Casting Copper
Material Description
Copper is a versatile and widely used metallic element known for its excellent electrical and thermal conductivity. It is characterized by its lustrous reddish-brown appearance, malleability, and ductility. In its pure form, copper is a soft and highly malleable metal, making it suitable for various industrial applications. Its atomic number is 29, and it has a melting point of approximately 1,984 degrees Fahrenheit (1,085 degrees Celsius). Copper is often alloyed with other metals to enhance its mechanical properties, such as strength and corrosion resistance. Common copper alloys include bronze and brass, which incorporate elements like tin and zinc. In addition to its electrical and thermal conductivity, copper also boasts antimicrobial properties, making it suitable for use in healthcare and food processing equipment. Its excellent corrosion resistance makes it an ideal choice for plumbing, roofing, and architectural applications. Copper’s natural aesthetic appeal, durability, and recyclability further contribute to its popularity in various technical and industrial contexts.
Copper is essential in numerous technical applications due to its unique combination of properties. Its high electrical conductivity, surpassed only by silver, makes it an ideal choice for electrical wiring, power transmission, and electrical components. Its exceptional thermal conductivity makes it valuable in heat exchangers and cooling systems. Additionally, copper’s excellent corrosion resistance and natural patina formation over time further extend its applications, particularly in outdoor and architectural elements. The metal is highly ductile, allowing for seamless manufacturing processes, such as extrusion, casting, and machining. Furthermore, its use in various alloys, such as cupronickel and beryllium copper, enables specialized applications in industries ranging from aerospace to electronics. Copper’s importance in technology, construction, and industrial sectors remains significant, underlining its status as a fundamental material in the modern world.
Industry Applications
Copper castings are used in electrical components and artistic applications due to their excellent electrical conductivity and malleability.
Finishing Options
Polishing
| Density | Tensile Yield Strength (MPa) | Fatigue Strength (MPa) | Hardness (Brinell) | Thermal Conductivity (W/m-K) | Coeff. of Thermal Expansion (mm/mdeg) | Electrical Resistivity (micro Ohm-cm) |
|---|---|---|---|---|---|---|
| 8.92 | 210-220 | 40-60 | 35-120 | 398 | 16.6 | 1.68 x 10^-8 |
Design Recommendation
Copper’s high thermal conductivity and corrosion resistance make it an attractive material for various applications. In your design, aim for even wall thickness to ensure uniform cooling during the casting process. Consider how the geometry may impact heat distribution, as copper can transfer heat rapidly. Copper castings often require precision to meet tight tolerances.
Cost Saving Tip
Cost-saving strategies for copper castings revolve around efficient use of materials and energy. First, careful design optimization is vital to minimize the amount of copper used, which is particularly crucial given copper’s relatively high cost. This involves creating intricate molds that reduce waste and employing advanced CAD tools for precision. Second, energy efficiency is paramount during melting and casting. Using energy-efficient induction furnaces and recycling scrap copper can lead to substantial cost reductions. Moreover, optimizing the pouring and cooling processes minimizes defects, reducing the need for costly rework. Ensuring a well-trained workforce to handle copper safely and efficiently further contributes to cost savings.
