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Copper Academy:
Processing high conductivity materials
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
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
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
1. INTRODUCTION – ANALYSIS OF THE TOPIC
Periodic Table of the Elements 114 elements (91 metals)
PROCESSING HIGH CONDUCTIVITY MATERIALS
62,1 MS/m
100 MS/m
• DePiep; Periodic table (polyatomic); http://commons.wikimedia.org/wiki/File:Periodic_table_%28polyatomic%29.svg
1. INTRODUCTION – ANALYSIS OF THE TOPIC
Periodic Table of the Elements 114 elements (91 metals)
PROCESSING HIGH CONDUCTIVITY MATERIALS
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
• DePiep; Periodic table (polyatomic); http://commons.wikimedia.org/wiki/File:Periodic_table_%28polyatomic%29.svg
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
PROCESSING HIGH CONDUCTIVITY MATERIALS
AGENDA
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
IFLUENCE OF IMPURITIES ON COPPER ELECTRICAL CONDUCTIVITY
Copper Cathode Copper Ore
2. ELECTROREFINING PROCESS – CHEMICAL PURITY OF CATHODE
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
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 S
S, Fe gases, slag
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,
2. ELECTROREFINING PROCESS – CHEMICAL PURITY OF CATHODE
COPPER PRODUCTION PROCESS
2. ELECTROREFINING PROCESS – CHEMICAL PURITY OF CATHODE
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
MOUNT
ISA
MINES
KGHM
POLSKA
MIEDŹ
LME
CATHODE OLEN AU ISA HMGB LME
OXYGEN,
ppm 50 – 70
SUMMARY
CONTENT
(WITHOUT Ag)
ppm
<22 <20 <15 <20 45
CHEMICAL COMPOSITION = IMPURITIES CONTENT + OXYGEN CONTENT
2. ELECTROREFINING PROCESS – CHEMICAL PURITY OF CATHODE
COPPER CATHODE
EXAMPLES OF POOR QUALITY CATHODES
AGENDA
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
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
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
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 WIRE
drawing process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
electrorefining process
COPPER WIRE ROD Cu-ETP
continuous melting, casting and rolling process
WIRE and CABLES, TRANSFORMERS, MOTOR
WINDINGS
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
COPPER WIRE ROD Cu-ETP
OXYGEN-FREE COPPER WIRE Cu-OFE
COPPER PRE-ROLLED STRIP
COPPER BILLETS
Source: KGHM Polska Miedź S.A., Aurubis Group
COPPER CATHODE
electrorefining process
OXYGEN-FREE COPPER WIRE Cu-OFE
continuous melting and casting process
COPPER WIRE
drawing process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
WIRE and CABLES (audio-video, fire-resistant etc.)
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
Source: KGHM Polska Miedź S.A., Aurubis Group
COPPER WIRE ROD Cu-ETP
OXYGEN-FREE COPPER WIRE Cu-OFE
COPPER STRIP
COPPER BILLETS
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
electrorefining process
UPCAST COPPER ALLOY WIRE ROD
continuous melting and casting process
SECTIONAL Cu-Ag WIRE (TROLLEY WIRE)
drawing process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
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
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
electrorefining process
COPPER ALLOY WIRE ROD
continuous melting and casting process
CLAMPS and CONNECTORS FOR TROLLEY WIRES
forging process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
COPPER WIRE ROD Cu-ETP
OXYGEN-FREE COPPER WIRE Cu-OFE
COPPER PRE-ROLLED STRIP
COPPER BILLETS
Source: KGHM Polska Miedź S.A., Aurubis Group
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
electrorefining process
COPPER STRIP
continuous casting process
COPPER SHEET
hot rolling process
COPPER SHEET
cold rolling process
CONTACTS
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
COPPER WIRE ROD Cu-ETP
OXYGEN-FREE COPPER WIRE Cu-OFE
COPPER PRE-ROLLED STRIP
COPPER BILLETS
Source: KGHM Polska Miedź S.A., Aurubis Group
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
COPPER CATHODE
electrorefining process
COPPER BILLETS
continuous casting process
COPPER PROFILE
