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Conex Metals is a leading manufacturer and exporter of copper forged parts<\/strong>, supplying precision copper hot forged components and cold forged copper parts to electrical OEMs, EPC contractors, power utilities, and industrial distributors worldwide. Our copper forgings are produced from high-conductivity electrolytic tough pitch (ETP) copper and oxygen-free copper (OFC) to meet the most demanding mechanical and electrical performance requirements. With ISO-certified manufacturing, tight dimensional tolerances, and comprehensive material traceability, Conex Metals delivers copper forged components for switchgear, transformers, busbars, earthing systems, hydraulic fittings, and heavy electrical infrastructure globally.<\/p>\n <\/p>\n Copper forging is a manufacturing process that shapes heated or room-temperature copper billets under controlled compressive forces using dies, resulting in components with a refined grain structure, superior mechanical strength, and excellent electrical conductivity. Unlike cast or machined parts, forged copper components exhibit better fatigue resistance, reduced porosity, and consistent density\u2014critical for high-current electrical applications.<\/p>\n Hot forged copper parts are produced by heating copper billets to 600\u2013900\u00b0C and pressing them into precision dies. This process is ideal for manufacturing copper terminal lugs, copper contact tips, copper busbar connectors, copper electrical contacts, copper stud terminals, copper cable end ferrules, copper pivot pins, copper flanges, and copper socket contacts<\/strong>. The elevated temperature increases malleability and allows material flow into complex geometries while maintaining electrical conductivity above 99% IACS. Hot forging is the preferred method for large cross-sections exceeding 50 mm.<\/p>\n Cold forged copper components are formed at room temperature, utilizing the work-hardening characteristics of copper to achieve tight tolerances and smooth surface finishes. Typical cold forged copper products include copper press-fit contacts, copper rivet contacts, copper relay contacts, copper pin contacts, copper connector shells, copper threaded inserts, copper precision shafts, copper anchor bolts, and copper grounding studs<\/strong>. Cold forging produces near-net-shape parts with excellent repeatability\u2014suitable for high-volume electrical and electronics manufacturing where dimensional accuracy within \u00b10.05 mm is required.<\/p>\n Electrical-grade copper forgings are engineered specifically for high-current and high-voltage applications in power transmission and distribution. Products include copper palm terminals, copper compression lugs, copper bus clamps, copper earthing clamps, copper power line connectors, copper bolted cable connectors, copper transformer terminals, copper switchgear contacts, and copper high-current busbars<\/strong>. These components are forged from C11000 ETP copper or C10200 OFC, ensuring resistivity values below 1.724 \u00b5\u03a9\u00b7cm and contact resistance in the micro-ohm range.<\/p>\n Copper forgings are extensively used in hydraulic and fluid systems due to copper’s corrosion resistance, pressure integrity, and leak-free sealing. Conex Metals supplies copper forged compression fittings, copper forged elbow fittings, copper tee fittings, copper end caps, copper reducing couplings, copper flare fittings, copper union nuts, copper olive inserts, and copper pressure nipples<\/strong>. These hydraulic-grade copper forged fittings conform to EN 1254, ASTM B61, and DIN 86252 standards and are rated for pressures up to 250 bar depending on wall thickness and alloy grade.<\/p>\n In addition to pure copper forgings, Conex Metals produces forged parts in leaded brass (CW614N), naval brass (CW712R), phosphor bronze (CW451K), silicon bronze, aluminum bronze (CW307G), and beryllium copper (C17200)<\/strong>. These copper alloy forgings offer enhanced machinability, wear resistance, or spring properties depending on alloy selection. Brass forged fittings, bronze forged valves, phosphor bronze forged bushings, and aluminum bronze forged bearing housings are standard product categories.<\/p>\n Conex Metals manufactures custom copper forgings to customer drawings, 3D models, or samples. Engineering support is available for die design, material selection, and process optimization. Custom capabilities include multi-cavity forging dies, progressive cold forging, warm forging (300\u2013500\u00b0C), backward extrusion forging, upset forging, open-die forging, closed-die drop forging, press forging, and roll forging<\/strong>. Minimum order quantities start from 500 pieces for custom dies, with rapid tooling lead times of 3\u20134 weeks.