Processing high conductivity materials

Copper Academy:

Piotr Osuch, PhD AGH University of Science and Technology Faculty of Non-Ferrous Metals Krakow, January 2015

AGENDA – SCOPE OF THE PRESENTATION

1. INTRODUCTION

2. ELECTROREFINING PROCESS – CHEMICAL PURITY OF CATHODE

3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT

4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS

5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS

6. CRITICAL FACTORS OF WROUGHT PROCESSING FOR HIGH CONDUCTIVITY COPPER PRODUCTS

7. CONCLUSIONS AND SUMMARY

AGENDA – SCOPE OF THE PRESENTATION

1. INTRODUCTION

1. INTRODUCTION – ANALYSIS OF THE TOPIC

Periodic Table of the Elements 114 elements (91 metals)

PROCESSING HIGH CONDUCTIVITY MATERIALS

• DePiep; Periodic table (polyatomic); http://commons.wikimedia.org/wiki/File:Periodic_table_%28polyatomic%29.svg

62,1 MS/m

100 MS/m

58,6 MS/m

36,6 MS/m

44,2 MS/m 17,9 MS/m

29,8 MS/m

62,1 MS/m

100 MS/m

Meterials Conductivity Price, US$ per tonne

Carbon (graphene C) 100,0 MS/m 1 000 000 (?)

Silver (Ag) 62,1 MS/m 513 000

Copper (Cu) 58,6 MS/m 6 200

Gold (Au) 44,2 MS/m 38 500 000

Aluminium (Al) 36,6 MS/m 1 800

Calcium (Ca) 29,8 MS/m 300

Tungsten (W) 17,9 MS/m 36 500

AGENDA

IFLUENCE OF IMPURITIES ON COPPER ELECTRICAL CONDUCTIVITY

Copper Cathode Copper Ore

METALLURGY OF COPPER

Copper ore 1÷2,5% Cu Copper ore 1÷2,5% Cu

Concentrate 30÷40% Cu Concentrate 30÷40% Cu

Converter copper 98%Cu (blister) Converter copper 98%Cu (blister)

Electrolytic copper 99,9%Cu (cathode) Electrolytic copper 99,9%Cu (cathode)

ORE EXTRACTION TECHNOLOGY ORE EXTRACTION TECHNOLOGY

ORE ENRICHMENT TECHNOOGY ORE ENRICHMENT TECHNOOGY

SMELTING TECHNOLOGY SMELTING TECHNOLOGY

REFINING TECHNOLOGY REFINING TECHNOLOGY

Refined copper 99% Cu

REFINING TECHNOLOGY REFINING TECHNOLOGY Pb, Zn, Fe, S As, Sb, Bi, Ni

Ag, Au

Pb, Zn, Fe, S As, Sb, Bi, Ni

Ag, Au

S, Fe gases, slag

Ag, Au, Se, Te, As, Sb, Bi, Ni, Fe,

Zn, Mn, Pb,

Ag, Au, Se, Te, As, Sb, Bi, Ni, Fe,

Zn, Mn, Pb,

COPPER PRODUCTION PROCESS

ELECTROREFINING PROCESS

CONVENTIONAL ELECTROREFINING

TECHNOLOGY ON COPPER STARTER PLATE

MODERN ELECTROREFINING

TECHNOLOGY ON REUSABLE STARTER PLATE

Copper Cathode

IMPURITIES CONTENT: 20 – 30 ppm

IMPURITIES CONTENT: <15 ppm wag

PRODUCER CUMERIO AURUBIS

POLSKA

MIEDŹ

CATHODE OLEN AU ISA HMGB LME

OXYGEN,

ppm 50 – 70

SUMMARY

CONTENT

(WITHOUT Ag)

<22 <20 <15 <20 45

CHEMICAL COMPOSITION = IMPURITIES CONTENT + OXYGEN CONTENT

COPPER CATHODE

EXAMPLES OF POOR QUALITY CATHODES

AGENDA

COPPER CATHODE

COPPER WIRE ROD Cu-ETP

OXYGEN-FREE COPPER WIRE Cu-OFE

COPPER STRIP

COPPER BILLETS

Source: KGHM Polska Miedź S.A., Aurubis Group

COPPER CATHODE

COPPER STRIP

COPPER BILLETS

COPPER WIRE

drawing process

COPPER CATHODE

electrorefining process

continuous melting, casting and rolling process

WIRE and CABLES, TRANSFORMERS, MOTOR

WINDINGS

COPPER CATHODE

COPPER PRE-ROLLED STRIP

COPPER BILLETS

COPPER CATHODE

continuous melting and casting process

COPPER WIRE

drawing process

WIRE and CABLES (audio-video, fire-resistant etc.)

