Cu–4.7 wt. % Sn alloy wire with Ø10 mm was prepared by two-phase zone continuous casting technology, and the temperature field, heat and fluid flow were investigated by the numerical simulated method. As the melting temperature, mold temperature, continuous casting speed and cooling water temperature is 1200 °C, 1040 °C, 20 mm/min and 18 °C, respectively, the alloy temperature in the mold is in the range of 720 °C–1081 °C, and the solid/liquid interface is in the mold. In the center of the mold, the heat flow direction is vertically downward. At the upper wall of the mold, the heat flow direction is obliquely downward and deflects toward the mold, and at the lower wall of the mold, the heat flow deflects toward the alloy. There is a complex circular flow in the mold. Liquid alloy flows downward along the wall of the mold and flows upward in the center.
High prices of tin and its limited resources, as well as several valuable properties characterising Cu-Sn alloys, cause searching for materials of similar or better properties at lower production costs. The influence of various nickel additions to CuSn10 casting bronze and to CuSn8 bronze of a decreased tin content was tested. Investigations comprised melting processes and casting of tin bronzes containing various nickel additions (up to 5%). The applied variable conditions of solidification and cooling of castings (metal and ceramic moulds) allowed to assess these alloys sensitivity in forming macro and microstructures. In order to determine the direction of changes in the analysed Cu-Sn-Ni alloys, the metallographic and strength tests were performed. In addition, the solidification character was analysed on the basis of the thermal analysis tests. The obtained results indicated the influence of nickel in the solidification and cooling ways of the analysed alloys (significantly increased temperatures of the solidification beginning along with increased nickel fractions in Cu-Sn alloys) as well as in the microstructure pattern (clearly visible grain size changes). The hardness and tensile strength values were also changed. It was found, that decreasing of the tin content in the analysed bronzes to which approximately 3% of nickel was added, was possible, while maintaining the same ultimate tensile strength (UTS) and hardness (HB) and improved plasticity (A5).