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| Material: | Mallory 100 |
| Type: | Cobalt, Beryllium, Copper. |
| Description: | Precipitation hardened (age hardenable) copper alloy with high strength and hardness and moderate electrical and thermal properties. |
| Applications: | Mallory 100 is a harder and stronger material than Mallory 328 but with a reduced conductivity. It has many uses particularly in hostile environments where a tough yet conductive material is required. Its primary function is to produce resistance welding electrodes for: |
| 1. Spot and seam welding of stainless steel and heat resistant alloys. | |
| 2. Projection welding. | |
| 3. Heavy duty cross wire welding. | |
| It can also be used to produce holders, gun arms, flash butt welding dies and as a backing for Elkanite inserts and facings. | |
| Other applications include plunger tips in pressure die casting machines (see Data Sheet 1300:320 – Mallory 353), hot upsetting dies and as a chiller for automated M.I.G. and T.I.G. welding operations. | |
| Associated data–Mallory 100 Health & Safety 1300:131. | |
| Supply Condition: | Material is supplied as standard in the fully heat treated condition Material suitable for bendingcan be provided to special order. |
| Nominal Composition: | Cobalt 2.5% |
| Beryllium 0.5% | |
| Copper balance | |
| Forms of Supply | This material is available in round, square, rectangular and hexagonal drawn bar, plate, sheet, extrusions, forgings, castings, discs and rings. |
| Standard Sizes | |
| Round bar from 6mm to 200mm diameter | |
| Square bar from 10mm sq. to 100mm sq. | |
| Rectangular bar from 20mm x 10mm to 305mm x 85mm | |
| Discs from 200mm dia. to 320mm dia. with thicknesses from 10mm to 29mm. | |
| Non-standards can be produced to order. |
| Mechanical Properties | ||||
| Hardness | Rockwell B | Vickers | Brinell 30 | |
| Minimum | (Note 1) | 90 | 183 | 183 |
| Typical | (Note 2) | 96-104 | 218-273 | 220-270 |
| (Note 3) | 95-103 | 213-260 | 210-260 | |
| (Note 4) | 92-99 | 197-235 | 195-235 | |
| (Note 5) | 95-103 | 213-260 | 210-260 | |
| Tensile Strength | Ton/in2 | MPa | ||
| Minimum | (Note 1) | 44.5 | 690 | |
| Typical | (Note 2) | 48-0-61.5 | 740-940 | |
| (Note 3) | 44.5-58.0 | 690-900 | ||
| (Note 4) | 44.5-52.0 | 690-800 | ||
| (Note 5) | 42.0-48.5 | 650-750 | ||
| Yield Strength | Ton/in2 | MPa | ||
| Typical | (Note 2) | 47.0 min | 730 min | |
| (Note 3) | 44.0 min | 680 min | ||
| (Note 4) | 32.5 min | 500 min | ||
| (Note 5) | 32.5 min | 500 min | ||
| Elongation | % | |||
| Minimum | (Note 1) | 9 | ||
| Typical | (Note 2) | 10-18 | ||
| (Note 3) | 12-20 | |||
| (Note 4) | 12-20 | |||
| (Note 5) | 15-25 | |||
| Modulus of Elasticity (Tension): | Approximately 7640 Ton/in2 | 118000 MPa | ||
| Modulus of Rigidity (Torsion): | Approximately 2654 Ton/in2 | 41000 MPa |
| Electrical Properties: | |||
| Electrical Conductivity | % I.A.C.S.* | m/ohm.mm2 | |
| Minimum | (Note 1) | 45 | 26.1 |
| Typical | 45-55 | 26.1-31.9 | |
| Electrical Resistance | Microhm.cm | ||
| Typical | 3.831-3.134 | ||
| Thermal Properties: | |||
| Softening Temperature + | 500 deg C | ||
| Themal Conductivity | W/mK | ||
| Typical | 20 deg C | 209 | |
| 200 deg C | 280 | ||
| 300 deg C | 320 | ||
| Heat Capacity | 0.42 J/gK | ||
| Mean Coefficient of Thermal Expansion | 0-300 deg c | 17.8 X 10-6 | |
| 0-100 deg c | 16.7 X 10-6 | ||
| Density: | 8.8 g/cm3 |
| All Mallory Alloys Group products conform to, if not exceed, the relevant standards as assured by the Quality Management System |  |
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