COPPER CATHODE

COPPER STRIP

COPPER BILLETS

COPPER CATHODE

UPCAST COPPER ALLOY WIRE ROD

SECTIONAL Cu-Ag WIRE (TROLLEY WIRE)

drawing process

COPPER CATHODE

COPPER STRIP

COPPER BILLETS

COPPER CATHODE

COPPER ALLOY WIRE ROD

CLAMPS and CONNECTORS FOR TROLLEY WIRES

forging process

COPPER CATHODE

COPPER BILLETS

COPPER CATHODE

COPPER STRIP

continuous casting process

COPPER SHEET

hot rolling process

COPPER SHEET

cold rolling process

CONTACTS

COPPER CATHODE

COPPER BILLETS

COPPER CATHODE

COPPER BILLETS

COPPER PROFILE

hot extrusion process

COPPER PROFILE

drawing process

BUSBARS COMMUTATORS

COPPER CATHODE

COPPER STRIP

COPPER BILLETS

COPPER CATHODE

COPPER BILLETS

COPPER BAR

extrusion process

forging process

WORLD COPPER FEEDSTOCK PRODUCTION (ELECTRICAL USES)

Source: CRU INTERNATIONAL

Wire rod 12,6 mln tons

Others 4,6 mln tons

COPPER BILLETS

COPPER STRIP

COPPER WIRE ROD

WORLD COPPER FEEDSTOCK PRODUCTION (ELECTRICAL USES)

Source: CRU INTERNATIONAL

Wire rod 12,6 mln tons

Others 4,6 mln tons

COPPER BILLETS

COPPER STRIP

COPPER WIRE ROD

AGENDA

CONTINUOUS CASTING AND

HOT ROLLING TECHNOLOGY CONTINUOUS CASTING

TECHNOLOGY

Cu-ETP (Electrolytic Tough Pitch)

Cu-OFC (Oxygen

Free Copper)

HIGH PURITY COPPER FOR ELECTRONIC USES

Knych, T.; Smyrak, B.; Walkowicz, M.: Research of Oxygen Free Copper of Upcast® Technology for Electric and Electronic Uses; World of Metallurgy – ERZMETALL 64 (2011) No. 1

HOT DEFORMATION OF COPPER WIRE-ROD (CONTINUOUS MELTING, CASTING AND ROLLING SYSTEM)

CATHODES FEEDSTOCK

MELTING FURNACE

HOLDING FURNACE

CASTING MACHINE

ROLLING MILLS COIL

DIMENSIONS: 60 x 120 = 7200 mm 2

Przekrój pasma, mm2

5066841001201311862743444857179261452232539505581

--------------

16151413121110987654321

Nr klatki walcowniczej

Przekrój pasma, mm2

5066841001201311862743444857179261452232539505581

--------------

16151413121110987654321

Nr klatki walcowniczejNumber of rolling stand

Cross section, mm2

COPPER WIRE-ROD

ETP COPPER

KGHM SA; Contirod Process Scheme; http://www.kghm.pl/index.dhtml?category_id=278&lang=en

CROSS-SECTION MACROSTRUCTURE – ETP CAST

DENSITY= 8,77 g/cm3

200 mm

Cu2O Cu2O

OXYGEN FREE COPPER

CONTINUOUS MELTING AND CASTING SYSTEM

ZAŁADUNEK KATOD

PIEC TOPIELNY

CASTING TUBE CONTROL PANEL

COILING MACHINES

Cu CATHODE CHARGE MELTING

FURNACE

CASTING MACHINE

WITH CRYSTALLISERS

SETTINGFURNACE

8mm 12mm 16mm 20mm 25mm

DIAMETER RANGE

• KGHM SA; Upcast proces scheme; http://www.kghm.pl/index.dhtml?category_id=278 • UPCAST OY; Upcast picture galery; http://www.upcast.com/wire-picture-gallery.html

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

CASTING SPEED [m/min]

OXYGEN FREE COPPER

INFLUENCE OF CASTING SPEED ON ELECTRICAL PROPERTIES

Knych, T.; Smyrak, B.; Walkowicz, M.: Selected aspects of evolution properties of oxygen free copper for high-advanced electrotechnical application; ELECTRICAL REVIEW, ISSN 0033-2097, R. 87 NR 9a/2011

