Application Notes Copper English

8/3/2019 Application Notes Copper English

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Application

NotesCoppe, togethe with god and tin weethe st metas put to use by ancient man.The ease with which it coud be shaped andomed, its attactive coou and its coo-sion esistance wee among some o theeasons why it ound widespead use in themanuactue o eay weapony, jeweey,itugica vesses and eveyday domesticobjects.

Metaic coppe has been known since

about 9.000 BC and was widey used by5.000 BC. When its vaue as an aoy withtin was ecognised, the bith o the BonzeAge initiated a poound cutua andeconomic deveopment in Euope and theMediteanean counties.

Histoicay, casting o bonze has a ongtadition, but it is ony since the 1920s thathot oing and extusion o coppe andits aoys have been pacticed. Nowadays,most o the coppe poduced is in woughtom, and with its high eectica conductiv-ity coppe is much used as cabes, switch-gea components, tansomes, motowindings, and geneatos. Oxygen eecoppe is mainy used in the eecto-nicsindusty.

The coosion esistance and high themaconductivity o coppe make it suitabe otubes, vesses and heat exchanges in thechemica, and ood and beveage industy.Apat om the taditiona appications o

Metallographicpreparation o copperand copper alloys

coppe o wate and heating pipes, achi-tects have in ecent yeas discoveed theappea o designing acades with oxidisedcoppe sheets.

The metaogaphy o coppe and its aoysis used o gain size measuement andpuity checks by quaiying and quantiyingthe coppe oxide content. On occasion, incetain basses, the distibution o ead isdetemined as it can infuence the machin-ing pocess. In cast aoys the geneamicostuctue and distibution o eutectico ead is evauated as we as the pesenceo shinkage cavities o poosity.

Pue coppe is sot and ductie, easy todeom and pone to om scatches.

Difculties in the preparation o copper and its alloys Solution

Bonzes, and even some o the hadebasses, may be susceptibe to seveescatching.

- Avoiding coase ginding abasives

- Thoough diamond poishing withsot coths

- Chemica-mechanica ne poishing

Aluminium bronze, CuAl8, shows dendritic structurewith- eutectoid. Colour etching according to Klemm,

pol. light, 100x.

Fig.1: Pure copper wire, with fnal polish oOP-S, DIC, 200x.

Fig. 2: Same sample as Fig.1 with fnal polish oOP-S-ammonia water-hydrogen peroxide-mixture,

DIC, 200x.


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Athough metaic coppe occus natuay,it is mainy extacted om suphide oes ina metaugica smeting pocess. A smaamount o coppe is aso poduced by hy-do-metaugica pocess. A bie descip-tion o the ou steps in the coppe poduc-tion pocess is povided beow.

1. Coppe mae, 75% C:In this st smeting pocess o extaction,coppe concentates, mainy chacopyite(CuFeS

2

), ae oasted and meted withfuxes in an oxygen fash unace to mattecoppe. Matte is a mixtue o coppe su-phide and ion suphide and contains ap-pox. 75% coppe.

2. Be coppe, 96-98% C:In a convete ai is bown into the iquidmatte to oxidise the suphides. The esut-ing biste coppe contains appox. 96-98%coppe.

3. Aoe coppe, 99% C:

Biste coppe is ened in the anodeunace. It is meted with coppe scapand ests o anodes om the eectoyticening. Ai bowing the met, poduces anoxidizing atmosphee which educes theimpuities that ae then dischaged as sag.The high oxygen content o the met needsto be oweed to ess than 0.1% as coppeoxides make the coppe bitte. The oxygencontent is oweed by bowing natua gasinto the met, which educes the coppe ox-ide to coppe, eeasing steam and cabondioxide. The esuting coppe is 99% pue

and cast into anodes that ae subsequentyused o eectoytic ening.

4. Eecoc ef, coppe caoe,99.99% C:The coppe anodes ae sti contaminatedwith metas such as Ni, Pb, Ag, Pd and Au.Duing the eectoytic ening pocess,high puity coppe is poduced wheebythe impuities dop to the bottom o theeectoyses ce and ae ecoveed. A sou-tion o suphuic acid and coppe (II) su-phate, unctions as eectoyte. Using diect

cuent, the oxidation occus at the anode,which is dissoved, and the pue coppe isdeposited at the cathode state sheet o

Production andapplication

Coppeom aw mateia to eectoytic coppe

Coppecoceae

Aoe cap

Coppe capBe coppe

Eea caoe,pe coppe cap

OxygEn lAsh urnACE

COnvErtEr

AnOdE urnACE

Sag

Sag

State sheetStainess stee

Anode99% Cu

Biste coppeca. 96% Cu

Coppe matte

ca. 75% Cu

PrECIOUSMETAlS

SiveGodPatinumPaadiumSeenium

Anode sudgeteatment

Unaoyed o aoyedcoppe poducts

round biets

Squae biets

roed pates

rewoking to continuousycast wie o diect sae

Slag

Anoderemnants

ElECtrOlysis

Oundry

Eectoytic coppe99,99% Cu

Simplifed schematic diagram ocopper production

Fig. 3:Electrolytic refning


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pue coppe o stainess stee, om whichit is mechanicay emoved.

