THE PRESENT INVENTION relates to a corrosion resisting copper alloy and more particularly to a corrosion resist¬ ing copper alloy specially suitable for use with a heat exchanger and the invention also relates to heat exchangers using such an alloy. Such heat exchangers may be intended to be used under severe corrosive conditions and may, for example , be heat exchangers for heating cooling water for automobile engines or heat exchangers intended for industrial use. In general, heat exchanger used for cooling water for use in connection -with automobile engines, which are generally termed "radiators" , are composed of a brass material which comprises 65 per cent copper by weight and 35 per cent zinc by weight. It is to be apprecia ed that when an automobile is in use the heat exchanger may be affected directly by harmful elements contained in exhaust gas emanating from the automobile, or other automobiles running on the same road, and also such a heat exchanger may be affected by salinity when the automobile is used near the sea shore. Additionally the heat exchanger is always in contact with the heat exchanging media circulating therein, and such a heat exchanging media may be corrosive, particularly if the heat exchanging media contains anti-freeze components. Thus heat exchangers of the type under the discussion are frequently used under severely corrosive conditions. A heat exchanger such as an automobile radiator operates by circulating a heat exchanging medium through a large number of tubes, and during the circulation of the heat exchanging medium heat is conducted to heat radiating

fins which are in thermal contact with the tubes. Therefore, in order to ensure that there is sufficiently good heat conductivity between the interior of the tubes and the fins it is preferred to make the tubes with walls that are as thin as possible. It is also preferable to make the heat exchanger as light as possible, again by making the walls of the tubes as thin as possible. Not only does this facilitate handling of the heat exchanger but also minimises the amount of material used in making the heat exchanger, and this minimises the costs of the materials itilised.

However, since a heat exchanger is made of brass will corrode (by means of the so-called dezincifying corrosion) under the above mentioned severe corrosive conditions, there is a minimum practical thickness for the tube walls when the tubes are made of conventional brass and thus th.ere.is a minimum practical limit to the improvement of heat conductivity and the saving of material cost that can be effected by minimising thfe thickness of the tube walls.

The present invention seeks to provide a copper alloy which has a very high corrosion resistance which will thus facilitate the manufacture of heat exchangers having tubes with thinner walls than heretofore. It is also an object of the invention to provide such a heat exchanger.

According to the broadest aspectof this invention there is provided a copper alloy exhibiting corrosion resisting prόperties, said copper alloy comprising copper and zinc, characterised in that said alloy comprises 25 to 30 per cent zinc by weight of the alloy, 0.005 to 0.0 per cent phosphorus by weight, the rest of the alloy comprising copper, the recrystaUised grain size of the alloy being within the ränge of 2μ to ^• 10u inclusive.

According to another aspect of this invention there i provided a heat exchanger which comprises a plurality of

tubes in which a heat exchanging medium may flow and which are composed of a copper alloy exhibiting corrosion resisting properties comprising copper and zinc characterised in that said alloy comprises 25 to 3-0 per cent zinc by weight of the alloy, 0.005 to ^■ 0.04 per cent phosphorus by weight, the rest of the alloy comprising copper, the recrystaUised grain size of the alloy being within the ränge of 2u to 10 μ. inclusive. Such a heat; exchanger may be used as a heat exchanger for cooling a fluid heat exchange medium for an internal combustion engine.

In order that the invention may be more readily understood and so that further features thereof may be appreciated the invention will now be described by way of example with reference to the accompanying drawings in which:

FIGURE 1 is a graphical figure illustrating the. ma ^~ ximum depth of corrosion of various copper zinc alloys, not being alloys in accordance with the invention;

FIGURE 2 is a graphical representation showing the maximum depth of corrosion in a copper zinc alloy relative to the quantity of phosphorus contained within the alloy; FIGURE 3 is a graphical representation illustrating the maximum depth of corrosion in a copper zinc alloy which does not contain phosphorus relative to the recrystaUised grain size of the alloy;

FIGURE is a graphical figure showing the inter relation between the maximum depth of corrosion of copper zine alloys and the quantity of phosphorus contained in the alloy, showing the effect of specific recrystaUised grain sizes;

FIGURE 5 is a graphical figure showing the relation between the x*ecrystalised grain size and Vickers hardness of an alloy comprising only zinc and copper.

