Copper Material

Copper has been a fundamental material for human innovation for thousands of years.

From ancient civilizations to cutting-edge modern technologies, copper’s versatility, conductivity, and durability have made it indispensable.

This post will explore the various grades and types of copper, delve into its key properties, and discuss its diverse applications.

And provide useful selection tips to help you choose the right copper for your next project.

1. What is Copper?

‌Copper (Cuprum) is a metallic element with the chemical symbol Cu. ‌

Copper is a transition metal element with an atomic number of 29 and is located in the 4th period and group IB of the periodic table.

Pure copper is a soft metal with a reddish-orange color when the surface is just cut, with a metallic luster, a purple-red color when the element is pure,

good ductility, kekonduksian terma yang tinggi, and electrical conductivity.

Copper or Cu element belongs to the red metal category along with brass and bronze. Copper element is a non-ferrous and highly processable material, so it is easy to manufacture different parts.

It is the third most used metal in the world after iron and aluminum.

From the perspective of global copper mines and copper-containing production, according to ICSG, from January to October 2022,

the top three countries in the world in terms of copper mine production are Chile, Peru, and Congo, accounting for 24%, 11%, dan 10% of the global copper production, respectively.

China’s copper mine production ranks fourth in the world, accounting for 9%.

2. Manufacturing Processes

Extraction and Refining

• Mining: Copper is primarily extracted from ore deposits through open-pit or underground mining. Major copper ores include chalcopyrite (CuFeS2) and bornite (Cu5FeS4).
  Open-pit mining accounts for about 60% of global copper production.
• Smelting: After mining, the ore is processed to concentrate the copper content. This involves crushing, grinding, and flotation to separate copper minerals from waste rock.
  The concentrate typically contains 20-30% Tembaga.
• Refining: The concentrated copper is then refined to produce pure copper. Two main refining methods are:

• • Pyrometallurgical Smelting: This method involves heating the concentrate in a furnace to extract impurities and produce blister copper, which contains about 98-99% Tembaga.
  • Electrolytic Refining: Blister copper is further refined by passing an electric current through a solution of copper sulfate, depositing pure copper on the cathode.
    This process results in copper with a purity of 99.99%.

Forming and Shaping

Casting

Casting involves pouring molten copper into molds to create complex shapes and parts. This method is ideal for producing intricate components:

• Pemutus pasir: Molten copper is poured into sand molds, which are then cooled and broken to reveal the cast part.
• Mati Casting: Molten copper is injected under high pressure into metal dies, allowing for the production of precise and detailed parts.

Bergulir

Rolling is used to form copper into sheets, plates, and strips. This process involves passing the copper through a series of rollers:

• Hot Rolling: The copper is heated and passed through rollers to reduce its thickness and improve its uniformity.
• Cold Rolling: The copper is rolled at room temperature to achieve even greater precision and surface finish. Cold rolling can produce sheets as thin as 0.005 inci.

Drawing

Drawing is used to create wires and tubes by pulling the copper through dies:

• Wire Drawing: Copper rods are pulled through a series of progressively smaller dies to reduce their diameter. This process can produce wires as thin as 0.0005 inci.
• Tube Drawing: Copper rods are pulled through dies to form tubes of various diameters and wall thicknesses.

Forging

Forging involves shaping copper by hammering or pressing it into the desired form. This method is often used for high-strength applications:

• Open-Die Forging: The copper is placed between two flat dies and hammered or pressed to shape it.
• Closed-Die Forging: The copper is placed in a die with a specific shape and hammered or pressed to fill the die cavity.

Extrusion

Extrusion is used to create copper with specific cross-sectional profiles. The process involves forcing the copper through a die:

• Direct Extrusion: The copper is pushed through the die by a ram, creating the desired shape.
• Indirect Extrusion: The die is pushed through the copper, which is held in a container. This method is less common but can produce more complex shapes.

3. Types of Copper and Their Grades

Copper is a versatile metal widely used in a variety of industries, and its properties can be enhanced or modified by alloying it with other elements.

Understanding the types of copper and their respective grades is essential for choosing the right material for your specific application.

