copper & its alloys in aviationmetalworld.co.in/newsletter/2017/oct17/feature.pdf · ·...
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opper, as we all know has been Cused since pre historic times since
4000 BC. Since then advancements in
metallurgy has made it possible to alloy it
with certain other metals to fully exploit its
beneficial properties such as good
conductivity of heat and electricity and
improve those properties which it was
lacking such as hardness. In aviation
Copper and its alloys in (wrought )
are used in Aviation industry in various
forms like Electrical conductors, Winding
wires in numerous electro
pneumatic/hydraulic accessories like
valvesactuators etc, In alloy with other
metals its main application is as
bushings, bearing sleeves. These are used
in numerous assemblies with in the
aircraft and is an important alloy to the
aviation manufacturing industry. The
unique property of high strength ,
excellent bearing characteristic with high
load bearing capability make its
application extensive. These are also used
as hydraulic and fuel line fittings.
Among these alloys, the Age
hardenable alloys like beryllium- copper
provides the highest strength among
copper alloys. Depending on the degree
of cold work, these alloys can attain
strength levels greate than 895Mpa (130
ksi) on precipitation hardening. Copper
Berrylium fabrication requires special
care as its powders are considered a
health hazard.
Copper alloys used In Aerospace
applications are classifed as per the SAE
Aerospace Material Specifications, the AMS
Below are the common AMS
Secifications routinely referenced in the
design drawings.
AMS 4533 (C17200) Beryllium Copper
This copper alloy can have the highest
mechanical properties of all copper alloys.
This alloy also has excellent bearing
qualities with extremely high compressive
strength for high loading applications. It
also has excellent abrasion and corrosion
resistant properties, plus outstanding
cryogenic characteristics (for space
applications).
AMS 4640 'H' (C63000) Nickel
Aluminium Bronze
This is a high strength, tough nickel
Aluminium bronze used where high
mechanical properties are required. This
alloy is a heat treatable Aluminium bronze
containing 5% nickel, that provides
excellent bearing properties with good
corrosion resistance. It is used extensively
for aircraft landing gear bushings,
October 201735
- T. HarilalConsultant
Aircraft Materials & ProcessesEmail : harilal05@gmail.com
Copper & its alloys in AviationCopper & its alloys in AviationCopper & its alloys in Aviation
Feature
Feature
October 201736
Table ICommon classification of Copper alloys ( adapted from ASM handbook )
Common Name UNS Number Composition
Coppers
High-copper alloys
Brasses
Leaded brasses
Tin brasses
Phosphor bronzes
Leaded phosphor bronzes
Copper-phosphorus and copper-silver-
phosphorus alloys
Aluminium bronzes
Silicon bronzes
Other copper-zinc alloys
Copper-nickels
Nickel silvers
C10100-C15760
C16200-C19600
C20500-C28580
C31200-C3890
C40400-C49080
C50100-C52400
C53200-C54800
C55180-C55284
C60600-C64400
C64700-C66100
C66400-C69900
C7000-C79900
C73200-C79900
>99% Cu
>96% Cu
Cu-Zn
Cu-Zn-Pb
Cu-Zn-Sn-Pb
Cu-Sn-P
Cu-Sn-Pb-P
Cu-P-Ag
Cu-Al-Ni-Fe-Si-Sn
Cu-Si-Sn
. . .
Cu-Ni-Fe
Cu-Ni-Zn
Major alloys of copper in use today and compositions of these alloys aregiven in the Table 1 below
Copper alloys are identified and numbered as per the
Unified Numbering System (UNS) as follows
Fig.1 Typical Aircraft parts bushing in C 63000 Ni Al Bronze
Fig.2. Aluminium Bronze Bushingin an aircraft landing gear part
bearings, and other components.
AMS 4881 'D' Continuous Cast
(C95520) Nickel Aluminium Bronze
This alloy is an extra high strength
version of nickel Aluminium bronze. A
special heat treatment process improves
the mechanical properties beyond the
range of commercial Aluminium bronzes.
It is used where parts require extra high
strength and hardness with some ductility
and toughness. Typical applications
include military aircraft bushings involving
heavy loads, abrasion, and high
deformation. The extra high strength
characteristics provide extreme wear
resistance for extreme loads, abrasive
wear, and high impact landings (such as
aircraft carrier landings).