FIGURE 6 is a front view, partially cut away showing one embodiment of a heat exchanger in accordance with the

present invention;

FIGURE 7 is a photo-micrograph showing a cross section of an element made of an alloy in accordance with the present invention; FIGURE 8 is a graphical diagram illustrating the number of. corrosion holes formed in heat exchangers in accordance with the present invention and in conventiona prior jroposed heat exchangers;

FIGURE 9 is a micro photograph showing plug dezinc- ification corrosion of analloy;and

FIGURE 10 is a micro photograph showing laminar dezincification corrosion of an alloy.

Referring now to the accompanying drawings in Figure 1 to 4 show- the results of corrosion tests conducted firs with alloy materials which comprise merely copper and zinc and secondly with alloy materials which comprise copper, zinc and phosphorus, the tests being carried out for 30 days consecutively according to the JISZ 2371 - salt water spray testing meth.od.2ieah/case. the alloy material used in the test is of rectangular shape having a length of 100 mm, a width of 20 mm and a thickness of 0.5 nun. Thesalt water used in these tests is a 5 by weight NaC1 solution at 3 C. The maximum depth of corrosion shown in each of Figures 1 to 4 shows the deepest corrosion of the corroded parts relative to the original surface of the alloy material.

Initially considering Figure 1 , it is to be noted that the alloy material subject to the test does not contain phosphorus, brfc has a recrystaUised grain size of 10 u. The relation of the maximum depth of corrosion is plotted relative to the quantity of zinc contained within the alloy. It can be seen from Figure 1 that the greater the quantity of zinc, the deeper the corrosion depth becomes, and after the quantity of zinc exceeds 38 in the alloy the so-called B phase is educed in large quantities, with the result of lower corrosion resistivit and lower cold-workability of the material. On the other

hand, whilst the smaller the quantity of zinc, the less the corrosion of the material, the higher quantity of copper brings about a higher manu acturing cost and the excellent characteristics peculiar to brass are lost. Therefore experience has shown that the quantity of zinc present in the alloy should not be lower than 25 by weight, and thus it can be seen that it is most desirable for the quantity of zinc within the alloy to be within the ränge of 25$ by weight to 8$ by weight, and the optimum compromise between cost corrosion resistance is found in the ränge of 25$ to 30$ by weight.

Figure 2 illustrates the relationship between the quantity of phosphorus contained within the alloy and the maximum depth of corrosion, the maximum depth of corrosion being plotted against the percentage by weight - of phosphorus. In Figure 2 the quantity of zinc in the alloy is aintained at a constant 35$ by weight, but it will be appreciated that the quantity of copper varies inversely with the ^" quantity of phosphorus. The recry- stalised grain size of the samples tested to form the graph of Figure 2 was set at 10 u.

From Figure 2 it can be seen that the corrosion resisting effect of the material varies over a relatively wide r nge with the maximum depth of corrosion falling rapidly from a maximum when no phosphorus is present until a phosphorus content of approximately 0.005$ by weight is reached, the corrosion resistance then tailing off. It is to be noted that after a phosphorus content of 0.01$ by weight has been reached the addition of further phosphorus does not significantly alter the maximum depth of corrosion. It has been found that the increase in the quantity of phosphorus above 0.01$ by weight does slightly increase the resistivity to corrosion but if the quantity of phosphorus exceeds 0.04$ by weight grain boundary corrosion is liable to occur at the crystal grain boundaries which constitute the alloy. Thus it is preferred that, in the alloy in accordance with the invention, the

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quantity of phosphorus is within the ränge of 0.005$ by weight to 0.04$ by weight, and must preferably within the ränge of 0.01$ to 0.04$ by weight.

Figure 3 is a further graphical figure illustratin the -relation between the recrystaUised grain size of the alloy and the maximum depth of corrosion. In this figure the material tested dddnot contain any phosphoru and is thus not a material in accordance with the invention. The material comprises merely 35$ by weight zinc and 65$ by weight copper.

