Computational Materials Design of a High-Strength Copper Alloy for Replacing BeCu Alloys Navy SBIR FY2005.1 Sol No.: Navy SBIR FY2005.1 Topic No.: N05-009 Topic Title: Computational Materials Design of a High-Strength Copper Alloy for Replacing BeCu Alloys Proposal No.: N051-009-0302 Firm: QuesTek Innovations LLC 1820 Ridge Avenue Evanston, Illinois 60201-3621 Contact: James Wright Phone: (847) 328-5800 Web Site: www.questek.com Abstract: QuesTek Innovations is proposing to use its computational materials design technology to demonstrate the feasibility of improving the strength of beryllium-free copper alloys to create a non-toxic substitute for beryllium-copper (BeCu) alloys. Beryllium is a unique element used in various alloys that are indispensable in a wide range of demanding military and commercial applications. When used as an alloying element, Be dramatically affects the properties of several base metals. Due to their low inherent coefficient of sliding friction, high-strength BeCu alloys are widely used for load-bearing applications such as bushings. Cu with 1.9 wt% Be, designated as C17200, is a precipitation hardening alloy that achieves the highest strength in Cu-based alloys. However, the Federal government, through OSHA and the DHHS, has issued alerts to the potentially deadly consequences of exposure to beryllium and beryllium compounds. These health hazards have forced suppliers, manufacturers and end users away from using beryllium whenever possible, but for many applications, BeCu is currently the only suitable material. Based on the technical advances in the computational design of unique materials, this Phase I program will design and evaluate prototype beryllium-free high-strength, high-conductivity copper alloy for "drop-in" substitution of existing BeCu alloys. Benefits: Due to the growing concern among manufacturers and end users regarding the health and environmental liability issues associated with beryllium-copper (BeCu) alloys, there is a growing market pull for developing a suitable replacement material. Utilize emerging computational materials design techniques it is now possible to economically accelerate the development and insertion of new enabling materials into both the military and commercial marketplace. The anticipated results of this proposed Phase I SBIR program will be the successful preliminary design for an alloy and the production of prototype samples with high strength needed to perform as a "drop-in" replacement material for existing BeCu applications. The effort will determine feasible alloy concepts and the scope of the modeling and design activities that will be required to successfully pursue a Phase II effort to optimize the design and develop a commercially unique copper alloy suitable for use in military/defense and commercial aerospace components. An environmentally benign materials solution would immediately benefit all Be-Cu alloy producers, secondary material processors, component manufactures and the end-uses by mitigating the environmental hazard associated with the handling and disposal of beryllium and begin to reduce the risk associated with longer-term liability issues. Beyond aerospace and defense applications, which typically require a significant material qualification period, QuesTek has identified a number of commercial product market segments that can be targeted, which have significantly shorter time to market and lower qualification requirements, but possess the same risks and potential liability associated with the handling and disposal of beryllium. Specifically, electrical components, such as electronic connectors and battery contacts, in cell phones and base stations are essential applications for which BeCu is currently the only material suitable for the given the reliability and miniaturization requirements for these applications. Return