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Defects caused by precipitation of in liquid copper–nickel–aluminium–bronze alloys dissolved carbon and removal by treatment of melt

Abstract Castings made of copper–nickel–aluminium bronze (CuAl10Fe5Ni5) alloys regularly show defects in the thick, slowly solidifying parts of the castings, which give rise to rejections. Metallographic examination has been made on material of scrap castings showing porosity accompanied with film-like inclusions located beside the iron rich κII phases. Investigations of large failed cast structures of copper–nickel–aluminium bronze show the same characteristic defects on which fatigue cracks initiate and grow. Investigation has been made to the nature and the cause of appearance of the film-like inclusions. Microanalysis indicates a high intensity of carbon at the place of the film-like inclusions. Hereafter, an investigation has been made into the solubility of carbon in liquid copper–nickel–aluminium bronze, and it is found that besides hydrogen, also carbon is soluble in copper–nickel–aluminium bronze alloys. The appearance of the carbon as flakes in the fracture surface of materials with defects does suspect there is a nucleating effect on the formation of microporosity causing the defects. To prevent the formation of the casting defects by the interaction between solved hydrogen and carbon, it is necessary to remove the carbon as far as possible by treatment of the melt.