Dalam bahagian ini, we’ll explore the main types of copper and the most common grades used in manufacturing.

3.1. Pure Copper (Unalloyed Copper)

Pure copper is the highest-grade form of copper and is often used where electrical conductivity, kekonduksian terma yang tinggi, and malleability are the most critical factors.

It contains 99.9% Tembaga, with only trace amounts of other elements.

Common Grades of Pure Copper:

• C11000 (Electrolytic Tough Pitch Copper – ETP): This is the most commonly used grade of pure copper.
  It has excellent electrical conductivity (Kira -kira 100% IACS), making it ideal for electrical wiring, power cables, and components in electrical equipment.
  It is also resistant to corrosion and highly ductile, which is useful in various industrial applications.

• C10100 (Oxygen-Free Copper): Oxygen-free copper is refined to a higher purity level than C11000 by removing oxygen content,
  making it ideal for high-performance applications that require high conductivity and resistance to hydrogen embrittlement,
  such as vacuum tubes, high-end audio equipment, and sensitive electrical systems.

3.2. Copper Alloys

While pure copper is useful in many applications, copper alloys are often more practical due to their enhanced mechanical properties, including increased strength, Rintangan kakisan yang lebih baik, and better performance in high-stress environments.

Copper alloys are typically made by combining copper with elements like zinc, tin, aluminium, and beryllium.

A. Tembaga (Copper-Zinc Alloys)

Tembaga is an alloy of copper and zinc. It is known for its gold-like appearance, excellent machinability, dan rintangan kakisan, which makes it useful in a wide range of applications,
such as plumbing, electrical connectors, and musical instruments.

• C36000 (Free-Machining Brass): One of the most popular brass alloys, C36000 is ideal for machining and is widely used for producing threaded parts, kelengkapan, and fasteners.
  It has high machinability and can be easily formed into complex shapes.
• C27000 (Commercial Brass): Containing around 30% zink, this alloy is less machinable than C360 but provides a balance of strength, Rintangan kakisan, and ease of soldering.

B. Gangsa (Copper-Tin Alloys)

Gangsa is another important copper alloy, made primarily of copper and tin. It is known for its hardness, Rintangan kakisan, and wear resistance, making it ideal for use in high-stress and marine environments.

• C51000 (Phosphor Bronze): Contains small amounts of phosphorus, which increases its strength and wear resistance. It is widely used in electrical contacts, mata air, and bearings.
• C61400 (Aluminum Bronze): This bronze alloy contains both aluminum and copper, providing excellent strength, Rintangan kakisan (especially in seawater), and wear resistance.
  It is commonly used for marine hardware, injap, and turbine blades.

C. Beryllium Copper (Copper-Beryllium Alloys)

Beryllium copper is a high-strength copper alloy that contains beryllium (usually 0.5-3%) along with copper.
It has excellent electrical conductivity and is stronger than many other copper alloys, which makes it useful in applications requiring high strength, conductivity, dan rintangan kakisan.

• C17200 (Beryllium Copper): This is the most widely used grade of beryllium copper.
  It is commonly used for applications requiring high fatigue strength, such as electrical contacts, mata air, and connectors in aerospace, Automotif, and industrial machinery.
• C17000 (Beryllium Copper, Kekuatan tinggi): This grade has an even higher strength than C17200 and is used in precision instruments, permohonan ketenteraan, and high-performance springs.

D. Aluminum Bronze (Copper-Aluminum Alloys)

Aluminum bronze combines copper and aluminum to form an alloy that is stronger and more resistant to corrosion than regular bronze.
It is known for its excellent wear and fatigue resistance, making it suitable for high-stress applications.

• C95400 (Aluminum Bronze): Containing up to 11% aluminium, this alloy is used for marine applications, silinder hidraulik, and bearings.
• C95800 (High-Strength Aluminum Bronze): A high-strength aluminum bronze used for highly stressed components in industries such as aerospace and automotive.

