1. Raw material pretreatment and smelting

Raw material selection: Based on electrolytic copper (purity ≥ 99.9%), nickel (1.0-1.2%), lead (0.8-1.2%), phosphorus (0.15-0.35%) and other trace elements (such as zinc, iron, etc., the content is <0.05%) are added in proportion.

Vacuum smelting: vacuum induction smelting technology is used to avoid oxidation impurities and ensure the uniformity of alloy composition. The smelting temperature is controlled at 1050-1100°C, the slag is removed by a slag remover (such as borax), and electrolytic copper and zinc ingots are added to adjust the composition.

Composition detection: After smelting, the element ratio is adjusted in real time through spectral analysis to ensure that it meets the chemical standards of C19160 (Cu≥97.8%, Ni 1.0%, Pb 1.0%, P 0.2%).

2. Casting and forming

Semi-continuous casting: Molten copper is injected into the crystallizer and rapidly solidified into an ingot through a water cooling system. This process requires controlling the cooling rate to avoid segregation.

Hot working: The ingot is initially formed into a billet by hot rolling or hot extrusion (temperature 750-875°C) to eliminate casting defects and refine the grains.

Cold working: The size is further refined through cold working processes such as drawing and rolling. The cold deformation rate can reach 30-50%, significantly improving the tensile strength (to more than 600 MPa).

3. Heat treatment and strengthening

Solution treatment: Heating to 700-800°C and then quenching in water to dissolve nickel phosphate (Ni3P) in the copper matrix to form a supersaturated solid solution.

Aging hardening: Aging treatment at 350-450°C for 2-4 hours to precipitate nano-sized Ni3P particles, achieve precipitation strengthening, and maintain electrical conductivity (≥50% IACS).

Surface treatment: pickling, polishing or electroplating (such as nickel/tin plating) according to needs to improve corrosion resistance and appearance.

4. Quality control and inspection

Non-destructive testing: ultrasonic flaw detection and eddy current testing are used to ensure that there are no cracks or pores inside.

Performance testing: including conductivity (55% IACS), hardness (HRB 75-90), tensile strength (450-600 MPa) and salt spray resistance test (≥500 hours)

Product advantages of C19160 copper rod

1. Balance of high strength and high conductivity

Ternary strengthening mechanism: through nickel solid solution strengthening, phosphorus precipitation strengthening and cold working deformation strengthening, the tensile strength is 450-600 MPa and the yield strength is ≥350 MPa, while the conductivity is maintained at 50-55% IACS, which is significantly better than ordinary brass (30-40% IACS) and beryllium copper (20-25% IACS).

Stress relaxation resistance: After aging treatment, the stress relaxation rate is <5% (100°C/1000 hours), which is suitable for long-term load-bearing scenarios (such as elastic elements).

2. Excellent processing performance

Easy cutting: Lead (1.0%) is distributed in the matrix in a free state, reducing cutting resistance, and the cutting efficiency is 30% higher than that of lead-free copper alloy, and the tool life is extended by 50%.

Hot and cold forming compatibility: The hot working temperature range is wide (750-875°C), the cold rolling elongation can reach 20%, and complex shape processing (such as connector pins) is supported.

3. Excellent corrosion resistance

Adaptation to marine environment: The corrosion rate in 3.5% NaCl solution is <0.02 mm/year, which is suitable for seawater cooling pipes, ship propellers, etc.

Chemical medium resistance: It shows good resistance to sulfuric acid (concentration ≤50%), sodium hydroxide (concentration ≤30%), etc., and can be used for chemical reactor lining.

4. High temperature stability

High softening temperature: Hardness retention rate below 562°C>90%, better than ordinary bronze (softened at 400°C).

Low thermal expansion coefficient: 9.8×10⁻⁶/°C (20-100°C), matching silicon chips to avoid thermal stress failure of electronic packaging.

5. Cost and environmental advantages

Replacing beryllium copper: Performance is close to beryllium copper (such as C17200), but the cost is reduced by 40%, and there is no beryllium toxicity risk.

Recyclability: Waste recycling rate>95%, in compliance with RoHS directive.