Phosphor bronzes are alloys consisting of tin, phosphorus and copper as main constituents, sometimes with additions of zinc and lead. The structure is made up of three phases: a matrix of copper with tin in solid solution, known as the alpha phase, which is comparatively soft, a tin rich delta phase which is hard and interspersed throughout the matrix, a hard constituent of copper phosphide associated with the delta constituent, which is also hard but brittle.
The phosphor bronzes can be sand cast, chill cast, continuously cast and centrifugally cast; they are largely used in the chill cast form, in which, owing to the quick cooling, the amounts of the hard constituents are increased and much more finely dispersed throughout the matrix than in the sand cast state giving an extremely tough and hard wearing alloy.
The grain structure of the chill cast and continuously cast alloy is not only finer than the sand cast alloy, but usually freer from porosity. The centrifugally cast alloy is usually sounder even than the chill cast alloy, equal in strength to it and higher in ductility.
The phosphor bronzes can be recommended for all services where toughness, wear resistance and hardness are required; they have good corrosion resistance to tap waters, mine waters, mild alkalis and petroleum derivatives. As their thermal and electrical conductivities are only a little inferior to the gunmetals, they are often useful when such properties are required because of their high mechanical strength.
The above properties make the phosphor bronzes very suitable for the following uses:
It is used for gears, bearings and bushes for heavy loads and high duty with adequate lubrication, and for duty with hard steel shafts. Typical are bearings for aero engines, diesel engines, electrical generators and rolling mills. The alloy is also greatly used for gear and worm wheels, for pump parts particularly in mine waters and for marine work. The alloy can be chill cast, continuously cast, centrifugally cast and sand cast. For bearings and bushes a large amount is produced in the form of chill cast stick and continuously cast tubes and rods. For gears the alloy is mostly centrifugally, continuously or chill cast.
The alloy can be sand cast, chill cast and centrifugally cast; large quantities are used in chill cast stick form for various types of bearings and bushes; it is also used for plant not required to stand the rigorous duties.
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