hot extrusion process
COPPER PROFILE
drawing process
BUSBARS COMMUTATORS
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
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
electrorefining process
COPPER BILLETS
continuous casting process
COPPER BAR
extrusion process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
CLAMPS and CONNECTORS FOR TROLLEY WIRES
forging process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
WORLD COPPER FEEDSTOCK PRODUCTION (ELECTRICAL USES)
Source: CRU INTERNATIONAL
Wire rod 12,6 mln tons
Others 4,6 mln tons
COPPER BILLETS
continuous casting process
COPPER STRIP
continuous casting process
COPPER WIRE ROD
continuous melting and casting process
COPPER WIRE ROD Cu-ETP
continuous melting, casting and rolling process
3. PROCESSING TECHNOLOGIES FROM CATHODE TO PRODUCT
WORLD COPPER FEEDSTOCK PRODUCTION (ELECTRICAL USES)
Source: CRU INTERNATIONAL
Wire rod 12,6 mln tons
Others 4,6 mln tons
COPPER BILLETS
continuous casting process
COPPER STRIP
continuous casting process
COPPER WIRE ROD
continuous melting and casting process
COPPER WIRE ROD Cu-ETP
continuous melting, casting and rolling process
AGENDA
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
CONTINUOUS CASTING AND
HOT ROLLING TECHNOLOGY CONTINUOUS CASTING
TECHNOLOGY
Cu-ETP (Electrolytic Tough Pitch)
Cu2O
Cu-OFC (Oxygen
Free Copper)
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
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
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
ETP COPPER
KGHM SA; Contirod Process Scheme; http://www.kghm.pl/index.dhtml?category_id=278&lang=en
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
CROSS-SECTION MACROSTRUCTURE – ETP CAST
DENSITY= 8,77 g/cm3
~4 m
m
~5 mm
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
200 mm
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
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
Cu2O Cu2O
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
OXYGEN FREE COPPER
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
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
58.0
58.2
58.4
58.6
58.8
59.0
59.2
59.4
59.6
59.8
60.0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
ELEC
TR
IC
AL C
ON
DU
CT
IV
ITY
[M
S/
m]
CASTING SPEED [m/min]
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
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
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
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
Cu-OF LONGITUDINAL
SECTION
Cu-ETP LONGITUDINAL
SECTION
Fig. TENSILE CURVES of Cu-ETP and Cu-OF
0
20
40
60
80
100
120
140
160
180
200
220
240
0 5 10 15 20 25 30 35 40 45 50 55 60
ε, [%]
UT
S, [M
Pa
]
CuETP
CuOFC
CHARACTERISTICS of ETP and OF WIRE ROD
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
CROSS SECTION
CROSS SECTION
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
AGENDA
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
II. ROLLING PROCESS
IV. SHEET METAL FORMING PROCESS
V. FORGING PROCESS
III. EXTRUSION PROCESS
I. DRAWING PROCESS
Hot Working Cold Working
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
II. ROLLING PROCESS
IV. SHEET METAL FORMING PROCESS
V. FORGING PROCESS
III. EXTRUSION PROCESS
I. DRAWING PROCESS
COPPER BILLETS
continuous casting process
COPPER STRIP
continuous casting process
COPPER WIRE ROD
continuous melting and casting process
COPPER WIRE ROD Cu-ETP
continuous melting, casting and rolling
process
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
I. DRAWING PROCESS
Die
Metal Drawing; Figure 237; Contirod Process Scheme; http://thelibraryofmanufacturing.com/metal_drawing.html
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
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
Fig. Drawing machine
CONTINUOUS CASTING AND
HOT ROLLING TECHNOLOGY CONTINUOUS CASTING
TECHNOLOGY
Cu-ETP (Electrolytic Tough Pitch)
Cu2O
Cu-OFC (Oxygen
Free Copper)
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
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
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
COPPER UTP CABLE – SIGNAL ATTENUATION
