistance, which is critical in bearing applications.
- Strength and Hardness: The alloy exhibits good strength and hardness, ensuring durability and a prolonged operational lifespan.
- Corrosion Resistance: Exhibits good resistance to corrosion, making it applicable in various environments.
- Machinability: Lead enhances the alloy’s machinability, facilitating ease of manufacturing.
Applications of 85-5-5-5 Bronze Bearings
Industrial Equipment
Used in the manufacturing of gears, bushings, and bearings for various industrial machinery due to its wear-resistant properties.
Automotive Industry
Employed in components like bushings and bearings within automotive assemblies due to its durability and resistance to wear.
Marine Applications
Utilized in applications like pump components and valve assemblies because of its resistance to corrosion and wear.
Hydraulic and Pneumatic Systems
Applied in hydraulic and pneumatic systems for components like cylinders and pistons due to its excellent sliding properties and wear resistance.
Advantages of 85-5-5-5 Bronze Bearings
Low Maintenance
The wear resistance and self-lubricating properties minimize the need for frequent maintenance.
Durability
The alloy’s hardness and strength ensure a longer operational lifespan under varied working conditions.
Versatility
With its balanced mechanical properties, QSn5-5-5 bronze bearings can be applied in various industrial applications.
Economical
The durability and low maintenance needs of 85-5-5-5 bronze bearings offer a cost-effective solution in the long run.
Manufacturing Processes
Alloying
The first step involves the precise alloying of copper with tin, phosphorus, zinc, and lead to create the 85-85-5-5-5 bronze alloy.
Casting
The alloy is cast into semi-finished forms using methods like continuous casting or centrifugal casting.
Forming and Machining
Through various forming and machining processes, the semi-finished material is shaped into the desired bearing components.
Heat Treatment
Heat treatment processes like annealing may be applied to enhance specific mechanical properties of the bearings.
Quality Assurance
Quality control measures are implemented to ensure that the final product adheres to the required specifications and standards.
Conclusion
85-5-5-5 bronze, recognized under various designations like H5111, CAC406, B30-92, C93200, DIN1705, and G-Cu5n5ZnPb/2.1096, is a versatile and reliable material in the manufacturing of bearings. With its commendable wear resistance, strength, and corrosion resistance, it finds applications across numerous industries, including automotive, marine, and industrial machinery. These bearings not only ensure smooth operations but also provide durability and reliability, affirming their significance in various mechanical assemblies.
Note: Always consult with a materials engineer or a bearing specialist when selecting bearing materials to ensure they meet the specific requirements and standards of your applications.
CuSn5Zn5Pb5 (2.1096) Base Embedded Solid Lubricants Bearing: A Pivotal Mechanical Component
Introduction
Bearings play a crucial role in mechanical systems by enabling smooth motion and reducing friction between moving parts. CuSn5Zn5Pb5, designated under the identifier 2.1096, is a tin-bronze alloy recognized for its distinctive properties and applications in bearing technology, particularly when embedded with solid lubricants. In this context, we shall explore the characteristics, manufacturing processes, and applications of bearings made from this notable alloy.
CuSn5Zn5Pb5 (2.1096) Alloy: A Snapshot
Composition
- Copper (Cu): Forms the primary matrix, excellentowing excellent conductivity and corrosion resistance.
- Tin (Sn): Provides wear resistance and structural strength.
- Zinc (Zn): Enhances the alloy’s mechanical properties.
- Lead (Pb): Improves machinability and provides supplementary wear resistance.
Noteworthy Properties
- Wear Resistance: Significant resistance to wear, essential for maintaining bearing integrity.
- Corrosion Resistance: Applicable in varied environments due to its ability to resist corrosion.
- Machinability: Lead content ensures ease of machining, facilitating the manufacturing process.
- Strength: Offers substantial structural strength, ensuring durability under load.
Embedded Solid Lubricants Bearing: Key Insights
Significance
Solid lubricant embedded bearings are crafted with lubricant reservoirs or channels filled with solid lubricants like graphite, reducing friction and wear even in challenging working conditions.
Advantages
- Self-Lubricating: Continuous lubrication minimizes maintenance and operational downtimes.
- Enhanced Lifespan: Reduced wear and friction extend the operational lifespan of the bearing.
- Operational in Varied Environments: Effective in environments where liquid lubricants might fail, such as high temperatures or corrosive conditions.
Applications of CuSn5Zn5Pb5 (2.1096) Bearings
Industrial Machinery
Implemented in various machinery due to its wear-resistant and self-lubricating properties, enhancing machinery lifespan and reliability.
Automotive Industry
Used in vehicle components, such as transmission systems and suspension assemblies, offering durability and reduced maintenance.