Cu-ETP ELECTROLYTIC TOUGH PITCH COPPER

Cu-OF OXYGEN FREE COPPER

Cu2O Cu2O

MICROSTRUCTURE OF ETP AND OFE COPPER

Cu-OF LONGITUDINAL

SECTION

Cu-ETP LONGITUDINAL

SECTION

Fig. TENSILE CURVES of Cu-ETP and Cu-OF

0 5 10 15 20 25 30 35 40 45 50 55 60

ε, [%]

CHARACTERISTICS of ETP and OF WIRE ROD

CROSS SECTION

AGENDA

II. ROLLING PROCESS

IV. SHEET METAL FORMING PROCESS

V. FORGING PROCESS

III. EXTRUSION PROCESS

I. DRAWING PROCESS

Hot Working Cold Working

II. ROLLING PROCESS

V. FORGING PROCESS

I. DRAWING PROCESS

COPPER BILLETS

COPPER STRIP

COPPER WIRE ROD

continuous melting, casting and rolling

process

I. DRAWING PROCESS

Metal Drawing; Figure 237; Contirod Process Scheme; http://thelibraryofmanufacturing.com/metal_drawing.html

I. DRAWING PROCESS

Finished product: wire(Φ1.0mm)

Feedstock: rod (Φ8.0mm)

Metal Drawing; Figure 237; Contirod Process Scheme; http://thelibraryofmanufacturing.com/metal_drawing.html

Fig. Drawing machine

CONTINUOUS CASTING AND

HOT ROLLING TECHNOLOGY CONTINUOUS CASTING

TECHNOLOGY

Cu-OFC (Oxygen

Free Copper)

HIGH PURITY COPPER FOR ELECTRONIC USES

COPPER UTP CABLE – SIGNAL ATTENUATION

nal att

enuation [

nal att

enuation [

nal att

enuation [

nal att

enuation [

Frequency [MHz] Frequency [MHz]

PAIR 1 PAIR 2

PAIR 3 PAIR 4

COPPER UTP CABLE – PROPAGATION SPEED

Frequency [MHz] Frequency [MHz]

PAIR 1 PAIR 2

PAIR 3 PAIR 4

pagation s

peed [

pagation s

peed [

pagation s

peed [

pagation s

peed [

Cu-ETP ϕ = 0,58 mm

Cu-OF ϕ = 0,56 mm

COPPER UTP CABLE (UNSHIELDED TWISTED PAIR)

𝑮 = 𝝈𝑨

where:

σ (sigma) – electrical conductivity, measured in Siemens per meter (S·m−1),

l - length of the conductor, measured in metres [m],

A - cross-sectional area of the conductor, measured in square metres [m²].

The conductance G of a conductor of uniform cross section can be computed as:

II. ROLLING PROCESS

Metal Rolling; Fig. 131; http://www.thelibraryofmanufacturing.com/metal_rolling.html

II. ROLLING PROCESS

Finished product: sheet

Feedstock: strip

Metal Rolling; Fig. 131; http://www.thelibraryofmanufacturing.com/metal_rolling.html

MACHINES USED IN ROLLING

Achenbach; Rolling Mills; http://www.achenbach.de/produkte/walzwerkanlagen/buntmetall-walzwerke/

Direct Extrusion; Figure 209; http://thelibraryofmanufacturing.com/extrusion.html

Finished product: profiles, pipe,

rods, bars, tubes, welding electrodes etc.

Feedstock: billet

Direct Extrusion; Figure 209; http://thelibraryofmanufacturing.com/extrusion.html

MACHINES USED IN EXTRUSION PROCESS

SMS Group; Extrusion Presses; http://www.sms-meer.com/en/portfolio/forging/extrusion-presses.html

MACHINES USED IN EXTRUSION PROCESS

SMS Group; 25 MN HybrEx Press; http://www.sms-meer.com/news-medien/news/single/article/als-erster-kunde-hat-hmt-hoefer-metall-technik-sich-fuer-die-neu-entwickelte-hybrex-strangpresse-von.html

CONTINUOUS EXTRUSION PROCESS

continuous extrusion

cooling finished product cleaning transport

Metalite; Deep Drawing; Contirod Process Scheme; http://www.metalite.net/WhatisDeepDrawing.html

Feedstock: sheet

Finished product:

cups, pans, cylinders, irregular shaped

products

Metalite; Deep Drawing; Contirod Process Scheme; http://www.metalite.net/WhatisDeepDrawing.html

MACHINES USED IN SHEET METAL FORMING PROCESS

V. FORGING PROCESS

1. 2. 3.

