CuSn5Zn5Pb5C (CC491K) EN 1982 bronze Bearings

QSn5-5-5 Bronze Bearing Material: Detailed Analysis of H5111 (CAC406/B30-92/C93200/DIN1705/G-Cu5n5ZnPb/2.1096)

Oilless Die Components CuSn5Zn5Pb5C (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 QSn5-5-5 bronze alloy, widely recognized by standards such as H5111, CAC406, B30-92, C93200, 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.

ZCuSn5Pb5Zn5 is a cast copper alloy known for its excellent wear and corrosion resistance.

Material Name: Cast Copper Alloy (5-5-5 Tin Bronze, Sand and Metal Casting)

Grade: ZCuSn5Pb5Zn5

Characteristics and Applications:

The ZCuSn5Pb5Zn5 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

Mechanical Properties (Min. Values)

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

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

Our Company Material Code	Chinese Grade (GB1776-87)	Equivalent Foreign Grade	Applicable Conditions
International (ISO 1338)	China	Japan	USA
500#SP	CuZn25Al6FeMn3 (Soft)	CuZn25Al6FeMn3 (Soft)	H5102
500#SP1	CuZn25Al6FeMn3 (Hard)	CuZn25Al6FeMn3 (Hard)	H3102
500#SP5	CuZn25Al6FeMn3 (Very Hard)	CuZn25Al6FeMn3 (Very Hard)	H3102
–	CuAl10Fe3	CuAl10Fe3	H5114
–	CuSn5Pb5Zn5	QSn5-5-5	H5111

Solid Lubricants

Solid Lubricant	Characteristics	Typical Application
SL1	High-purity graphite + additives	Very good wear resistance and chemical stability, operating temperature < 400°C
SL4	PTFE + additives	Extremely low coefficient of friction and excellent water lubricity, operating temperature < 300°C

Additional Notes:

• 500#SP, 500#SP1, and 500#SP5 seem to be specific material codes possibly utilized within a particular company or context. They represent variations of the CuZn25Al6FeMn3 alloy, differing in hardness levels (Soft, Hard, and Very Hard respectively).
• SL1 and SL4 refer to specific types of solid lubricants, each with their own characteristics and typical applications, offering different performance aspects in terms of wear resistance, chemical stability, friction coefficient, and water lubricity.

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 QSn5-5-5 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 QSn5-5-5, 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 QSn5-5-5 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 QSn5-5-5 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 QSn5-5-5 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 QSn5-5-5 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

QSn5-5-5 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.

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