AMS 4616 (C65620) Silicon Bronze
A special high-strength silicon bronze;
the additional iron content provides added
strength in conjunction with the self-
lubricity of the silicon for excellent bearing
and load properties.
AMS 4634 (C64200) Silicon
Aluminium Bronze
This silicon Aluminium bronze
combines the self-lubricity of the silicon
with the higher mechanical properties of
Aluminium bronze and is sometimes used
in place of C63000 where specifications
permit a lower strength material offset by
its lubricity. Typical applications involve
valve stems, gears, wing pylons, bolts,
nuts, bushings and valve body
components.
C67300 (SAE J463, J461)
Manganese Bronze
This is a high strength manganese
bronze with typically good bearing and
self-lubricity properties. This alloy
maintains high impact resistance with good
machinability making it well suited for
clutch bearings, shaft bushings, sleeve
bearings, thrust bearings, pump parts, drive
shafts, bearing pins, wear plates, gears and
cams. Resists squashing out under high
loads and extreme wear applications.
AMS 4862 (C86300)
Manganese Bronze
This cast manganese bronze is
typically supplied in a continuous cast
or centrifugally cast bars and tubes for
high load gear and bearing applications.
This alloy can achieveover 110 KSI
tensile strength and an elongation of
14% minimum. It is excellent for
October 201737
Fig. 2 Disc Spring made of CopperBeryllium alloy
Fig.3. Aircraft Main Landing gearBushing made from Aluminium
Phosphour bronze
applications requiring high strength
metal to metal wear.
AMS 4842 (C93700) High Leaded Tin
Bronze '80-10-10'
This is a high leaded tin bronze used
for high speed and heavy pressure
applications where corrosion resistance is
necessary. The increased lead content
provides added self-lubricity within the
family of tin bronzes and has excellent
machinability.
AMS 4871 (C95400)
Aluminium Bronze '9C’
This is the most popular Aluminium
bronze and is used in a lot of different
industrial applications. This extra tough
bearing material is used for heavy loads
with good resistance to impact and
corrosion. Aluminium bronze has a lot of
good properties and is the most readily
available high strength bearing material.
AMS 4880 'E' Continuous Cast
(C95510) Nickel Aluminium Bronze
These are the most popular landing
gear bushing materials specified today
along with C63000 material. These
continuous/centrifugal cast alloys are heat
treated alloys and exhibit high mechanical
strengths which meet the properties of
C63000 (AMS 4640). In many cases,
C95510 (AMS 4880) can be substituted
for C63000
AMS 4590 (C63020)
Nickel Aluminium Bronze
A special heat treatment process
improves mechanical properties and
strength-weight ratio beyond the range of
commercial Aluminium bronzes. For
applications involving heavy loads,
abrasive wear, friction, deformation and
high temperatures.
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C95500 Nickel Aluminium
Bronze '9D’
C95500 Nickel Aluminium Bronze,
also known as 9D, contains nickel similar
to other grades of high strength Aluminium
bronzes, which makes it one of the
toughest alloys. C95500 Nickel
Aluminium Bronze also has superior
resistance to sea water corrosion, heat
resistance, good machinability, and
weldability. Other benefits are exceptional
yield, compressive strength, high hardness,
and fairly high elongation. This alloy can
also be readily used for all lead-free
applications.
UZ19AL6 Aircraft Bronze
This is a European high strength
bearing bronze which is being used by
Airbus for landing gear components.
UN14ALZ Aircraft Bronze
This non-magnetic alloy has very high
mechanical properties. This alloy is also
resistant to seawater corrosion and to
oxidation. This alloy also has excellent
fatigue resistant properties.
UA11N (CuAl11Ni5Fe5) Nickel
Aluminium Bronze
This Nickel Aluminium Bronze alloy
has high mechanical properties and is
oxidation and corrosion resistant in a
saline mist atmosphere. Mainly used in
the aeronautical industry for pump blocks,
rings, bushings, and in bearings for landing
gears.
SAE 841 (ASTM B-438, B-4831)
Sintered Bronze
This oil impregnated bronze is one of
the finest powder metal bearings on the
market. The sintering process provides
superior strength, reduced coefficient of
friction, and uniform oil coating of the
mating shaft during operation.
C96900 Spinodal Bearing & Bushing
Bronze Systems
This is a high-performance alloy
which can withstand high loads and
operate under severe conditions. An
excellent low friction, non-corrosive
bronze alloy.
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