Forging Presses; Fig. 176; http://thelibraryofmanufacturing.com/presses.html

Feedstock: ingot/billet

V. FORGING PROCESS

1. 2. 3.

Finished product:

components like holders,

jaws, clamps, inserts,

pads, etc.

Forging Presses; Fig. 176; http://thelibraryofmanufacturing.com/presses.html

MACHINES USED IN FORGING PROCESS

Hyundai Forging Co, Ltd.; Forging Press; http://www.hd-forging.co.kr/EN/html/sub02_03_01.html HFM Press Group Limited; Forging Press; http://www.hfm-press.com/Hydraulic-Press/Hydraulic-Drawing-Press/220-Open-Die-Forging-Press.html

AGENDA

CHOICE OF HIGH QUALITY COPPER CATHODE CHOICE OF HIGH QUALITY COPPER CATHODE

25 COUNTRIES 25 COUNTRIES

44 PRODUCERS 44 PRODUCERS

76 GRADES OF

COPPER CATHODE

76 GRADES OF

COPPER CATHODE

London Metal Exchange (LME)

COPPER CATHODE

London Metal Exchange (LME)

Continent Producer Country

Elements weight content[wt. ppm]

Ag As Bi Cd Co Cr Fe Mn Ni P Pb S Sb Se Sn Te Zn Σ/{A

Europe KGHM Polska Miedź S.A. Poland 10 0,7 0,6 1,0 0,5 0,5 0,5 0,8 1,0 1,0 1,0 7,0 1,0 0,5 0,5 1,0 1,0 19

Aurubis Germany 10 1,0 0,5 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 5,0 1,0 0,5 1,0 0,5 1,0 19

Africa Konkola Copper Mines Zambia 10 1,0 0,5 0,1 1,0 1,0 2,0 1,0 1,0 1,0 1,0 7,0 1,0 0,5 1,0 0,5 1,0 21

America Codelco Chile 9,0 0,6 0,8 0,1 0,5 0,5 0,1 0,4 0,5 0,3 2,0 6,0 1,0 0,3 0,3 1,0 1,5 16

America Grupo Mexico Mexico 10 1,0 0,5 1,0 1,0 1,0 2,0 1,0 1,0 1,0 1,0 7,0 1,0 0,5 1,0 0,5 1,0 22

Australia Xstrata Australia 9,0 0,7 0,8 0,1 0,5 0,5 0,1 0,5 0,5 0,5 2,0 6,0 1,0 0,3 0,3 1,0 1,5 16

Asia Mitsubishi Materials

Corporation Japan 10 0,8 0,6 1,0 1,0 0,5 1,0 1,0 1,0 1,0 1,0 6,0 1,0 0,5 1,0 0,5 1,0 19

100 120 140 160 180 200 220 240 260 280 300 320 340 360

TEMPERATURE, °C

Cu-ETP

Cu-OFE

ε=93% t=1h

MICROSTRUCTURE OF WIRE ROD AFFECTING TECHNOLOGICAL REQIUREMENTS

RECRYSTALLIZATION TEMPERATURE

Cu-OF (Oxygen

Free Copper)

COPPER BILLETS

COPPER BAR

extrusion process

forging process

COPPER CATHODE

COPPER WIRE ROD

PROCESSING TECHNOLOGY

COSTS OPTIMIZATION

AGENDA

CONCLUSIONS 1. Since chemical purity of copper is crucial for electrical conductivity, all

technological steps involving metallurgical processes should contribute itself to achiving higher purity of the copper product. Especially in case of conventional electrorefining technology qualitative selection of cathodes is necessary.

2. It has been proven the microstructure (along with chemical purity) is one of the factors influencing copper’s electrical properties (such as conductivity, reflection losses, signal propagation rate, etc.), therefore it is recommended to adjust the processing route for specific application.

3. Optimization of technological route can be beneficial for production costs of final product. Examples: • Replacing extruded profiles by continuous casted ones as a

feedstock for forging clamps and connectors for railway traction. • Better electrical properties of oxygen free copper wires allow for

thinning the wires within a UTP cable

Thank you for your attention

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