Dispersion-Strengthened Copper Alloys with Useful Electrical and Mechanical Properties

Dispersion-strengthened alloys have been made which combine a high level of tensile strength at temperatures up to at least 600°C with an electrical conductivity better than that of most precipitation-hardened copper alloys. The reverse gel precipitation process has been used to co-precipitate hydroxides which were then selectively reduced in hydrogen, consolidated under an atmosphere of pure argon, and finally hot-extruded to bar. Copper−3 vol.-% zirconia alloys were prepared in which all the particles were <150 nm dia., while copper–1·5 vol.-% thoria and copper–3 vol.-% thoria alloys were prepared with most particles <50 nm dia. Although the dispersion in the Cu–zirconia alloys was somewhat inferior to that obtained in the Cu–thoria alloys, useful properties were obtained. The Cu–zirconia alloys were as strong as the commercial alloy Cu–1 wt.-%Cr at 500°C and twice as strong at 600°C. There was little difference in the strength of a Cu–1·5 vol.-% thoria alloy and the Cu–zirconia alloys but the former was more ductile. The most interesting properties were obtained from Cu–3 vol.-% thoria alloys which exhibited an electrical conductivity in excees of 90% IACS at 20°C and tensile strength five times that of Cu–1%Cr at 600°C, even after annealing at 600°C for 1 h. The Cu–3 vol.-% thoria alloys were readily cold-worked, exhibited exceptional stability, and were resistant to recrystallization up to 900°C. Grain sizes were of the order of 1·5 μm for unalloyed copper, 1 μm for Cu–1·5% thoria, and 0·5 μm for Cu–3% zirconia or Cu–3% thoria. Grain growth was severely restricted by the dispersions.