From Figure 3 i"t can be seen that, in general, the smaller the recrystalised grain size, the less the dept of maximum corrosion. This is as a consequence of the mechanism of dezincification corrosion which will be explained below in more detail. In connection with the corrosion of brass by dezincification it has been known that two types of dezincification, termed plug dezinci ication and laminar dezincification, may occur. Figures 9 and 10 are, respectively, microphotographs of sections cut through elements of brass alloys that have been corroded by these two types of dezincificatio Figure 9 illustrates an element that has been corroded plug dezincification, and as can be seen from Figure 9 the corrosion progresses unevenly and tends to form pin holes through the corroded element. Corrosion of this type is most undesirable in connection with the tubes of a heat exchanger, since such corrosion can rapidly result in water leakage. On the other hand, in laminar corrosion, the material corrodes evenly, and there is no the same tendency to -form pin holes. Thus, whilst clea it would be preferred that if dezincification is to occur the dezinci ication should be laminar dezincifica no specific way has previously been proposed to make th brass dezinci y in a laminar manner rather than in a plug manner.

However, the present applicants, after the microsco examination of many corroded elements, and appropriate

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experimentation have now determined that by making the recrystalized grain size of the alloy very fine, the form of dezincification can be changed gradually from plug corrosion to laminar corrosion, with the consequent result that the maximum depth of corrosion can be minimised if an Optimum recrystaUised gran ^' size is used. Thus, the finer the recrystaUised grain size, the better the alloy, but it has also been found that if the recrystaUised grain size is selected to be less than 2μ recrysta_Hisatipn is often not completed by the final heat treatment and the initial processed construction of the alloy remains since all the alloy is not recrystalB-sed, with a resultant lowering of corrosion restivity. Thus it is thought proper that lowest limit of the recrystaUised grain size should be 2u.

Figure 4 further illustrates the relation between the quantity of phosphorus contained in the alloy and the recrystaUised grain size of the material on the maximum depth of corrosion. It is to be noted that in Figure 4 the quantity of zinc contained within the various alloys tested in a constant 35$ by weight, but the quantity of copper varies inversely with the quantity of phosphorus. Figure 4 shows that in the case where the recrystaUised grain size of the material is constant, there is only a very little advantage to be obtained by adding more than 0.01$ of phosphorus to the material. However Figure 4 does make it clear that the maximum depth of corrosion is reduced with finer recrystalxsed grain sizes. As can be seen most clearly in Figure 8, which should be read in conjunction with Table 2 as explained below, the most advantageous material can be obtained when the alloy includes a quantity of phosphorus between 0.005 and 0.004$ by weight and when the alloy has recrystaUised grains of a size less than 10 μ. Thus, it is to be noted that the upper bound of the recrystaUised grain size should be 10 μ, but most preferably the recrystaüsed grain

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size should be within the ränge of 3 ) *o 6 JJ.

Figure 5 is a graphical representation showing the relation between the recrystaUised grain size and the Vickers hardness of an alloy material. The alloy material in question is composed of 35$ by weight and 65'fc copper by weight. As can be readily appreciated from Figure 5 the smaller the recrystaUised grain size the better the hardness of the material.

It is to be noted that the recrystaUised grain size of an alloy in accordance with the present invention can be ad usted by a usting the annealing conditions, that is to say the temperature of the annealing process and the time of the annealing process of the alloy material. Figure 6 illustrates, by way of example, a heat exchanger made from the above described alloy material in accordance with the present invention. The heat exchanger comprises a number of parallel tubes 1 which are associated with a heat radiating metal fin 2. The tubes are made from the above described alloy in accord¬ ance with the present invention. The tubes are arranged in spaced parallelism between a header tank 3 _> which has an associated inlet pipe 4, and which has a core plate 5 which connects the tank to the tubes 1. The tubes are also connected to a sump tank 6 which has an outlet 7 _» and which also has a drain plug 8. The sump tank 6 is connected to the tubes 1 by means of a core plate 9 which corresponds with the core plate 5 - The header tank 3 is provided with a filier spout 10 which is provided with a cap 11. The radiator assembly is provided with fixing brack-ets 12.

