Corrosion-resistant coated copper and method for making the same

Abstract

A corrosion-resistant coated base metal coated with a corrosion resistant alloy. The corrosion resistant alloy includes tin and zinc. The corrosion resistant coated base metal includes a heat created intermetallic layer primarily including copper and zinc.

1 - 64 . (canceled) 
   
   
       65 . A corrosion-resistant metal strip having a base metal strip coated with a corrosion-resistant metal alloy by a hot dip process, said base metal strip having a surface that includes copper prior to said metal alloy coating being coated on said base metal strip, said metal alloy coating including at least about 15 weight percent tin, and zinc to form at least a two phase metal alloy coating after said metal alloy coating cools on said base metal strip, said tin content plus said zinc content at least about 90 weight percent, said metal alloy coating including at least one metal additive to positively affect the chemical and/or physical properties of said metal alloy coating, said metal additive including a plurality of different metals, at least one metal additive is selected from the group consisting of antimony, bismuth, copper, lead, and mixtures thereof, and at least one other metal additive is selected from the group consisting of aluminum, chromium, magnesium, manganese, molybdenum, nickel, silicon, titanium, and mixtures thereof. 
   
   
       66 . The corrosion-resistant metal strip as defined in  claim 65 , wherein said base metal strip includes a majority of copper. 
   
   
       67 . The corrosion-resistant metal strip as defined in  claim 66 , wherein said base metal strip is a copper strip. 
   
   
       68 . The corrosion-resistant metal strip as defined in  claim 65 , including a heat created intermetallic layer between said metal alloy coating and said base metal strip, said heat created intermetallic layer including a majority of copper plus zinc. 
   
   
       69 . The corrosion-resistant metal strip as defined in  claim 68 , wherein said heat created intermetallic layer includes at least about 75 weight percent copper plus zinc. 
   
   
       70 . The corrosion-resistant metal strip as defined in  claim 65 , wherein said metal alloy coating includes at least about 9 weight percent zinc. 
   
   
       71 . The corrosion-resistant coated base metal as defined in  claim 65 , wherein said metal alloy comprises: 
     
       
         
               
               
               
             
                   
                   
               
                   
                 Tin 
                 15-90 
               
                   
                 Zinc 
                 10-85 
               
                   
                 Aluminum 
                 0-2 
               
                   
                 Antimony 
                 0-2 
               
                   
                 Bismuth 
                   0-1.7 
               
                   
                 Copper 
                 0-2 
               
                   
                 Iron 
                 0-1 
               
                   
                 Magnesium 
                 0-2 
               
                   
                 Nickel 
                 0-2 
               
                   
                 Titanium 
                 0-1