Copper Casting and Copper Forgings, Copper Components, Copper Parts, Copper Casting, Copper cast and Machined parts, Copper Forged Components, Copper casting foundry in India.

Copper Castings and Copper Forgings

Conex Metals offers a wide range of Copper Casting and Copper Forgings, Copper Components, Copper Parts, Copper Casting, Copper cast and Machined parts, Copper Forged Components, CNC machined Copper parts, Copper casting foundry in India, Copper and its alloys are widely used in various industries due to their excellent electrical and thermal conductivity, corrosion resistance, and formability. This post explores the world of copper castings and forgings, detailing the material grades, manufacturing processes, products, and their applications.

Material Grades (Alloys)

Copper Casting Alloys

1. C83600 (85-5-5-5 Bronze): 85% Cu, 5% Sn, 5% Pb, 5% Zn
   • Properties: Good corrosion resistance, high strength, excellent machinability
   • Applications: Bearings, bushings, pump components
2. C90300 (Tin Bronze): 88% Cu, 8% Sn, 4% Zn
   • Properties: High strength, good wear resistance, low friction
   • Applications: Gears, worm wheels, marine propellers
3. C95400 (Aluminum Bronze): 85% Cu, 11% Al, 4% Fe
   • Properties: High strength, excellent corrosion resistance, good wear properties
   • Applications: Marine hardware, pump impellers, valve components
4. C95800 (Nickel-Aluminum Bronze): 81% Cu, 9% Al, 5% Ni, 4% Fe
   • Properties: Superior corrosion resistance, high strength, good weldability
   • Applications: Offshore oil and gas components, marine propellers, pump casings
5. C10200 (Oxygen-Free Copper): 99.95% Cu minimum
   • Properties: Excellent electrical conductivity, high purity
   • Applications: Electrical components, semiconductor manufacturing
6. C86300 (Manganese Bronze): 60% Cu, 35% Zn, 2% Mn, 1% Fe, 1% Al
   • Properties: High strength, good wear resistance, moderate corrosion resistance
   • Applications: Heavy-duty bearings, gear blanks, marine propellers
7. C93200 (High-Leaded Tin Bronze): 83% Cu, 7% Sn, 7% Pb, 3% Zn
   • Properties: Excellent machinability, low friction, good bearing properties
   • Applications: Sleeve bearings, bushings, wear plates
8. C87600 (Silicon Bronze): 95% Cu, 3% Si, 1% Mn
   • Properties: High strength, good corrosion resistance, excellent castability
   • Applications: Pumps, valves, marine fittings, architectural hardware

Copper Forging Alloys

1. C11000 (ETP Copper): 99.90% Cu minimum
   • Properties: Excellent electrical conductivity, good formability
   • Applications: Electrical connectors, busbars, terminals
2. C17200 (Beryllium Copper): 98% Cu, 2% Be
   • Properties: High strength, excellent spring properties, good conductivity
   • Applications: Springs, diaphragms, electrical contacts
3. C26000 (Cartridge Brass): 70% Cu, 30% Zn
   • Properties: Good strength, excellent formability
   • Applications: Ammunition casings, hardware, fasteners
4. C37700 (Forging Brass): 60% Cu, 38% Zn, 2% Pb
   • Properties: Good machinability, moderate strength, excellent hot formability
   • Applications: Valves, fittings, architectural hardware
5. C63000 (Aluminum Bronze): 82% Cu, 10% Al, 5% Ni, 3% Fe
   • Properties: High strength, excellent corrosion resistance, good wear properties
   • Applications: Marine propeller shafts, pump shafts, valve stems
6. C18150 (Chromium Copper): 99% Cu, 1% Cr
   • Properties: High conductivity, good strength, heat resistance
   • Applications: Resistance welding electrodes, electrical connectors
7. C46400 (Naval Brass): 60% Cu, 39% Zn, 1% Sn
   • Properties: Good corrosion resistance, moderate strength, good machinability
   • Applications: Marine hardware, propeller shafts, pump shafts
8. C67500 (Manganese Bronze): 58.5% Cu, 39% Zn, 1.4% Fe, 1% Mn, 0.1% Pb
   • Properties: High strength, good wear resistance, moderate corrosion resistance
   • Applications: Gears, sprockets, bushings, wear plates