3.3. Other Copper Alloys and Grades

A. Copper-Nickel Alloys

Copper-nickel alloys are known for their corrosion resistance in seawater and other harsh environments.
These alloys are used in marine applications, desalination plants, and chemical processing equipment.

• C70600 (90/10 Copper-Nickel): This alloy contains 90% copper and 10% Nikel. It is commonly used in marine environments for heat exchangers, condenser tubes, and seawater piping.
• C71500 (70/30 Copper-Nickel): With a higher percentage of nickel, this alloy offers better strength and corrosion resistance than the 90/10 alloy and is used in more demanding marine and industrial applications.

B. Copper-Lead Alloys

These copper alloys have small amounts of lead added to improve machinability. They are often used for manufacturing parts that require easy machining, such as bushings, galas, and gears.

• C93200 (Leaded Tin Bronze): This alloy has a high content of lead and tin, making it ideal for high-load-bearing applications, such as bushings and bearing sleeves.

3.4. How to Choose the Right Copper Grade

Choosing the right copper grade depends on several factors:

• Keperluan permohonan: Consider the mechanical properties needed, seperti kekuatan, Rintangan kakisan, and conductivity.
  For electrical components, high-conductivity copper like C11000 is ideal, while for high-strength applications, beryllium copper alloys (C17200) may be more appropriate.
• Environmental Conditions: Will the part be exposed to seawater, high temperatures, or corrosive substances?
  Aluminum bronze (C95400) or copper-nickel alloys (C70600) are better suited for such environments.
• Pertimbangan kos: Pure copper (C11000) may be more expensive than alloys, but its high conductivity makes it indispensable for electrical applications.
  Sebaliknya, brass or bronze alloys may offer a more cost-effective option for general-purpose use.
• Kebolehkerjaan: If you need a material that’s easy to machine, free-machining brass like C36000 is a good choice, as it has a high machinability rating.

4. Key Properties of Copper

Copper’s unique properties make it an invaluable material across various industries. Understanding these properties is crucial for selecting the right type of copper for specific applications.
Here, we delve into the chemical and physical properties of copper.

Chemical Properties

Rintangan kakisan

• Natural Patina Formation: One of copper’s most notable chemical properties is its ability to form a protective patina.
  When exposed to air and moisture, copper develops a green layer of copper carbonate and copper sulfate.
  This patina acts as a barrier, preventing further corrosion. The formation of the patina can take several years, depending on environmental conditions.
• Resistance to Water and Acids: Copper does not react with water, making it ideal for plumbing and water supply systems.
  Walau bagaimanapun, it can react with strong acids like nitric acid and sulfuric acid, as well as strong bases.
  Copper is generally resistant to most non-oxidizing acids and alkalis, which enhances its durability in various environments.

Reactivity

• Pengoksidaan: Copper can oxidize when exposed to air, forming a layer of copper oxide (CuO).
  This oxidation is slower compared to other metals and does not significantly affect the material’s integrity.
• Kakisan galvanik: When copper is in contact with more active metals like aluminum or steel in the presence of an electrolyte (Mis., salt water), galvanic corrosion can occur.
  To prevent this, proper insulation or the use of compatible materials is recommended.

Environmental Stability

• Atmospheric and Marine Environments: Copper’s natural resistance to atmospheric and marine environments makes it a preferred material for outdoor and marine applications.
  It can withstand prolonged exposure to air, rain, and seawater without significant degradation.

Sifat fizikal

Ketumpatan

• Value: 8.96 g/cm³
• Significance: Copper’s density is relatively high, which can be a disadvantage in weight-sensitive applications like aerospace.
  Walau bagaimanapun, this property also contributes to its stability and structural integrity in many other uses.

Melting Point

• Value: 1,085° C. (1,984° f)
• Significance: Copper’s high melting point makes it suitable for high-temperature applications, such as heat exchangers and furnaces.
  It can maintain its structural integrity and conductivity at elevated temperatures.

Kekonduksian terma

• Value: 385 W/m · k
• Significance: Copper has one of the highest thermal conductivities among metals, second only to silver.
  This property makes it ideal for applications that require efficient heat transfer, such as cooling systems, penukar haba, and cookware.
  It can quickly dissipate heat, improving the performance and efficiency of these systems.

