2. Introduction
• History
• Characteristics
• Uses and Applications
• Characteristics Of Alloys
• UL Evaluations
• What’s New
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3. A Little About Copper
§ Distinctive Reddish Orange Color
§ Mostly Found In Ore Form
§ Density = 8.9 g/cm3
§ Melting Point = 1083°C
§ Boiling Point =2595°C
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5. The Copper Age 5000-3000 BC
• Age Following The Stone Age
• Believed First Used On Cypress
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6. The Bronze Age 3000-750 BC
• Milestone In History
• First Large Scale Use of Metals
• Stronger & Harder Than Plain Copper
• Stronger Tools, Weapons, Armor
• Bronze Age Replaced by Iron Age
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9. An Excellent Electrical Conductor
• 99.99% Cu Used For Wiring Applications
• (5.95x107 /O-m ) Electrical Conductivity Cu
• (6.15x107 /O-m) Electrical Conductivity Ag
• 97% Conductivity Ag At 1/8 Cost
• All Cu Applications - 60% Electrical
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10. Optional Electrical Conductors?
Aluminum
• (3.77x107 /O-m) Electrical Conductivity
• 3.5 X Cheaper Than Cu
• Need Larger Wire Dia. For Same Current
• Transmission Lines, (lightweight)
• Compatibility Issues With Copper
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11. An Excellent Thermal Conductor
• 2nd Best Heat Transfer Metal (400W/m°K)
• Ag (429W/m°K), Al (250W/m°K)
• Refrigeration/Air Conditioning Applications
• Heat Exchangers, Radiators
• Heat Sink Applications, Electronics Cooling
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13. Excellent Corrosion Resistance
• Generally Less Subject To Corrosion
• Plumbing Applications – Very Stable
• Avg. Home Has 250lbs. Of Cu
• Great Salt Water Resist., Copper-Nickel
• Susceptible to Galvanic Corrosion
• Green “Patina” -Long Term Air Exposure
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15. Corrosion Resistance
• Tarnishes After Air Exposure (Dull Tan), CuO
• After Few Years Dark Orange Color
• Corrosion Rate Slows After Patina Formation
Avg. Corrosion Rates
• 0.05 mil/yr (Industrial), 0.02 mil/yr (Marine)
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16. Corrosion Resistance
Not Recommended For Following Exposures:
• Ammonia (Fertilizers, Household Cleaners)
• Nitric Acid (Lab Uses, Commercial Cleaning)
• Chromate Acid (But Used To Brighten Brass)
• Sulfuric Acid (Car Battery Acid, Restores Fe)
• Acetic Acid (Vinegar)
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20. Antimicrobial
• Kills Bacteria, Viruses, & Micro-organisms
• Feb. 2008, EPA Registered 275 Cu Alloys
• Tarnishing Doesn’t Affect Property
• Many Applications For This Feature
E Coli Methicillian Resistant Staphylococcus
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21. Antimicrobial
• Great For High Touch Areas
• Door Knobs, Hand Rails, Push Plates
• Hospital Applications
• Marine Applications (Barnacle Resistant)
• HVAC Ductwork Improves IAQ
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23. Properties Of Copper
• Excellent Electrical & Thermal Conductor
• Excellent Corrosion Resistance
• Excellent Workability
• Antimicrobial
• An Abundant Element
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24. An Abundant Element
• 3.7 Billion Tons Known Worldwide
• 8.3 Million Tons Mined Yearly Worldwide
• Most Mining Western N & S. America
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25. USA Copper Mining
• Phelps Dodge - 60% of US Copper/Yr.
• AZ, UT, NM, NV, MT
• 20 Mines Account For 99% GP
• 1 Ton Ore Produces 6 lbs. Cu
• 550 Million Tons Estimated Resources
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26. Consumers Of Copper
• China: Single Leading Country
• Big Spike In Last 10 Years
• US: Steady For Last 30 Years
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27. China’s Consumption Growth
• Economic Growth: 10% YOY 10 Yrs
• Explosion In Automotive Production
• Electric Car Production 2X Copper
• Expansion In Home Building
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28. Recycling Copper
• 100% Recyclable
• 160,000 Tons = 10% Cu Consumption
• Relied Upon For US Self Reliance
• Meets 41% Of Global Yearly Demand
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32. POP QUIZ
• 99.99 % Copper is the second best metallic electrical
conductor. Which is the best?
Silver
• What period of time was revolutionary in human history,
which was earmarked by man’s first wide spread
exploitation of metals?
Bronze Age
• The United States Produces what percentage of the
world’s copper? What single Country Produces the
Most?
8%, Chile 37%
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33. POP QUIZ
• Why should 99.99 copper be used for electrical
conductor applications?
Small addition of other elements/impurities
reduces conductivity. Only 0.20% Arsenic
reduces electrical conductivity by 15%.
• Why is Aluminum sometimes considered an
alternative to Copper (alloy)?
Reduced Cost, with still good electrical and
thermal conductivities, strength, and
corrosion resistant properties.
