Production process

Raw material pretreatment and smelting

Use waste brass, waste copper, zinc ingots and other raw materials, and remove impurities through radiation inspection (to ensure safety) and manual sorting. Then smelt in an industrial frequency furnace or smelting furnace, add electrolytic copper, slag remover and other ingredients to adjust the composition to ensure the precise ratio of key elements such as silicon (Si), nickel (Ni), and chromium (Cr). The smoke and slag generated during the smelting process are treated by wet screening, bag dust removal and other methods to achieve environmentally friendly production.

Melting and forming

After being treated in a holding furnace, the molten copper liquid enters the continuous casting or casting stage, and is formed into a copper rod billet by a continuous casting machine. Some processes use hot extrusion (such as hot extruder) for further forming, combined with drawing (skin pulling, polishing) process to remove the surface oxide layer and improve the surface finish. The cooling stage uses a circulating water system to control the temperature to avoid grain coarsening.

Heat treatment and processing

The copper rods after continuous casting need to be annealed (annealing furnace) to eliminate internal stress and optimize mechanical properties. Diamond tools are used in the precision machining stage (such as turning, grinding, and polishing), and high-precision surface treatment (roughness up to 15nm) is achieved by optimizing parameters such as tool radius and feed rate.

Quality control

The whole process includes component analysis (such as spectrometer detection of element content), tempering/aging treatment (improving hardness) and finished product inspection (tensile strength, conductivity, etc.).

Product advantages

Excellent physical and mechanical properties

High conductivity (45% IACS) and thermal conductivity (200W/m·K): suitable for high temperature and high conductivity scenes such as resistance welding electrodes and motor commutators.

High strength and wear resistance: tensile strength of 650MPa, Rockwell hardness HRB 190, excellent wear resistance, especially suitable for high-load parts such as molds and brake discs.

High temperature softening resistance: softening temperature reaches 1040℃, and can maintain stable performance in high temperature environment.

Wide range of applications

Welding industry: resistance welding electrode head, stud welding head, due to high conductivity and low electrode loss.

Mold manufacturing: injection mold cavity, metal die-casting machine plunger head, with high hardness and thermal conductivity.

Automobile and machinery: motor commutator, brake disc, conductive nozzle, etc., to meet high strength and wear resistance requirements.

Advantages brought by production process optimization

Controllable composition: performance customization can be achieved by adjusting the silicon and nickel content (such as slightly higher silicon content can increase hardness).

Environmental protection and high efficiency: waste recycling (such as remelting of scraps) and smoke treatment technology reduce pollution, and continuous casting and hot extrusion processes improve production efficiency.

Excellent surface quality: precision machining technology ensures mirror effect (roughness 15nm), meeting high-precision industrial needs.