It is to be appreciated that the general constructio of the radiator is conventional, but the material utilise for forming the tubes 1 is novel. The header and sump tanks 3 and 6 and the associated inlet and outlet pipes

4 and 7 may be made of brass, but may alternatively be' mad of thermosetting resin. It is to be appreciated that sinc

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the tahks and the inlet and outlet pipes have no relation to the thermal radiation capabilities of the heat exchanger they can be of any desired thickness to resist corrosion, and thus it is preferred that the tanks and the pipes be made from pure brass from the point of view of minimising cost. However the alloy of the present invention may, if desired, be utilised to form the tanks and the inlet and outlet pipes.

It is to be appreciated that the fin 2 is preferably made of copper, but fins other than those having the wavy form shown in Figure 6 may be utilised. Thus, for example, plate-like fins may be used. ^" When using such plate-like fins they may be fitted mechanically to the tube 1 by.locating the tube through apertures in the plate-like fins and expanding the outside diameter of the tube by utilising a conventional tube expanding method. This method is also applicable to the fitting of the tube 1 to the core plates 5 and 9« It is to be appreciated that the various elements of- the illustrated heat exchanger may, where appropriate, be connected to each other by means of soldering, as is conventional. The present invention is described further below with reference to specific examples.

Ingots (22mm thick x 1 0 mm wide x 200 mm long) each of different composition as shown in Table 1 were produced by melting copper at a high temperature, covering the surface of molten copper with charcoal powder in order to prevent oxidation, adding appropriate quantities of zinc and phosphorus thereto to form the appropriate alloy, and casting the resultant alloy into a metal mould. Each of the resultant ingots were scalped, subjected to repeated cycle and intermediary annealing, and then made into 0.5 mm thick plates. The plates were then annealed at a temperature and for a duration as shown in Table 1 to adjust the recrystaUised grain size.

The plates were then cut to form elements having a size of 100 mm in length, 20 mm in width and 0.5 mm in

.

thickness to produce elements of the alloy for testing purposes. Each of these elements were subjected to the salt water spray test utilising 5$ by weight NaC1 solution at 35°C according to JISZ 2371, and subsequently, after the period of 30 days, the depth of corrosion of each sample was measured.

Each of the sample alloys was utilised to form a respective core portion of a heat exchanger such as that shown in Figure 6, each core portion comprising the tubes i and the fins 2. In each case the core portion had an overall length, in the axial direction of the tubes 1, of 150 mm, a width of 70 mm and a thickness of 32mm. The core included two rows, each row containing 5 tubes, and thus the overall tube length in the core portion was 1500 mm. These core portions were each then subjected to a salt water spray test for 8 consecutive days and the number of corrosion holes, including corrosion holes that fully penetrate the tube and those corrosion holes that partially penetrate the tube was determined. ¥ith regard to the soldering properties, the surface of a sample element of each alloy having a thickness of 0.5 mm a width of 5 mm and a length of 50 mm was cleaned. The element was then dropped in a bath of molten solder comprising 20$ by weight tin and 80$ by weight led maintained at a temperature of 300 C. The element was left for 10 seconds immersed at a depth of 2mm in the bath and the maximum adhesion force, the force required to pull the material from the solder bath, at that time was measured. The recrystaUised grain size is shown in Table 1 were obtained by compari.son with a Standard photograph according to JISH 0501.

RecrystaUised grain sizes were obtained by comparison with the Standard photograph according to JISH 0501.

No. όf holes

Depth of (pcs./

Anneal¬ Recrys— Sold¬ corro¬ 1500mm)

Composi¬ ing talized ering sion after tion of condi- grain pro- (μ) 8 day ' alloy tion size perty after the

Sam¬ ($)(rest Temp (p) (mg wt )30 day salt ple Cu) (°C) salt water

No. Zn P (time = water spray 30 min) spray test test

1 24 0.019 400x30 5 300 27 2 2 25 5 305 28 2

3 27 350x30 3 300 30 2

4 27 ^• 400x30 7 310 31 2

5 27 420x30 9 305 33 2 6 27 450x30 10 320 3h 2

7 27 500x30 19 310 50 6 8 29 400x30 7 310 30 2

9 30 5 305 31 2

10 33 0 016 6 300 30 2 11 35 Ö 001 5 310 75 15 12 35 0 0025 7 305 60 10

13 35 0 005 6 305 32 2 14 35 0 011 6 300 30 2

15 35 0 019 6 305 32 2 16 35 0 025 5 305 31 2

17 35 0 04 6 310 30 2 18 35 - 5 315 80 20

19 35 - 500x30 20 305 120 22 20 3 ^β 0.017 400x30 5 310 33 2 21 37 0.019 5 315 3h 3- 22 38 0.019 5 310 50 7