Marine Engineering
Employed in marine applications for components like propeller shafts and rudder assemblies, due to corrosion resistance and operational reliability in wet conditions.
Aerospace
Utilized in components like landing gear assemblies and actuators, offering robust performance and reliability under high-load conditions.
Manufacturing Process of Embedded Solid Lubricant Bearings
Alloy Production
The alloy is created by melting and combining copper, tin, zinc, and lead in precise proportions to form the CuSn5Zn5Pb5 alloy.
Casting
Using methods such as die-casting or sand casting, the molten alloy is formed into semi-finished bearing components.
Machining
The components are machined to desired dimensions and specifications, ensuring precision in the final product.
Lubricant Embedding
Solid lubricants, typically graphite, are embedded into the bearing surface using various methods, such as grooving and filling or using powder metallurgy techniques.
Finishing
The bearing undergoes finishing processes to enhance surface properties and adhere to specified tolerances.
Quality Control
Rigorous testing and quality assurance processes ensure the final product complies with required specifications and standards.
Primary Base Alloy: Physical Properties and Chemical Composition
| Property/ Base Alloy | High Strength Brass (Very Hard) | High Strength Brass (Hard) | Copper Alloy 1 | Copper Alloy 2 | Copper Alloy 3 |
|---|---|---|---|---|---|
| Cu% (Copper) | 65 | 65 | 85 | 80 | 88 |
| Sn% (Tin) | – | – | 5 | – | 12 |
| Pb% (Lead) | – | – | 5 | – | – |
| Zn% (Zinc) | 25 | – | 5 | – | – |
| Ni% (Nickel) | – | – | – | 5 | – |
| Al% (Aluminum) | 6 | 6 | – | 10 | – |
| Fe% (Iron) | – | – | – | – | – |
| Mn% (Manganese) | 4 | 4 | – | – | – |
| Density (g/cm³) | 8 | 8 | 8.8 | 8.3 | 8.8 |
| Hardness (HB) | >235 | >210 | >70 | >150 | >80 |
| Tensile Strength (N/mm²) | >785 | >750 | >200 | >500 | >360 |
| Elongation (%) | >10 | >12 | 15 | >10 | >8 |
| Thermal Expansion Coefficient (1.9·10⁻⁵/℃) | 1.9·10⁻⁵/℃ | 1.9·10⁻⁵/℃ | 1.8·10⁻⁵/℃ | 1.6·10⁻⁵/℃ | 1.8·10⁻⁵/℃ |
| Temperature (℃) | 300~400 | 300~400 | 400 | 400 | 400 |
| Maximum Dynamic Load (N/mm²) | 118 | 100 | 60 | 50 | 70 |
| Maximum Linear Velocity (m/min) | 10 | 15 | 10 | 20 | 10 |
| Maximum PV (N/mm²·m/min) | 200 | 200 | 200 | 200 | 200 |
| Compression Permanent Deformation (400N/mm²) | <0.005 | <0.01 | <0.05 | <0.04 | <0.05 |
| Friction Coefficient: Oil Lubrication = 0.03, Dry Friction = 0.16 | Applicable for All Entries |
Notes:
- Copper (Cu%): A primary component, offering electrical conductivity and corrosion resistance.
- Tin (Sn%), Lead (Pb%), and Zinc (Zn%): Often used to enhance the alloy’s strength, wear resistance, and machinability.
- Nickel (Ni%), Aluminum (Al%), Iron (Fe%), and Manganese (Mn%): Can improve strength, hardness, and corrosion resistance.
- Density: Refers to the mass per unit volume of the material.
- Hardness (HB): Indicates resistance to indentation or abrasion.
- Tensile Strength: Represents the alloy’s resistance to breaking under tension.
- Elongation: Demonstrates how much the material can deform (stretch) before breaking.
- Thermal Expansion Coefficient: Indicates how much the material expands per degree increase in temperature.
- Maximum Dynamic Load: The maximum load that the bearing can handle under dynamic (moving) conditions.
- Maximum Linear Velocity: Indicates the highest speed at which the bearing can operate.
- Maximum PV: A factor that considers pressure (P) and velocity (V) to determine the maximum permissible value for safe operation.
- Compression Permanent Deformation: Indicates the deformation that remains in the material after unloading under compressive stress.
This table provides a comprehensive overview of the physical and chemical properties of various copper alloy variants utilized in bearing manufacturing. It is essential to select the appropriate material based on specific application requirements, considering factors like load, speed, and environmental conditions. Always ensure to validate material properties with detailed datasheets or specialists for accurate application in engineering and manufacturing.