Copper is a highly conductive metal renowned for its excellent electrical and thermal conductivity, malleability, and resistance to corrosion. As one of the oldest known metals, copper has been used for thousands of years in various applications, from electrical wiring to plumbing. Its unique properties make it an ideal choice in industries such as electrical, construction, and electronics. Copper is often alloyed with other metals like zinc (to form brass) and tin (to form bronze) to enhance its mechanical properties. Its ability to resist biofouling and its antimicrobial properties also contribute to its importance in plumbing and architectural applications.

Copper Grades

Copper grades are classified based on their purity and alloying elements, impacting their electrical, thermal, and mechanical properties. The choice of copper grade depends on the specific requirements of the application, including conductivity, strength, and corrosion resistance.

C10100 - Oxygen-Free Electronic (OFE) Copper

Highly pure copper with minimal impurities, ensuring excellent electrical performance.

Composition: 99.99% copper, minimal impurities (oxygen content ≤ 0.001%).
Properties: Excellent electrical conductivity; high purity.
Uses: Ideal for critical electrical applications like electronic components and high-performance wiring.

C10200 - Oxygen-Free (OF) Copper

Similar to OFE copper but allows for slightly higher impurity levels.

Composition: 99.95% copper, slightly higher impurities than C10100 (oxygen content ≤ 0.003%).
Properties: High conductivity; slightly higher impurity content than OFE.
Uses: Suitable for various electrical applications, including connectors and terminals.

C11000 - Electrolytic Tough-Pitch (ETP) Copper

A high-quality copper grade known for its excellent electrical conductivity and toughness.

Composition: 99.90% copper, with oxygen content of approximately 0.02%.
Properties: Excellent electrical conductivity; good formability.
Uses: Commonly used in electrical wiring, transformers, and motors.

C12000 - DHP (Deoxidized High Phosphorus) Copper

A copper alloy with phosphorus added as a deoxidizer, enhancing its performance.

Composition: 99.90% copper, 0.02-0.15% phosphorus, with minimal impurities.
Properties: Good conductivity; resistance to oxidation.
Uses: Often used in electrical applications requiring good conductivity and durability, such as bus bars.

C12200 - DHP (Deoxidized High Phosphorus) Copper

Similar to C12000, this grade also features phosphorus for improved characteristics.

Composition: 99.90% copper, 0.02-0.15% phosphorus, low levels of impurities.
Properties: Enhanced conductivity; oxidation resistance.
Uses: Utilized in various electrical applications, including conductors and connectors.

C12500 - Fire Refining, Tough-Pitch Copper

A tough-pitch copper grade produced through fire refining, enhancing its electrical properties.

Composition: 99.95% copper, minimal impurities.
Properties: Toughness; good conductivity.
Uses: Suitable for applications needing robust electrical performance.

C14500 - Tellurium-Copper

Copper alloyed with tellurium to improve machinability, making it ideal for precision parts.

Composition: 99.90% copper, 0.4% tellurium, with low levels of other impurities.
Properties: Enhanced machinability; good conductivity.
Uses: Ideal for precision machining applications like switches and contacts.

C14700 - Sulfur-Copper

This copper grade features sulfur for improved machinability, suitable for electrical applications.

Composition: 99.90% copper, 0.1% sulfur, minimal impurities.
Properties: Good machinability; solid conductivity.
Uses: Used in electrical applications, such as connectors and terminals.

C18200 - Chromium-Copper, Unwrought

An alloy of copper and chromium, offering high strength and temperature resistance.

Composition: 95.0% copper, 0.5-1.0% chromium, with low levels of impurities.
Properties: High strength; resistance to softening at high temperatures.
Uses: Suitable for aerospace and defense applications.

C19200 - Copper-Zirconium

A copper alloy that incorporates zirconium, providing enhanced strength at elevated temperatures.

Composition: 98.5% copper, 0.15-0.25% zirconium, with minimal impurities.
Properties: Enhanced strength at high temperatures; good conductivity.
Uses: Ideal for high-temperature applications, including aerospace components and welding electrodes.

Manufacturing Processes for Carbon Steel

Casting

Casting

Copper can be cast into various shapes using methods such as sand casting and die casting. In sand casting, molten copper is poured into a sand mold, allowing for the creation of intricate designs and larger components. Die casting involves forcing molten copper into a metal mold under high pressure, resulting in precision parts with smooth finishes. This method is particularly useful for producing fittings, valves, and intricate components used in electrical and plumbing applications.

Hot and Cold Rolling

Hot and Cold Rolling

Copper is often subjected to hot rolling to produce sheets, plates, and strips. During this process, copper is heated above its recrystallization temperature and passed through rollers, enhancing its mechanical properties, such as ductility and strength. The subsequent cold rolling process involves rolling the copper at room temperature, which further increases its strength and improves the surface finish. Cold-rolled copper products are often used in electrical conductors, automotive parts, and architectural applications due to their enhanced performance characteristics.

Extrusion

Extrusion

In the extrusion process, copper is heated and forced through a die to create rods, tubes, and profiles of uniform cross-section. This method is highly efficient for producing long lengths of copper products, making it ideal for wiring, plumbing pipes, and structural elements. The extruded copper can be further processed into various shapes and sizes, catering to specific industrial and construction applications.

Welding and Soldering

Welding and Soldering

Copper's excellent weldability enables the use of various welding techniques, such as TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) welding. These methods allow for strong and reliable joints in copper components. Additionally, soldering is commonly employed in electronics and plumbing to join copper parts. The process involves melting a filler metal (solder) to bond copper pieces together, providing strong connections essential for electrical circuits and plumbing fixtures. Copper's thermal conductivity and malleability enhance the effectiveness of these joining methods, making them suitable for a wide range of applications.

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