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CAL C900 is Copper Nickel Chromium Silicon alloy which can be heat treated by means of precipitation hardening to produce high strength and a range of thermal conductivity properties to accommodate a range of applications.

CAL C900 is the highest strength of this family of alloys close to Beryllium Copper (CuBe/BeCu) with the added advantage of greater hardness retention at elevated temperature which is important for high speed production for injection moulding applications.

Tests have shown that it is more than 4 times more conductive than 420 stainless steel, when used in injection moulding equipment and 25% better than CuBe.

The alloy also maintains its hardness and mechanical strength at higher temperatures and for longer periods than Beryllium Copper. (See graphs below).

Beryllium Copper starts to lose hardness rapidly after temperatures exceed approximately 350°C (662°F).

Despite their high strength, all of the Elite Thermal Alloys are completely resistant to hydrogen embrittlement.

They also would be an excellent choice for aggressive marine environments, possessing excellent corrosion resistance.

Mechanical & Conductivity Properties

Copper-Nickel-Chromium-Silicon-Alloy

CuNi2SiCr

Table 1 - Typical Mechanical and Conductivity Properties

Mechanical and Physical properties	Units	CAL C900	CuBe2
Tensile Strength Rm	N/mm² Ksi	938 136	1206 175
Yield Strength Rp 0.2%	N/mm² Ksi	820 119	1034 150
Elongation	%	5	5
Hardness Brinell	HB30	250	365
Rockwell Hardness	HRC	31	39
Electrical Conductivity	% I.A.C.S.	30	22
Thermal Conductivity 20ºc/68ºF	W/mK Btuft /hr.ft².ºF	156 90	113 65

Rod, Bar and Tube for Standard Tempers

Applications

Carefully controlled adjustments in composition and process parameters result in the three distinct Elite Thermal Alloys. This gives designers the opportunity to optimise material selection for their particular applications.

Marine applications requiring high strength coupled with excellent corrosion resistance.
Aerospace components, such as landing gear bushings and sleeves and bearing retainer rings. .
It can be used in the manufacture of mould components for the plastic, Zinc and Aluminium injection die casting market where its high heat conductivity over conventional tool steels offers distinct advantages for high production rates.
The alloy is utilised extensively in the motor racing circuit for valve guides and valve seats where high strength, wear and conductivity are important properties.
It is also used for electrical application in welding, for electrode holders, spot electrodes, projection and butt welding dies principally for stainless steel and Monel.
Other electrical applications include heavy duty switch gear components where greater strength is required than conventional high conductivity copper.
For high stressed structures and wear resistant parts such as bevel gears, worm wheels, valves, bolts and general fasteners.

Chart 1 - Effect of temperature on the Electrical Conductivity

Copper Alloys Ltd has expert Metallurgists who oversee the processes from casting through forging, rolling and heat treatment to control the precipitation of Ni2Si, which ultimately determines the optimum mechanical properties.

This family of alloys, in addition to its corrosion resistance in sea water it can be used in most industrial atmospheres and can be used for components coming into contact with non-oxidising acids and salt solutions.

They can also be used at sub zero temperatures where it does not suffer with embrittlement at low temperatures as do many of the steels.

They can be machined to a high tolerance and surface finish and are much easier to process then some of the harder tool steels.

Availability and Formats

The Elite Thermal Alloys can be supplied in the form of forgings, rounds, blocks, rings and tube to a maximum piece weight of 6000kgs.

The product can also be supplied in bar form in standard lengths.

Copper Alloys is experienced in fully machined components designed for the most extreme engineering applications and can support with turnkey precision machined components.

The Elite Alloys come in three groups:

Bars (square/flat/round) from 10mm to 500mm (0.375"-20") in section
Forgings (to 5 Tonnes): Blocks/Rings to 2400mm (8ft) outer ø / Shafts to 7M (23ft) long / Discs to 1250mm (50") ø
Proof machined or fully machined components

Chemical Composition

Copper-Nickel-Chromium-Silicon-Alloy

CuNi2SiCr

Table 2 - Elite Thermal Alloy Chemical Composition (weight percentage)

Alloy	Copper Alloy UNS Number	Cu	Ni	Si	Cr
CAL C900	None – new technology	Bal	6.0-8.0	1.5-2.5	0.5-1.5

* For reference only - does not form part of the acceptance criteria unless agreed.

Hardening Mechanism

Highly Engineered Alloys for Extreme Environments

Scientific control of precipitation hardening particles from solution enable extreme hardness to be achieved without impacting conductivity.

For most other alloys, there is a compromise between the two, for the first time, the Elite Thermal Alloys, in particular CAL C900 possesses both. The increased conductivity is enhanced by primary and secondary precipitating mechanisms.

The ageing for CuNiSiCr C900 is very complex and there are two hardening mechanisms precipitation hardening by the formation of Ni2Si,Cr3Si and Cr5Si2 and spinodial decompostion. Through precise control of ageing temperatures, Copper Alloys Ltd can maximise the electrical and thermal conductivity properties using both hardening mechanism whilst still achieving the highest mechanical properties.

The comprehensive employment of highly engineered process technology is revealed by the ability of CAL C900 to maintain its hardness at elevated temperatures, as shown in the charts below.

Chart 2 - Hardness Curve verses Temperature

At 550°C (1022°F) Beryllium copper has a rapid decline in surface hardness after only 30 minutes at temperature resulting in its hardness and tensile properties falling below that of CAL C900.