Kekonduksian elektrik

• Value: 59.6 × 10^6 S/m
• Significance: Copper’s high electrical conductivity is one of its most important properties.
  It is widely used in electrical wiring, printed circuit boards (PCBs), dan komponen elektronik.
  Copper’s ability to conduct electricity with minimal resistance ensures efficient and reliable electrical systems.

Ductility and Malleability

• Kemuluran: Copper can be drawn into thin wires without breaking. This property is crucial for the production of electrical wires and cables, which require flexibility and strength.
• Malleability: Copper can be hammered or rolled into thin sheets without fracturing.
  This property allows for the production of copper sheets, plates, and other thin components, making it versatile for various forming and shaping processes.

Pengembangan haba

• Value: 16.5 µm/m·°C (from 20°C to 100°C)
• Significance: Copper has a moderate coefficient of thermal expansion, meaning it expands and contracts with temperature changes.
  This property must be considered in applications where temperature variations are significant to prevent stress and potential failure.

Magnetic Properties

• Non-Magnetic: Copper is not magnetic, which is beneficial in applications where magnetic interference needs to be minimized, such as in electronic devices and medical equipment.

5. Advantages and Disadvantages of Copper

Kelebihan

• Excellent Electrical and Thermal Conductivity: Copper’s high conductivity makes it ideal for electrical wiring, penukar haba, and cooling systems.
  It is used in about 70% of all electrical wiring.
• Rintangan kakisan: Copper’s natural resistance to corrosion ensures long-lasting and durable components, especially in atmospheric and marine environments.
• Malleability and Ductility: Copper’s ability to be easily shaped and formed into various components makes it versatile for many applications.
• Recyclabality: Copper is 100% recyclable without loss of quality, making it an environmentally friendly material.
  Recycling copper saves up to 85% of the energy required to mine and refine new copper.

Disadvantages

• High Cost: Copper is more expensive than some alternative materials, which can increase project costs. The price of copper can fluctuate significantly due to market conditions.
• Weight: Copper is heavier than some other materials, which can be a disadvantage in weight-sensitive applications like aerospace.
• Softness: Pure copper is relatively soft and can deform under high stress, requiring alloying for increased strength.

6. Applications of Copper

Electrical and Electronic Applications

• Wiring and Cables: Copper is the preferred material for electrical wiring and power cables due to its high conductivity. It is used in residential, komersial, and industrial settings.
• Printed Circuit Boards (PCBs): Copper is essential for the conductive traces in electronic circuits, enabling the miniaturization and performance of modern electronics.
• Connectors and Terminals: Copper provides reliable electrical connections in various devices, from consumer electronics to industrial machinery.

Construction and Architecture

• Roofing and Cladding: Copper’s durability and aesthetic appeal make it a popular choice for roofing and cladding. It can last over 100 years with minimal maintenance.
• Piping and Plumbing: Copper’s resistance to corrosion and bacteria makes it ideal for water supply systems. It is used in both residential and commercial plumbing.
• Decorative Elements: Copper is used in architectural details and interior design for its aesthetic appeal, adding a touch of elegance and warmth to spaces.

Aplikasi perindustrian

• Penukar haba: Copper’s high thermal conductivity makes it ideal for heat exchangers in HVAC systems and industrial processes.
  It can efficiently transfer heat, improving energy efficiency.
• Pumps and Valves: Copper’s corrosion resistance and durability make it suitable for various industrial equipment, including pumps and valves.
• Marine Equipment: Copper’s resistance to seawater corrosion makes it a preferred material for boat hulls, propellers, and marine hardware.
  It helps prevent biofouling and extends the life of marine components.

Produk pengguna

• Alat memasak: Copper’s excellent heat distribution and aesthetic appeal make it a popular choice for pots, pans, and kitchen utensils.
  It ensures even cooking and adds a luxurious look to the kitchen.
• Jewelry: Copper’s malleability and ability to form intricate designs make it a popular material for fashion accessories.
  It is often used in combination with other metals to create unique and beautiful pieces.
• Musical Instruments: Copper is used in brass instruments for its acoustic properties and durability. It contributes to the rich sound and longevity of musical instruments.