The cathode pates o this vey pue coppeae meted with 50% pue coppe scapand cast into pates, ound and squaebiets which ae then conveted to sheets,pipes, wie and casts. (Amost ha the de-mand o coppe today is coveed by coppescap and ecyced coppe.)

With inceasing puity, the eectica andthema conductivity, as we as the piceo coppe incease. Theeoe the use opue coppe depends on the appication othe poduct. Due to its exceent popeties,oxygen ee coppe o eectonics (OFE) isused as a basic mateia o semi conduc-tos, switches and seaing ings in vacuumtechnoogy and eecton tubes.

The agest amount o coppe is used inconstuction o acades, oos, potabewate pipes and heating instaations, as

we as the eectica pats industy omoto cois, geneatos and powe suppysystems. Additiona eds o appicationsae cyogenics and ai conditioning tech-noogy, chemica industy and beveageand bewing technoogy.

Copper alloysThee ae a age ange o coppe aoys;howeve, zinc (bass) and tin (bonze) aethe most impotant aoying eements ocoppe. Some o the most impotant aoysand thei appications wi be biefy de-scibed in the oowing section.

Bae ae coppe aoys with 5 - 45%zinc. Coppe has a high soubiity o zincand the aoys ae vey homogenous. Bass

with ess than 28% zinc is caed ed bassand is especiay suitabe o machining.With inceasing zinc content the eddishcoppe coou changes to the yeow obass. Aoys up to 37% zinc consist o- soid soution and ae suitabe o codoming. With inceasing zinc content thebass becomes hade and theeoe easieto machine. Fom 38% zinc, the aoysdispay a two-phase - micostuctuewhich is suitabe o hot oming. By add-ing auminium, manganese, ion, nickeand tin, specia types o bass, which have

specic chemica o mechanica pope-ties, can be poduced. Additions o smaamounts o ead impove the machinabiityo bass.

Depending on the zinc content, dieentbasses ae used in vaious eds o ap-pication: om watches and jeweey toeecto-technoogy (CuZn5), to spings,scews, pins, die oged pats (CuZn30),to amatues (CuZn40) and beaingso sea wate esistant pump housings(CuZn10Sn2).

Fig.4:Control valve or the distribution

o potable water.

Fig. 5: Copper with red copper oxides,dark feld, 500x.

Fig. 6: Oxygen ree copper, etched with ammoniumperoxydisulat, 100x.

Danish Embassy, Berlin, cladded with oxidisedcopper plates.

Courtesy: Danish Foreign Ministry

Fig. 7: Copper cathode, etched accordingto Klemm, 100x.

Fig. 8: Anti-riction and roller bearing brass cages


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Fig.10:-brass, colour etched, 200x.

Fig.12:--brass cast, etched according to Klemm, light-solid solution in dark matrix o-solid solution, 100x.

Fig.13: Cast bronze pump housing

Fig.14: Wrought bronze liners with graphite

CitoPressHot mounting press

Fig. 11:--brass cast (CuZn40Pb2) with grey-blue leadnclusions, unetched, 500x.

Fig. 9:Wrought bronze tubes

and profles

Boze ae coppe-tin aoys that ae di-vided into wought aoys, with up to 8.5%tin, and cast aoys, with usuay 9-12%tin, and aso so-caed be casts with up to20% tin.

Depending on the equied popeties,sma amounts o zinc and phosphous canbe added to the wought aoys, e.g. obeaings. These aoys ae caed phosphobonzes. lead, nicke and ion ae commonadditions to cast aoys.

Cu-Sn-Zn-aoys ae caed gun meta. Theyae oten used o the manuactue o sidebeaings, wom geas, beaing bushes;pats which need a beaing suace capabeo withstanding high contact oads. As weas good coosion esistance, Gun metahas a ow iction coecient which meansit can opeate unde such conditions with-out seizue.

Auminium bonzes ae coppe aoys withup to 11% auminium, dispaying highstength at eevated tempeatues and veygood coosion esistance. They ae suitedo maine popees, highy stessed o-tos o pumps and wate tubines, andbeaings and pats o the chemica indus-ty. Coppe-auminium wought aoys aeused in mechanica and ight engineeing.Beyium bonze has high stength andhadness, with the specic popety o notpoducing spaks when stiking o impin-ging othe metas. Theeoe this type obonze is suited o toos in an exposiveenvionment such as eneies.