Sig
nal att
enuation [
dB]
Sig
nal att
enuation [
dB]
Sig
nal att
enuation [
dB]
Sig
nal att
enuation [
dB]
Frequency [MHz] Frequency [MHz]
Frequency [MHz] Frequency [MHz]
PAIR 1 PAIR 2
PAIR 3 PAIR 4
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
COPPER UTP CABLE – PROPAGATION SPEED
Frequency [MHz] Frequency [MHz]
Frequency [MHz] Frequency [MHz]
PAIR 1 PAIR 2
PAIR 3 PAIR 4
Pro
pagation s
peed [
-]
Pro
pagation s
peed [
-]
Pro
pagation s
peed [
-]
Pro
pagation s
peed [
-]
Cu-ETP ϕ = 0,58 mm
Cu-OF ϕ = 0,56 mm
COPPER UTP CABLE (UNSHIELDED TWISTED PAIR)
𝑮 = 𝝈𝑨
𝒍
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:
4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
II. ROLLING PROCESS
Metal Rolling; Fig. 131; http://www.thelibraryofmanufacturing.com/metal_rolling.html
II. ROLLING PROCESS
Finished product: sheet
Feedstock: strip
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
Metal Rolling; Fig. 131; http://www.thelibraryofmanufacturing.com/metal_rolling.html
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
MACHINES USED IN ROLLING
Achenbach; Rolling Mills; http://www.achenbach.de/produkte/walzwerkanlagen/buntmetall-walzwerke/
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
III. EXTRUSION PROCESS
Direct Extrusion; Figure 209; http://thelibraryofmanufacturing.com/extrusion.html
III. EXTRUSION PROCESS
Finished product: profiles, pipe,
rods, bars, tubes, welding electrodes etc.
Feedstock: billet
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
Direct Extrusion; Figure 209; http://thelibraryofmanufacturing.com/extrusion.html
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
MACHINES USED IN EXTRUSION PROCESS
SMS Group; Extrusion Presses; http://www.sms-meer.com/en/portfolio/forging/extrusion-presses.html
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
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
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
CONTINUOUS EXTRUSION PROCESS
continuous extrusion
cooling finished product cleaning transport
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
IV. SHEET METAL FORMING PROCESS
Metalite; Deep Drawing; Contirod Process Scheme; http://www.metalite.net/WhatisDeepDrawing.html
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
IV. SHEET METAL FORMING PROCESS
Feedstock: sheet
Finished product:
cups, pans, cylinders, irregular shaped
products
Metalite; Deep Drawing; Contirod Process Scheme; http://www.metalite.net/WhatisDeepDrawing.html
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
MACHINES USED IN SHEET METAL FORMING PROCESS
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
V. FORGING PROCESS
1. 2. 3.
Forging Presses; Fig. 176; http://thelibraryofmanufacturing.com/presses.html
Feedstock: ingot/billet
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
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
5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
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
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
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
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
g}
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
South
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
North
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
Ʃ/{A
g}
200
250
300
350
400
450
500
100 120 140 160 180 200 220 240 260 280 300 320 340 360
TEMPERATURE, °C
UT
S,
MP
a
12 43
Cu-ETP
Cu-OFE
60°C
ε=93% t=1h
MICROSTRUCTURE OF WIRE ROD AFFECTING TECHNOLOGICAL REQIUREMENTS
RECRYSTALLIZATION TEMPERATURE
Cu-ETP (Electrolytic Tough Pitch)
Cu-OF (Oxygen
Free Copper)
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
COPPER BILLETS
continuous casting process
COPPER BAR
extrusion process
CLAMPS and CONNECTORS FOR TROLLEY WIRES
forging process
COPPER CATHODE
electrorefining process
COPPER WIRE ROD
continuous melting and casting process
PROCESSING TECHNOLOGY
COSTS OPTIMIZATION
!!!
AGENDA
1. INTRODUCTION – ANALYSIS OF THE TOPIC
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
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