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34. Copper Alloys
• The Most Commonly Alloyed Metal
• Over 475 Distinct Alloys
• Wrought and Cast Products
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35. Wrought Alloys of Copper
7 Main Families (Wrought Alloys)
• High Copper Alloys
• Brasses
• Bronzes, (Sn/P, Al, Si)
• Copper-Nickels, Nickel Silvers
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36. Effect Of Alloying Elements
• Al - Hardness, Strength, Corrosion Resist
• Si - Most Effective at Increasing Strength
• Pb, Te- Increases Machinability
• Sn- Increase Strength, Decreases Conduc.
• Zn, Increase Strength, Decreases Conduc.
• Ni - Hardness, Strength, Corrosion Resist
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37. High Copper Alloys (C1xxxx)
• High Percentage of Copper (97-99.99)
• Retains Many Properties Of Elemental Cu
• High Strengths Attainable (Be Cu)
• Electrical: (Wire, Conductors, Switches)
• Mechanical: (Condenser Tubing, Plumbing)
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38. Wrought Brass Alloys
• Red Brass Cu, Zn (C2100-C28000)
• Leaded Brass Cu, Zn, Pb (C31400-C38500)
• Gun Metal Cu, Zn, Sn (C40500-C46700)
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39. Brasses
(C2xxxx)(C3XXXX)(C4XXXX)
• Alloy of Copper & Zinc (5-40%)
• Most Common Alloy Of Copper
• Overall Low Cost
• Inexpensive Machining And Fabrication
• Resistance To Aggressive Environments
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40. Mechanical Props. Of Brass
• Highest Strength Brass Alloy
• C36000 The Standard In Machinability
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43. Sn/P Bronze (C50100-C52400)
• Alloy of Copper & Tin
• Excellent Marine Corrosion Resist.
• Harder & Heavier Than Brass Counterpart
• Good Stength and Wear Resistance
• Excellent Cast ability
• Bearings, Diaphragms, Fasteners
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44. Aluminum Bronze (C60600-64200)
• 5-12% Al
• Stronger Than Tin Bronze
• More Corrosion Resistant: Al2O3 Skin
• Very Little Tarnishing With Time
• Bearings, Bushings, Gears, Pinions
• Wear Resistant Applications
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45. Silicon Bronze (C64700-C66100)
• Great Strength
• Great Inert Chemical Properties
• Gets Stronger More Its Worked
• Harder To Fabricate, (Machine)
• Pumps, Boilers, Chemical Vessels, Marine
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51. 10 Day Moist Ammonia Test
• In More Than 50 UL Standards
• Dezincification of Alloys (Brass) >15% Zn
• Fire Protection, Gas & Oil
§ Valves, Pipe and Fitting
§ Sprinklers
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54. Al Conductors - Safe
• Home Fires: AL Mixed with Cu
• Marking Required In Most UL Standards
• High Thermal Coefficient of Expansion
• Highly Galvanic with Cu – High Resistance
• Oxides Not As Conductive
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59. CA, VT Lead Law
• Plumbing, Potable H2O
• California Lead Law: Jan. 1, 2010
• Fittings: 8% Pb to 0.25% Pb Max.
• Affects Existing and New Constructions
• Switch From Lead Alloys To Bismuth
• QNVB – UL Subject 116875
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60. High Efficiency Motors
• 50% All Electricity Consumed
• DOE - 3 Phase Integral HP Motors
• Dec. 19, 2010 Mandate Date
• High “E” Motors: 25% More Cu
• 70% Increase In Demand by 2013
• 15 Million Dollar Increase Projected
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61. High Efficiency Motors
• Greater Conductor Sizes
• Attack 5 Areas For Losses
• Electrically Commentated Motors
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63. Summary Engineering Uses
• High Electrical Conductivity
• Excellent Conductor of Heat
• High Strength Applications
• Corrosion Resistant
• Antimicrobial
• Excellent Machinability & Workability
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64. POP QUIZ
• Name 3 Features of Bronze
Increase strength, hardness, durability,
highly cast able, poor thermal and
electrical conductivities, Tin is main
alloying ingredient (as much as 10%).
• What is the most common Alloy of
Copper?
Brass
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66. Additional Resources
• ASM Metals Handbook: Vol. 2, 10th Ed.
• Copper Development Association
www.cda.org or www.copper.org
• CA Lead Law - Thomas Bowman x43797
• High E Motors – Frank Ladonne x41888
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68. Copper Tubing
• All Tubing 99.9% Cu
• Ease In Cutting, Bending, Installing
• Lighter Weight Than Steel
• Does Not Burn, Release VOCs
• Corrosion Resistant
• Mech. Factors Drive Cu Tube Selection
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69. Copper Tubing
• Type K - ASTM B 88
• Type L - ASTM B 88
• Type M – ASTM B 88
• Type DMV – ASTM B306
• Type ACR – ASTM B 280
• Type OXY/MED – ASTM B 819
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70. Type K, Tubing
• Provided in ¼ in. - 12 in. Diam.
• Thickest Wall For Given Size
• Highest Strength
• Hardest To Bend
• Fire Suppression, Med. Gas, Compres. Air
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72. Type M, Tubing
• Thinnest Wall Thickness
• Lightest Weight
• Easiest To Bend
• Cheaper Than K, or L Tubing
• Underground. H20 Dist., Heating, Fire,
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