Wires made of copper-based alloy compositions

Abstract

Wires made of copper-based compositions are disclosed, in which the compositions preferably contain aluminum, tin, and silicon. Formulations containing solely tin and aluminum, and solely tin and silicon are also disclosed. By practice of the invention, substantial improvements in bond strength and quality of the surface finish are achieved, as compared with prior art wire compositions.

We claim: 
     
       1. A flux cored wire for application to essentially bare metal surfaces, said wire being constructed of a copper-base alloy consisting essentially of about 10.0% tin and approximately 6.0% aluminum. 
     
     
       2. A flux cored wired for thermally spraying bare metal surfaces having imperfections therein, said wire being constructed of a copper-base alloy consisting essentially of about 10.0% tin and approximately 6.0% aluminum. 
     
     
       3. A flux cored wire for thermally spraying essentially bare metal surfaces having surface imperfections therein, said wire being constructed of a copper-base alloy consisting essentially of from about 0.5% to about 20.0% tin, from about 0.25% to about 5.0% silicon, and from about 0.5% to about 6.0% aluminum. 
     
     
       4. A flux cored wire as defined in claim 3, in which tin is present in an amount of about 10%, silicon is present in an amount of about 0.25%, and aluminum is present in an amount of about 6.0%. 
     
     
       5. A flux cored wire as defined in claim 3, in which tin is present in an amount of about 0.5%, silicon is present in an amount of about 3.0%, and aluminum is present in an amount of about 0.5%. .Iadd. 
     
     
       6.  A solid wire for application to essentially bare metal surfaces, said wire being constructed of a copper-alloy consisting essentially of about 10.0% tin and approximately 6.0% aluminum..Iaddend..Iadd. 
     
     
       7.  A solid wire for thermally spraying bare metal surfaces having imperfections therein, said wire being constructed of a copper-base alloy consisting essentially of about 10.0% tin and approximately 6.0% aluminum..Iaddend..Iadd. 
     
     
       8.  A solid wire for thermally spraying essentially bare metal surfaces having surface imperfections therein, said wire being constructed of a copper-base alloy consisting essentially of from about 0.5% to about 20.0% tin, from about 0.25% to about 5.0% silicon, and from about 0.5% to about 6.0% aluminum..Iaddend..Iadd. 
     
     
       9.  A solid wire as defined in claim 8, in which tin is present in an amount of about 10.0%, silicon is present in an amount of about 0.25%, and aluminum is present in an amount of about 6.0%..Iaddend..Iadd.10. A solid wire as defined in claim 8, in which tin is present in an amount of about 0.5%, silicon is present in an amount of about 3.0%, and aluminum is present in an amount of about 0.5%..Iaddend.