C19140 copper rod production process

1. Raw material preparation and smelting

Raw material selection: mainly high-purity electrolytic copper (content ≥ 99.5%), with alloy elements such as nickel (0.80-1.20%), lead (0.40-0.80%), and phosphorus (0.15-0.35%) added.

Smelting: Use electric furnace or submerged furnace to smelt at a high temperature of 1200-1400℃, and add slag remover (such as charcoal) to remove impurities to ensure the purity of the molten liquid. Composition detection is required during the smelting process, and alloy elements are supplemented when necessary.

2. Casting molding

Continuous casting process: The mainstream adopts the upward continuous casting method to continuously draw the molten copper liquid through the crystallizer. This process achieves efficient solidification and microstructure optimization by controlling the cooling water temperature (inlet water ≤ 30℃, outlet water ≤ 45℃) and liquid level height (± 20mm error).

Traditional casting: Some companies use casting models, and the copper liquid is cooled to form a rough billet, but the efficiency is low.

3. Hot and cold processing

Rolling/extrusion: Through the hole rolling or forward extrusion process, the diameter of the copper rod is adjusted and the surface finish is improved. The initial tensile strength can reach 376MPa.

Drawing: Further reduce the diameter and increase the strength. The tensile process increases the yield strength to 746MPa while maintaining an elongation of 13%.

4. Heat treatment and surface treatment

Aging hardening: Artificial aging (such as Ausaging or Q+T process) is carried out after solution treatment to promote the precipitation of second phases such as nickel phosphide (Ni3P), significantly improving the hardness (Brinell hardness 414HBW) and stress relaxation resistance.

Annealing: Eliminate cold working stress and improve plasticity. The annealing temperature is adjusted according to process requirements.

Surface treatment: Use pickling, polishing or oiling process to prevent oxidation and improve aesthetics.

5. Inspection and finishing

Non-destructive testing: including ultrasonic flaw detection and chemical composition spectral analysis to ensure that there are no internal defects.

Finishing: Straightening and cutting to standard size (such as diameter 0.01-1000mm), packaging and shipment.

Product advantages of C19140 copper rods

1. Excellent mechanical properties

High strength: yield strength 746MPa, tensile strength 376MPa, far exceeding ordinary brass (such as H62 yield strength ≤240MPa).

High hardness: Brinell hardness 414HBW, excellent wear resistance, suitable for high friction environment.

Good plasticity: elongation 13%, fracture surface shrinkage 24%, taking into account strength and formability.

2. Excellent physical properties

Electrical conductivity/thermal conductivity: electrical conductivity ≥50% IACS (International Annealed Copper Standard), thermal conductivity 146 Btu/(ft²·hr·°F), suitable for electrical components and heat exchangers.

Thermal stability: thermal expansion coefficient 9.8×10⁻⁶/°F (77-212°F), elastic modulus 18,000ksi, good dimensional stability at high temperature.

3. Corrosion resistance and fatigue resistance

Corrosion resistance: The synergistic effect of lead and phosphorus elements has significant corrosion resistance in humid or sulfur-containing environments, and the service life is more than 30% longer than that of ordinary copper alloys.

Fatigue resistance: High fatigue limit, suitable for automotive or aviation parts with frequent vibration.

4. Processing and cost advantages

Easy cutting: The addition of lead (0.4-0.8%) improves cutting performance, reduces tool wear, and increases processing efficiency by 20%.

Cost-effectiveness: Compared with similar high-strength copper alloys (such as beryllium copper), C19140 material costs are reduced by about 40%, and no complex plating treatment is required.

5. Wide range of applications

Electronic and electrical: connector pins, relay contacts, coaxial cable contacts, relying on its high conductivity and arc resistance.

Automotive industry: engine sensor terminals, brake system components, resistant to high temperatures and vibrations.

High-end manufacturing: aerospace fasteners, ship valves, outstanding resistance to seawater corrosion.