7. How to Choose the Right Copper for Your Project

Selecting the right type of copper for your project is essential to ensure optimal performance, ketahanan, dan keberkesanan kos.
Here are key considerations to guide you in choosing the best copper material for your needs:

Determine the Key Properties Required

Different copper types excel in various attributes. Understanding the essential properties needed for your project will narrow down your options.

• Kekonduksian elektrik: For applications such as wiring, connectors, and electrical systems,
  high-purity copper (like C11000 ETP) or oxygen-free copper (C10100) is ideal due to its exceptional conductivity.
• Rintangan kakisan: If your project involves exposure to moisture, bahan kimia, or saltwater,
  consider copper alloys like aluminum bronze (C95400) or copper-nickel (C70600) for their superior corrosion resistance.
• Kekuatan dan ketahanan: For high-stress applications, such as heavy machinery or aerospace parts,
  beryllium copper (C17200) provides both strength and wear resistance, making it a durable choice.
• Kekonduksian terma: For heat exchangers or other components requiring efficient heat dissipation, choose high-purity copper grades like C11000.

Evaluate Environmental Conditions

The environment in which the copper material will be used is a critical factor:

• Marine Environments: Copper-nickel alloys (C70600 and C71500) are highly resistant to seawater corrosion,
  making them ideal for shipbuilding, desalination plants, and offshore equipment.
• Aplikasi suhu tinggi: Some alloys, like aluminum bronze, retain strength at higher temperatures, which is beneficial for aerospace and industrial furnace components.
• Corrosive Chemicals: For applications exposed to harsh chemicals, phosphor bronze (C51000) and aluminum bronze provide excellent resistance.

Consider Manufacturing Requirements

Your chosen copper material should be compatible with the desired manufacturing processes:

• Kebolehkerjaan: If your project requires extensive machining, free-machining brass (C36000) is an excellent choice for its ease of shaping and processing.
• Kebolehbaburan: For projects involving deep drawing, stamping, or bending, opt for copper alloys with high ductility, such as aluminum bronze or phosphor bronze.
• Casting or Forging: If casting is required, alloys like C93200 (leaded bronze) or aluminum bronze perform well in this process and offer enhanced wear resistance for heavy-duty applications.

Assess Cost Constraints

Budget plays a significant role in material selection:

• High-Purity Copper: While high-purity coppers (C11000, C10100) offer superior conductivity, they are typically more costly.
  They are best used in critical electrical applications where conductivity cannot be compromised.
• Alloys for Cost Efficiency: Brass alloys, such as C27000, offer good corrosion resistance and strength at a lower cost,
  making them suitable for plumbing, decorative hardware, and non-critical components.

Match with Specific Industry Standards

Many industries have specific standards for copper and copper alloys to ensure reliability and performance.
Check if your project has to meet specific standards, such as ASTM or SAE, as these guidelines will often recommend particular copper grades based on industry-specific requirements.

Longevity and Maintenance Needs

For components requiring low maintenance and high durability:

• Pakai rintangan: Beryllium copper (C17200) is a great choice for parts that endure repetitive motion and stress, like springs and connectors, due to its excellent wear resistance.
• Corrosion Protection: Copper-nickel alloys are often chosen in marine applications for their longevity and reduced maintenance under harsh conditions.

9. Kesimpulan

Tembaga is a versatile and essential material with a rich history and a promising future.
Its excellent electrical and thermal conductivity, Rintangan kakisan, and malleability make it suitable for a wide range of applications.
By understanding the different types of copper, their properties, and the manufacturing processes, you can make informed decisions to select the right copper for your project.

We hope this guide has provided you with valuable insights into copper and its applications.
If you have any questions or would like to share your experiences, feel free to leave a comment below.
Stay tuned for more informative content on DEZE manufacturing.

 

By the way, if you have any needs for customized copper products, Sila berasa bebas Hubungi kami.

References: https://internationalcopper.org/