Due to thei exceent coosion esistance,coppe-nicke aoys ae used in desaina-tion pants, o coins, heating wies intoastes and hai dies. The coppe-nicke-zinc aoys, caed Geman sive, dispayhigh stength, ae coosion esistant andae easiy omed. Fieds o appication aesugica instuments, ood industy, basemeta o sive cutey, contacts in connec-tos and jeweey.

Difculties in thepreparation o copper andcopper alloysWith inceasing puity, coppe becomessote and moe susceptibe to mechanicadeomation and scatches. Consequenty,ginding can cause deep deomation inhigh puity coppe whie ginding and po-ishing abasives can be pessed into thesuace. Coppe aoys ae hade, but stihave a tendency to om scatches, whichin some bonzes may ony occu ony insome individua gains.

Recommendations or thepreparation o copper andcopper alloysFo eco o coppe a had siiconcabide cut-o whee is used that is gene-ay suitabe o non-eous metas.Fo mo, a phenoic esin is in mostcases sucient.


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Mecaca a poIt is ecommended that pane ginding iscaied out with the nest possibe git inode to avoid any excessive mechanicadeomation. Hadness, size and numbeo sampes have to be taken into account,but even with age sampes o pue cop-pe, pane ginding with 500# SiC-pape issucient. lage cast pats o coppe aoyscan be gound with 220# o 320#. It is asoimpotant that the oce o ginding is owto avoid deep deomation.

As indicated in the tabe with the pepaa-tion data, o the sot aoys ne gindingwith SiC-pape with ne gits is ecom-mended, wheeas MD-lago with diamondcan be used o the hade aoys. Bettepaneness and edge etention is obtainedusing MD-lago.

Diamond poishing has to be caied outunti a deomation and embedded aba-sives om ginding have been emoved.The chemica-mechanica ne poishing

with siicon dioxide is especiay impotantas an amost scatch ee suace can beachieved. Fo pue coppe, the na poishwith a soution containing ion nitate haspoven to give vey good esuts, and ocoppe aoys, a mixtue o OP-S suspen-sion with hydogen peoxide and ammoniawate is ecommended (Fomua beowthe tabe). Ate 1 minute poishing theesut is checked unde the micoscope. Inecessay the poish shoud be continuedo anothe minute and the esut checkedagain. It is ecommended to continue this

poish/check sequence unti the equiedquaity o the esut has been achieved. Ithe attack is too ast o too stong the mix-tue shoud be diuted with wate.(Approx. 30 sec beore the end o polishing, water is

poured onto the polishing cloth to rinse the sample as

well as the cloth. Then the sample is washed again with

clean water rom the tap and then dried.)

The pepaation data ae o the automaticginding and poishing o 6 mounted sam-pes, 30 mm diamete, camped into ahode.

Eecoc Po is suited o puecoppe and - bass wought aoys. Two-phase - - bass can aso be poished

Mecaca PepaaoPue coppe and coppe aoys withow aoying contents.Grinding

sep Pg g 1 g 2 g 3

sace SiC- Pape SiC-Pape SiC-Pape SiC-Pape

g 320 800 1200 4000

lbca Wate Wate Wate Wate

pm 300 300 300 300

oce (n) 150 150 150 150

tme As needed 1 Min. 1 min. 1 min.

Polishing

sep dP OP

sace MD-Mo OP-Chem

spe-o

DiaPo Mo Ion (III)nitate*

pm 150 150

oce (n) 150 90

tme 4 min. 1 min.

Coppe aoysGrinding

sep Pg g

sace SiC-Pape MD-lago

K*/ speo 220 o 320 DiaPoAego/lago

lbca Wate

pm 300 150

oce (n) 180 180

tme As needed 4 min.

Polishing

sep dP OP

sace MD-Mo* OP-Chem

speo DiaPo Mo OP-S**

pm 150 150

oce (n) 150 90

tme 3 min. 1-2 min.

*Wet the polishing

cloth with water and

polish with a ew

drops o the etchant

without any polishing

medium.

Formula: see table

on page 6.

*Alternative: MD-Dac

**96 ml OP-S, 2 ml ammonia water (25%),2 ml hydrogen peroxide (3%)

Fig.15:--brass cast, mechanically polished,unetched, 200x.

Fig.16: Same specimen as Fig.15 electrolytically

polished, unetched, 200x.The lead inclusions are pulled out and thereore appearlarger and more numerous than in Fig.15.

Fig.18: Same specimen as in Fig.17, colour etched accor-ding to Klemm, dendritic structure with light blue eutectoid

and blue lead inclusions. Small lead inclusions can not beclearly dierentiated, 500x.