Chart 3 - Hardness Curve at 550ºc (1022ºF) in relation to time

This is vitally important at the mould, molten metal interface which can reach high temperatures particularly with high throughput rates.

Physical Properties

Copper-Nickel-Chromium-Silicon-Alloy

CuNi2SiCr

Table 3 - Physical Properties of Elite Thermal Alloys

Mechanical and Physical properties	Units	CAL C900 CuNi7Si2Cr	CuBe2
Youngs of elasticity	N/mm² Ksi	151 x10³ 22x10³	132 x10³ 19.2 x10³
Modulus of Rigidly	N/mm² Ksi	680x10² 99x10²	489 x10² 71 x10²
Compressive strength 0.1% perm set	N/mm² Ksi	710 103	896 130
Density ρ	g/cm³ lbs/in³	8.69 0.3140	8.25 0.3
Coefficient of expansion α 20-300°C	10ˉ6 /K 10ˉ6 /F	15.7 8.7	18 10
Thermal Conductivity 200ºc/392 ºF	W/mºK Btuft /hr.ft².ºF	200 116	138.5 80
Electrical Conductivity	m/Ω.mm² in/ Ωin²	17.4 685	11.6 457
Electrical Resistivity	μ Ωcm μ Ωin	5.7 2.2	8.6 3.4
Specific Heat	20ºC J/kg/°K BTU/lb°F	377 0.09	419 0.1
Magnetic Permeability	μr	<1.001	<1.001
Melting Point	ºC ºF	1040-1060 1904-1960	866-982 1590-1800

Additional information can be provided upon request

Corrosion Resistant

High resistance to seawater corrosion and industrial atmospheres.
Excellent all-round corrosion resistance.
Immune to hydrogen embrittlement.

Mechanical Properties

Copper-Nickel-Chromium-Silicon-Alloy

CuNi2SiCr

Table 1 - Guaranteed Minimum Mechanical Properties

Properties	Units	Guaranteed	Typical
0.2% Proof Stress	N/mm² Ksi	820 119	820-870 119-126
Tensile Strength (UTS)	N/mm² Ksi	900 131	900-965 131-140
Elongation	%	5	5-8
Hardness	HB	250	250-285

Every batch of forgings is certified to BS EN 10204.3.1 as standard using prolongated test pieces selected from each batch of forgings.
All material can be supplied ultrasonically tested to international requirements.
Copper Alloys manufactures a number of alloys in the CuNiSi family which exhibit varying properties of strength and conductivity to suit customer’s requirements.

Inspection and Certification

Full chemical analysis performed on every cast to ensure compliance with table 1.

Each batch (same size/same cast/same process-run) is mechanically tested to ensure compliance with minimum mechanical property requirements in table 2, which exceed the generic specification requirements.

100% ultrasonic inspection as standard - most test standards and acceptance criteria can be accommodated. Certification provided as standard in both wet-signed and electronic form (soft-copy) in accordance with EN 10204 type 3.1. 3.2 Certification can also be provided.

Detailed Specifications

Copper-Nickel-Chromium-Silicon-Alloy

CuNi2SiCr

Table 2 - Detailed Specifications

Specification	CAL C900 CuNi7Si2Cr
UK
EUROPEAN
GERMANY
USA	RWMA Class 4

Characteristics

High Strength
Can be manufactured to a range of high strength properties depending on the customer’s requirements.
High hardness
High modulus of elasticity compared with other copper based alloys.
No embrittlement at sub-zero temperatures.
Corrosion Resistant
High resistance to seawater corrosion and industrial atmospheres.
Excellent all-round corrosion resistance.
Immune to hydrogen embrittlement.

High Conductivity
Exhibits both high heat and electrical conductivity properties.

Biofouling resistant
Effectively resists the deposition and build-up of marine organisms.
Low Magnetic Permeability
Virtually non-magnetic.
Excellent anti-galling and wear resistant properties Very resistant to pick-up even against stainless steel.

Good machinability
Easily machined to an extremely fine finish and close tolerances.
Good dimensional stability.
Non Sparking
An important property when the component is in contact with potentially explosive environments.
Uniform Fine Grain Structure
Detailed ultrasonic inspection - most ultrasonic procedures / acceptance criteria accommodated to ensure material is sound.
Uniformity of mechanical and physical properties.

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CAL C900 is Copper Nickel Chromium Silicon alloy which can be heat treated by means of precipitation hardening to produce high strength and a range of thermal conductivity properties to accommodate a range of applications.

Mechanical & Conductivity Properties

Table 1 - Typical Mechanical and Conductivity Properties

Applications

Chart 1 - Effect of temperature on the Electrical Conductivity

Availability and Formats

The Elite Alloys come in three groups:

Chemical Composition

Table 2 - Elite Thermal Alloy Chemical Composition (weight percentage)

Hardening Mechanism

Chart 2 - Hardness Curve verses Temperature

Chart 3 - Hardness Curve at 550ºc (1022ºF) in relation to time

Physical Properties

Table 3 - Physical Properties of Elite Thermal Alloys

Corrosion Resistant

Mechanical Properties

Table 1 - Guaranteed Minimum Mechanical Properties

Inspection and Certification

Detailed Specifications

Table 2 - Detailed Specifications

Characteristics

Download CAL C900 Datasheet...

Keep up to date with the latest metallurgy

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