<\/p>\n Conex Metals produces a comprehensive range of copper forged earthing components including copper earth bars, copper earth clamps, copper rod-to-cable connectors, copper ground plate connectors, copper exothermic weld connectors, copper tape-to-rod clamps, copper parallel groove clamps, copper cable-to-earth rod bolted clamps, and copper bonding connectors<\/strong>. All earthing copper forgings comply with IEC 62305, BS 7430, and IEEE Std 80 for earthing system applications in substations, wind turbines, solar farms, railways, and industrial plants.<\/p>\n Copper forged components from Conex Metals are produced from electrolytic copper cathode with a minimum purity of 99.9% Cu + Ag. The forging process preserves and enhances the crystal structure without introducing contaminants, ensuring electrical conductivity above 100% IACS, contact resistance below 10 \u00b5\u03a9, low transition resistance, thermal conductivity of 385 W\/m\u00b7K, coefficient of thermal expansion 16.5 \u00b5m\/m\u00b7K, and dielectric properties<\/strong> that make them ideal for HV\/MV\/LV switchgear and power distribution terminals.<\/p>\n The forging process aligns the grain flow of copper along the contour of the part, dramatically improving mechanical performance over machined-from-bar alternatives. Key mechanical properties include 0.2% proof stress up to 250 MPa, ultimate tensile strength 250\u2013320 MPa, elongation 10\u201335%, Brinell hardness 60\u2013110 HB, fatigue limit at 10\u2078 cycles 90 MPa, impact resistance (Charpy), creep resistance at elevated temperatures, and stress relaxation resistance<\/strong>\u2014all critical for clamped electrical connections operating under vibration and thermal cycling.<\/p>\n Copper forgings exhibit outstanding resistance to corrosion in atmospheric, soil, and marine environments. The forging process produces a dense, pore-free surface that minimizes oxidation pathways. Conex Metals offers tin-plated copper forgings (5\u201325 \u00b5m), silver-plated copper forgings (3\u201315 \u00b5m), nickel-plated copper forgings (5\u201320 \u00b5m), hot-dip tinned copper components, electrolytic tinning, passivated copper parts, chromate conversion coated copper, and bare polished copper forgings<\/strong> depending on the service environment and contact requirement.<\/p>\n Precision closed-die forgings minimize secondary machining, reducing cost and lead time. Conex Metals achieves net-shape and near-net-shape copper forgings with flash-free precision die forgings, tight flash line control, coining operations for flat faces, thread rolling on forged shanks, CNC precision turning after forging, surface grinding of seating faces, broaching for internal profiles, and laser marking for part identification<\/strong>\u2014delivering complete finished components from a single supply source.<\/p>\n Surface treatment selection depends on application: tin plating for solderability and contact oxidation prevention, silver plating for high-temperature contacts and microwave applications, nickel plating for wear and chemical resistance. Conex Metals offers electroplating, electroless plating, barrel plating, rack plating, selective plating, brush plating, hot dipping, passivation, chromate treatment, and oxide patination<\/strong>. All plating is RoHS-compliant and REACH-conforming; thickness certification per ISO 2177 and salt spray testing per ISO 9227.<\/p>\n Conex Metals provides complete engineering support from concept to production. Services include DFM (Design for Manufacturability) analysis, forging simulation (Deform-3D), die stress analysis (FEA), prototype forging in 2\u20133 weeks, first article inspection (FAI), PPAP documentation, control plans, FMEA, SPC implementation, and production validation testing<\/strong>\u2014enabling customers to accelerate product development while minimizing tooling risk.<\/p>\nProduct Overview: Copper Forging & Forged Copper Parts<\/h2>\n
Hot Forged Copper Parts<\/h3>\n
Cold Forged Copper Parts<\/h3>\n
Copper Forged Electrical Connectors & Terminal Parts<\/h3>\n
Copper Forged Hydraulic & Plumbing Fittings<\/h3>\n
Copper Alloy Forgings \u2013 Brass and Bronze<\/h3>\n
Custom Copper Forged Components<\/h3>\n
Copper Forged Parts for Earthing & Grounding Systems<\/h3>\n
Key Features of Conex Metals Copper Forged Parts<\/h2>\n
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High Electrical Conductivity<\/h3>\n
Mechanical Strength and Fatigue Resistance<\/h3>\n
Corrosion and Oxidation Resistance<\/h3>\n
Dimensional Precision and Net-Shape Manufacturing<\/h3>\n
Plating and Surface Treatment<\/h3>\n
Custom Engineering and Prototyping<\/h3>\n
Technical Specifications<\/h2>\n
Standard Technical Parameters<\/h3>\n