Fig.17: Bronze cast, CuSn8Pb, unetched, large andsmall blue-grey lead inclusions, pale blue- eutectoid

discernable, 500x.

eectoyticay, but the esuts ae not vey

we suited o quantitative anaysis, espe-ciay i the aoy contains ead.Peequisite o a good eectoytic poishis a peceding ne ginding with SiC-papeup to 2400# o 4000#. Due to the dieentphases in cast aoys, they ae not suitedo eectoytic poishing.

Eecoe: d2

Aea: 0.5 cm2

voae: 24 v

ow ae: 10

tme 20 ec

Diecty ate poishing the sampe can beetched with the same eectoyte o 4 sec-onds with 2-4 vots.

EcThee ae numeous etchants o coppeand its aoys that ae eativey easy toappy. Most o the cast aoys ae not di-cut to etch. It can be moe dicut to ndthe ight etching soution o some o thewought aoys, especiay when they aeseveey cod woked. In these cases a co-ou etch can be hepu.It needs to be pointed out that ead is at-tacked by the etchants and mosty onyback voids emain. Micogaphs that ae todocument the quantity and distibution oead aways have to be taken beoe etching.The coou o pue ead is gey-bue.


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smmaDue to its good omabiity, high eectic

and thema conductivity and coosionesistance, pue coppe is mainy usedin eectic engineeing, the eectonicsindusty and in the ood and beveage in-dusty. The appication o bass and bonzewought and cast aoys anges om smapats to sea wate esistant pump hous-ings. The metaogaphy o coppe and itsaoys is used in quaity conto mainy ochecking puity and gain size detemina-tion. In addition, cast aoys ae examinedo genea stuctue evauation. Coppe issot and ductie and paticuay pone to

mechanica deomation. Theeoe caeneeds to be taken that o the st gindingstep the nest possibe git is used. Dia-mond poishing is caied out on mediumsot to sot coths and can take eativeyong o pue coppe. Chemica-mechani-ca na poishing with OP-S suspension isessentia and esuts in a scatch ee su-ace. lead ee wought aoys can aso beeectoyticay poished. Etching with thecommon etchants is aiy easy, wheebycoou etching can evea some attactivestuctues in cast bonzes.

ppcao Eca

ain aea etch ooppe, bass andonzes

100 m wate10 g ammonium peoxydisuateUse esh!

types o coppe 100-120 m wate o ethano20-50 m hydochoic acid5-10 g ion (III) choide(concentation vaiabe)

ain boundaies

ain aeas

25 m distied wate25 m ammonia wate5-25 m hydogen peoxide, 3%

less hydogen peoxide

Moe hydogen peoxide- bass

ast and good poish oue coppe

oou etch accodingo Kemm

120 m Wate10 g coppe (II) ammonium choideAdd ammonia wate unti pecipitate dissoves

100 m wate100 m ethano19 g i on (III) nitate

100 m cod satuated sodium thiosuate40 g potassium metabisut

Ao

Eisabeth Weidmann, Anne Guesnie, Stues A/S

Ackoweeme

We wish to thank Geb. Kempe, Ope, Gemany, o thepemission to epoduce the photos o the pump housingFig.13 and vave Fig. 4.

We wish to thank Buntmeta amstetten Ges.m.b.H.Amstetten, Austia, o sampe mateia and we thank SiiviaTopseve and Siegied Pisch o thei suppot.

We wish to thank Enzesed-Cao Metaweke AG, Enzesed,Austia, o the pemission to epoduce Figs. 8, 9 and 14,and we thank Andeas Divodeits o his suppot.

We wish to thank G. Kiesse and G. Esne, Max-Panck

Institut Metaoschung, Stuttgat, Gemany, o thepemission to epoduce Figs. 15 and 16.

We wish to thank Deutsches Kupeinstitut (Geman CoppeInstitute), Dssedo, Gemany, o the pemission toepoduce Fig. 3.

We thank Wieand Fische, Stues GmbH, Wiich, Gemany,o the mciogaphs Fig.1 and 2.

Bboap

Cuent pinted inomation om Deutsches Kupeinstitut,Dssedo, Gemany.

ASM Handbook, Vo. 9, Metaogaphy and Micostuctues,ASM, 2004.

Metas Handbook, Desk Edition, ASM, 1997.

Handbuch de metaogaphischen tzveahen, M. Becket

und H. Kemm, VEB Deutsche Veag Gundstondustie,leipzig, 1976.

Metaogaphische Aneitung zum Fabtzen nach demTauchveahen, E. Weck, E. leistne, Deutsche Veag Schweitechnik, Dssedo, 1982

Aluminium bronze, colour etched according to Klemm,pol. light, 200x.

Bronze cast, CuSn10, etched with iron (III) chloride,

dendritic structure- eutectoid, 200x.

Documents

Application Notes Copper English