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In the copper continuous casting machine, copper is liquefied in a crucible before being cast into rods. The main copper continuous casting alloys are as follows, including brass and bronze.
Copper
Copper has many uses. Its high conductivity makes it very useful in electronic and electrical applications. In construction, it is used for plumbing and roofing. Additionally, it is also used in the manufacturing of copper pipes.
C11000 electrolytic tough pitch copper (ETP)
ETP copper contains about 0.02% oxygen. It is then electrolytically refined to remove most of the oxygen. The remaining oxygen is not problematic since it helps to facilitate the bonding of copper with other metals.
ETP copper is ideal for electrical applications where high conductivity is expected. It is also ideal for water systems and architectural features.
C12200 Deoxidized High-Phosphorus Copper
C12200 comprises around 0.02% to 0.5% phosphorous and less than 0.01% sulfur. It is practically the same as ETP except that phosphorous remains in ETP copper. When high-strength brass backing is required, high-phosphorus bronze is ideal.
Since most of the oxygen is bonded to phosphorous, C12200 is ideal for applications where the copper will be subjected to high temperatures. It is also suitable for use in environments that can facilitate scar formation through chemical reactions with oxygen.
C26000 brass
C26000 consists of about 70% copper and 30% zinc with traces of other metals. The copper and zinc alloy called brass is what forms the base of this alloy. Brass has a gold-like color and is highly durable, corrosion-resistant, and easy to work with.
C26000 is the copper that is continuously cast into brass. It also has excellent electrical and thermal conductivity. Common applications include plumbing, heating, radiators, and electrical components.
C51000 silicon-bronze
C51000 has around 60% copper, 32% zinc, and 8% silicon. It is a type of bronze alloy that consists mostly of copper with traces of zinc and silicon. Silicon enhances the alloy’s mechanical properties, making it stronger and more corrosion-resistant.
Refer to the point above for the application of this material. Note that it is more eco-friendly as it uses less chemical agents in the production process.
C46400 aluminum-bronze
C46400 has high levels of copper, along with significant amounts of aluminum, iron, and nickel. It has about 60% copper, 20% to 25% aluminum, 5% iron, and 3% nickel. C46400 is strong, corrosion-resistant, and highly durable, making it ideal for marine, industrial, and mechanical components.
Excellent conductivity
Copper has high electrical and thermal conductivity. In fact, it has 97% electrical and 80% thermal conductivity compared to silver, which has 100% electrical and thermal conductivity.
Corrosion resistance
Copper is highly resistant to corrosion, especially in alkaline and saltwater environments. Continuous copper casting maintains this property within the copper.
Versatility
Copper has a wide range of applications because it is malleable, ductile, and can be easily alloyed to produce other materials. It can also be used in construction, electrical wiring, plumbing, and heat exchangers.
High tensile strength
Continuous casting copper exhibits high tensile strength, which allows the material to be used in different demanding structural applications without stretching, deforming, or breaking.
Eco-friendly
Copper is highly recyclable. In fact, more than half of the copper used in construction over the years has been sourced from recycled copper.
High melting point
Copper has a melting point of 1084 °C or 1984 °F. This means the metal remains solid and stable under extremely high temperatures, thus facilitating its use in high-temperature environments.
Antimicrobial properties
Copper’s surface is lethal to pathogens such as bacteria, viruses, and fungi. This makes it ideal for use in healthcare settings. It also improves air quality when used in HVAC systems because it eliminates microorganisms and allergens.
Refractory properties
Continuous copper casting has excellent refractory properties which makes it ideal for use in high-temperature applications. For instance, it is used in furnace parts and molds. In fact, it is one of the most durable continuous casting materials out there.
Continuous-cast copper has numerous commercial uses because manufacturers can control its quality and form it into various shapes. Here are some common applications:
Electrical applications
Oxygen-free copper is an ideal form of copper for electrical applications. With a conductivity of 99.97%, it is the second most conductive material after phosphorous. It is, therefore, ideal for making wires, cables, and electronic components. High-quality sound systems, motors, and electrical connections also use ETP copper.
Architectural and decorative applications
Architects use continuous-cast copper to make roofing, façades, and other architectural elements. Construction uses copper for gutters, downspouts, and decorative features because of its aesthetic appeal and resistance to corrosion.
Industrial machinery and components
Copper’s excellent thermal conductivity makes it ideal for heat exchangers, radiators, and other components that require efficient heat dissipation. In the HVAC industry, it is utilized in compressors, condensers, and evaporators.
Continuous copper casting also produces components used in gears, bearings, and other machinery. This helps improve wear resistance, minimising friction and extending the machine's life. Some of these components are used in marine and industrial environments.
Artwork and decorative items
Continuous copper casting produces a variety of artistic and decorative items such as sculptures, plaques, and inlays. The precision of the casting process allows for intricate designs and high-quality finishes that are prized in the art and décor markets.
Engine components
Copper is the go-to material for engine components such as pistons, cylinder heads, and liners, especially in high-performance or heavy-duty engines. Its thermal conductivity helps dissipate heat, reducing the risk of overheating and improving the engine’s overall efficiency.
Hydraulic systems
Copper and copper alloys are used in piping and fittings within hydraulic systems. Their corrosion resistance, strength, and durability make them ideal for transporting fluids under high pressure.
Art and decorative items
Continuous copper casting produces a variety of artistic and decorative items such as sculptures, plaques, and inlays. The precision of the casting process allows for intricate designs and high-quality finishes that are prized in the art and décor markets.
Choosing the ideal continuous copper cast for a certain application relies on how optimal its properties are for the job. Here are the main things to consider when buying the product.
Quality
The quality of continuous casting copper is crucial because it defines how adaptable the copper will be. The quality is mainly defined by the alloy composition, purity, and the manufacturing process. For instance, what the manufacturer uses to control the continuous casting process's speed, temperature, and cooling rate will determine the quality of the final product. Aim to purchase high-quality copper reinforced with essential elements to improve its strength, conductivity, and corrosion resistance.
Copper grade
Copper comes in many grades, each ideal for a different application. Some of the most popular grade compositions include ETP, oxygen-free copper, and high conductivity copper. A grade that has been tailored to a user’s unique application will not only perform but will also lower operational costs.
Application
The ideal continuous copper casting should be suitable for a certain application. People go for continuously cast copper for electrical applications, construction, machinery parts, art, marine components, and more. Consumable’s compatibility with a specific application should be part of the purchasing decision. Also consider other factors such as the industry standards required for the application in question.
Workability
Continuously cast copper is normally uniform in texture and composition, making it easy to machine, weld, and join. The ease to which the copper is alternatively worked will affect its cost and application suitability. If it is the first time buying the continuous casting copper, consider how easily it can be fabricatively processed.
C12200 has high mechanical strength and will remain chemically stable under high heat. It is suitable for high-pressure and high-temperature applications, making it one of the most versatile continuously cast coppers.
Manufacturers add beryllium to this type of continuously cast copper to give it exceptional durability and hardness. This makes it ideal for heavy-duty applications like aerospace and industrial machinery where great resistance to wear and tear is needed.
Continuous copper casting is an automated, uninterrupted process producing large, uniform quantities of copper shapes. In contrast, batch copper casting is a more traditional method where molten copper is poured into molds for smaller, often custom, production. Continuous copper casting is ideal for high-demand needs, while batch copper casting caters to specialized requirements.
C46400 is renowned for its exceptional strength, corrosion resistance, and durability. It is, therefore, eco-friendly since it requires fewer chemical agents during the production process.