Manufacturing Processes

Casting Processes

1. Sand Casting: Molten copper is poured into sand molds
   • Advantages: Suitable for large parts, low tooling cost
   • Applications: Pump housings, large valves, architectural elements
2. Investment Casting: Uses wax patterns for high precision parts
   • Advantages: Excellent surface finish, tight tolerances
   • Applications: Turbine blades, medical implants, complex shaped components
3. Die Casting: Molten copper is forced into metal molds under high pressure
   • Advantages: High production rates, good dimensional accuracy
   • Applications: Electrical components, small gears, decorative hardware
4. Continuous Casting: For producing long, uniform cross-section products
   • Advantages: High productivity, good internal quality
   • Applications: Rods, tubes, wire production
5. Centrifugal Casting: For cylindrical parts with good density and uniformity
   • Advantages: Excellent grain structure, minimal porosity
   • Applications: Bushings, sleeves, ring-shaped components
6. Lost Foam Casting: Uses foam patterns that vaporize when molten metal is poured
   • Advantages: Complex shapes possible, good dimensional accuracy
   • Applications: Engine components, pump impellers, valve bodies

Forging Processes

1. Open-Die Forging: For large, simple shapes
   • Advantages: Suitable for large parts, improved grain structure
   • Applications: Large shafts, discs, custom shapes
2. Closed-Die Forging: For complex shapes with tight tolerances
   • Advantages: Near-net shape, good mechanical properties
   • Applications: Gears, crankshafts, connecting rods
3. Roll Forging: For elongated parts with uniform cross-sections
   • Advantages: Good for long, symmetrical parts
   • Applications: Axles, shafts, leaf springs
4. Precision Forging: For near-net-shape parts with minimal machining required
   • Advantages: Reduced material waste, lower production costs
   • Applications: Turbine blades, connecting rods, gears
5. Upset Forging: For increasing the cross-sectional area of a workpiece
   • Advantages: Ideal for headed parts, good grain flow
   • Applications: Bolts, rivets, valve stems
6. Orbital Forging: Uses a rotating upper die to progressively form the workpiece
   • Advantages: Lower forging loads, good for thin-walled parts
   • Applications: Gears, bearings, flanges

Products and Applications

Copper Castings

1. Pump Components:
   • Products: Impellers, volutes, casings
   • Alloys: C95400, C95800
   • Industries: Water treatment, chemical processing, marine
2. Valve Bodies:
   • Products: Gate valves, globe valves, check valves
   • Alloys: C83600, C87600
   • Industries: Oil and gas, water distribution, industrial processes
3. Marine Hardware:
   • Products: Propellers, rudders, shaft sleeves
   • Alloys: C95800, C86300
   • Industries: Shipbuilding, offshore platforms
4. Bearings and Bushings:
   • Products: Plain bearings, thrust washers, wear plates
   • Alloys: C93200, C86300
   • Industries: Automotive, heavy machinery, material handling
5. Electrical Components:
   • Products: Switchgear parts, bus bar ends, terminal blocks
   • Alloys: C10200, C11000
   • Industries: Power distribution, electronics manufacturing
6. Architectural Elements:
   • Products: Decorative panels, door handles, light fixtures
   • Alloys: C87600, C95500
   • Industries: Construction, interior design

Copper Forgings

1. Electrical Connectors:
   • Products: Busbars, terminals, contact pads
   • Alloys: C11000, C18150
   • Industries: Power transmission, electronics, automotive
2. Valve Components:
   • Products: Valve stems, bonnets, trim
   • Alloys: C37700, C46400
   • Industries: Oil and gas, chemical processing, water management
3. Aerospace Parts:
   • Products: Landing gear components, brackets, fittings
   • Alloys: C17200, C63000
   • Industries: Aircraft manufacturing, defense
4. Industrial Machinery:
   • Products: Gear blanks, shafts, wear components
   • Alloys: C67500, C63000
   • Industries: Mining, construction equipment, material handling
5. Marine Applications:
   • Products: Propeller shafts, rudder stocks, pump shafts
   • Alloys: C63000, C46400
   • Industries: Shipbuilding, offshore oil and gas
6. Fasteners:
   • Products: Bolts, nuts, washers for critical applications
   • Alloys: C26000, C37700
   • Industries: Aerospace, high-performance automotive, chemical processing

Advantages and Considerations

Advantages

1. Excellent electrical and thermal conductivity
2. Good corrosion resistance, especially in marine environments
3. High strength-to-weight ratio for certain alloys
4. Ease of recycling and sustainability
5. Antimicrobial properties in some copper alloys
6. Wide range of alloys available for specific performance requirements
7. Good machinability and formability in many alloys

Considerations

1. Higher cost compared to some alternative materials
2. Potential for galvanic corrosion when in contact with certain metals
3. Specific alloy selection critical for optimal performance in given applications
4. Some copper alloys may require special handling or protective equipment during processing
5. Potential for stress corrosion cracking in certain environments
6. Color changes (patina formation) over time, which may be desirable or undesirable depending on the application

By understanding the various aspects of copper castings and forgings, engineers and designers can make informed decisions when selecting materials and processes for their specific applications. The versatility of copper and its alloys continues to make them essential in numerous industries, from traditional manufacturing to cutting-edge technologies.