23 4θ 0.019 5 305 150 30

As can be seen from the above Table 1 alloys accor¬ ding to the invention, listed as alloys .2 to 6, 8 to 10, 13 to 17 and 20 to 22 have soldering properties which are equivalent with the soldering properties of conventional brass as exemplified by alloys 18 to 19, whilst the. alloys in accordance with the invention exhibit corrosion properties such that the salt water spray test only corroded the alloy to a very slight OMPI

depth. Thus it will be appreciated that examples of alloys in accordance with the present invention have excellent corrosion resisting properties. On the other hand, alloys which have a composition similar to that of the present invention but which have recrystallized grains of a larger size than 10 μ for example comparitive alloy No.7 _» exhibit deep corrosion after being subjected to the salt spray test. Comparative alloys which contain only a very small quantity of phosphorus for example the comparative alloys specified as sample No.11 and that specified as sample No.12 have inferior corrosion resistance properties. It is to be noted that the comparative alloy, shown as sample No.23, which contains a large quantity of zinc, exhibits for inferior corrosion resistive properties.

As can be seen from Table 1 when core-portions made from alloys in accordance with the invention were subjected to the 8 day salt water spray test, the tubes exhibited a fewer number of corrosion holes than the number of corrosion holes exhibited by corresponding core portions fabricated from conventional alloys. It is to be noted that the alloy itemised as sample No.1 in Table 1, which is outside the scope of the present invention, does show fewer corrosion holes, but it is to be noted that this alloy contains a large quantity of copper and it is thus very expensive.

Figure 7 is a photomicrograph (lOO magnifications) showing a cross section of material corresponding to alloy 15, that is to say a material in accordance with the presen invention.

Subsequent investigations were made into the progress of the number of corrosion holes according to the number of days of salt water spray testing, and again core portions fabricated as described above were utilised. Table 11 shows the composition of the five alloys that were subjected to this investigation,and Figure 8 shows that the results of the investigation.

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Composition of Symbol alloy $ Recrys- Remark tallised P Zn Cu grain size

Cx 0 35 rest Comparative Alloy o 15

0 tl II 3 II II

▲ 0.021 II II 8 Alloy of the present invention

* 0.021 II II 3 ιι ιι

-\, 0.011 It II 3 ιι ιι

As can be seen from Figure 8 in each case four samples of each of the 5 alloys were utilised, and thus 20 samples were utilised, and thus 20 samples were utilised in all. It can be seen that after 2 days of spraying all 20 samples showed no signs of corrosion. After 4 days of spraying all four samples of an alloy having recrystaUised grains of a relatively large size showed signs of corrosion. After 6 days the corros¬ ion of these four samples were substantialj and also a second alloy, which does not contain any phosphorus, was also showing signs of corrosion. As the test proceeded the alloys having large grain sizes and having no phos¬ phorus showed maxium corrosion, whereas alloys in accordance with the present invention showed minimum corrosion and indeed, of the 12 samples of alloys in accordance with the invention tested, after 12 days seven samples showed no signs of corrosion.

From the foregoing paragraphs it will be appre¬ ciated that the present invention provides a copper alloy which displays excellent corrosion resistivity even when exposed to severely corrosive conditions. Also, by utilising a copper alloy in accordance with the present invention as a material for the tubes of a heat exchanger, the present invention makes it possible to utilise tubes having relatively thin walls for a heat exchanger with a resultant improvement of heat con¬ ductivity and with the important advantage that the heat exchanger is of light weight, and thus utilises a minimum amount of material

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and can consequently be fabricated at a relatively low cost. However, the thinness of the walls of the tubes made of copper alloy in accordance with the invention does not reduce the strength of the tubes or the corrosio resistivity of the tubes, as a result of the fine recrystaUised grain size of the alloy.