Application and importance of copper and copper powder on powder metallurgy field
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1 Application and importance of copper and copper powder on powder metallurgy field In recent years, powder metallurgy scholars have paid more attention to materials that have nanometer and composite feature. However, they have ignored the continuously extensive effect of base materials and base material technology on powder metallurgy. As copper will have huge effect on powder metallurgy field, it will continuously develop. This article mainly introduce the application of copper powder on powder metallurgy and the technology development as well as review the development history, characteristics and application of copper. We believe that in the future, the application of copper on powder metallurgy will increase a lot and it will have good application prospect in thermal management material field and traditional powder metallurgy industry. The application of copper and copper powder on powder metallurgy and metal injection molding field As early as 10,000 years ago, copper was discovered as the unique metal. In the beginning, it was used as jewelry and other decorations. Besides, it will be very easy to process natural copper block or cupric mineral into raw material, which can be called original cold working. Dating back to 8700 BC, copper was once used as necklace pendant.
2 Copper has good thermal and electrical conductivity as well as good corrosion resistance and mechanical property. It is easy to process into complex shape and filament. Architects often use the shiny red and verdigris as the decoration of buildings, ceilings and outdoor installations. Copper is easy to form alloy with other elements. This kind of alloy can be largely used in producing allotypic forge pieces, casting parts and powder metallurgy products. Alloys that made by copper and nickel will have good sea water corrosion resistance. Tin can improve the strength and corrosion resistance of copper in solid solution. Zinc and copper alloy, which can also be called brass powder, can be used in water pipe, locking piece, valve and pipe fitting. Copper alloy that contains nickel, tin, titanium, beryllium and cobalt will have same strength with high-strength steel as well as will have high electric conductivity and thermal conductivity. Copper and Cu-Zn-Al alloy are often used in producing flaky gold powder. By adjusting the content of tin and nickel in copper and Cu-Zn-Al alloy, they can generate specific color. In powder metallurgy field, pure copper metal powder is used in producing electrons and thermal conductive parts. Copper alloy that contains tin, zinc, nickel or iron is widely used in automobiles, grass and park equipments, tools and electronic industry. Copper powder is most used in oilless bearing, followed by Fe-Cu premix, dialysis in chemical
3 industry and friction material parts. One of important and special applications of copper powder is being used in powder metallurgy. Materials that used in this field are not obtained by smelting and casting. For example, dispersion strengthening Cu-Al2O3 can be used in intensifying and producing welding electrode (it can be used in automobiles and other industrial fields), while regarding the thermal management W-Cu and Mo-Cu that used in electronic components, the porosity should be controlled properly. Oilless bearing and filter are the two kinds of typical applications of powder metallurgy, in which the porosity should be controlled properly, thus the oil content will have good lubrication effect. By using metal injection molding technology, copper powder can be made into electrical and electronic components that have complex shapes as well as good electrical and thermal conductivity. We can also improve the electrical conductivity and thermal conductivity by using high-purity copper powder and improving the final density of parts. Besides, by using injection molding technology, it can also improve the compactness of copper powder as well as improve the electrical conductivity and thermal conductivity of products. The application of copper and copper powder on powder metallurgy products Copper powder is mainly used in producing bronze pieces by mixing copper powder and tin powder. In the early 1920 s, a metal refining factory (USMR) that located in Carteret autonomous region in New Jersey, America began to produce electrolytic copper powder. Although this factory was small, it was equipped with a large cathode tank. In the peak production period, it can even produce 455 tons of copper powder every month. In the mid 1980 s, many smelting and electrolytic refining enterprises were forced to shut down. As Carteret factory was also closed, although there were some
4 enterprises that tried to produce electrolytic copper powder, no more electrolytic copper powder products were produced in America. At present, electrolytic copper powder is mainly produced in Europe, Japan, Russia, India and South Korea. As electrolytic copper powder is in dendritic shape, by adjusting technology, the apparent density will be less than 1g/cm3 and the green strength will be more than 35MP. By adjusting sedimentation technology and using post-processing of powder, the apparent density also can be improved. In America, copper powder can be produced by using water atomization method and gas atomization method combined with oxidation reduction process, which will appear to be spherical shape or irregular shape. The physical properties of atomized powder (such as apparent density, mobility, particle size and green strength) will be related with process conditions including specific additives, smelting temperature, atomization pressure, reduction temperature and postprocessing of powder. Powders that produced by oxidation reduction method, of which the powder medium diameter will be 10 microns, the apparent density will be less than 1.5g/cm3 and the green strength will be more than 20MP. After atomizing, the powder particle size and reduction temperature will have important effect on the quality of powder products. The property of copper powder that produced by atomization method and oxidation reduction method is almost the same with electrolytic copper powder in the application field, but it requires dendritic powder and very low apparent density. Powder metallurgy can be used in processing self-lubricating copper-tin base oil bearing that will contain pores inside, which can be regarded as a unique feature. Once this kind of bearing is sintered into a certain density, the pore oil content can reach percents. It also should be lubricated regularly so as to ensure that it can operate safely in the equipment cycle life. In 1920, oilless bearing was firstly
5 used in Buick automobile industry. Besides, it also can be largely used in other industries and has changed the household appliances industry. The production of oilless bearing has consumed about 55 percents of copper powder output. Cu-Pb and Cu-Pb-Sn bearing can be used in automobile, turbine, thrust washer and industrial pump. Steel backing material has replaced casting and forging bronze bearing. By covering powder on the steel substrate, after sintering and pressing, it can reach certain compactness. Besides, the porosity of final products will be less than 0.25 percent. Copper powder and silver-nickel alloy powder can be produced by atomization method, in which the zinc content of copper powder is in the range of percents and lead will also be added so as to improve the mechanical property. They can be used in locking piece, meter needle and driving equipment. As brass has pretty color, it can be used in decorative metal medals. Brass powder metallurgy parts that have 2.6g weight have been used in robot arm part recently. Sintering parts that have the sintered density of 7.7g/cm3, of which the tensile strength can reach 193 MPa and the elongation percentage can reach 14 percents. In conclusion, copper base material will have large potential and creativity in powder metallurgy industry. Copper and copper powder market size In 2002, the copper powder usage amount in the world is estimated in the range of million tons, in which the usage amount is 2.2 million tons in North America, 1.8 million tons in Europe and 4500 tons in other countries. About 55 percents of copper powders are used in producing bronze piece, 13 percents are used in producing powder metallurgy parts by mixing with iron powders, 12 percents are used in producing permeable sintered parts, 10 percents are used in producing brass and 10 percents are used in other applications, such as friction material, chemical industry, W-Cu and Mo-Cu heavy
6 metal, coating, oil paint, paste and ink. Powder production companies in North America and around the world have been merged and recombined. 20 years ago, there were 8 copper powder factories in North America, but now, the number has reduced to 4 and may further reduce in the future. Development of copper and copper powder Powder that has the particle size of less than 10 microns is suitable for being used in producing injection molding parts. Injection molding technology can be used in producing complex shape parts that have high electrical and thermal conductivity in electrical and electronic industry. As the electrical conductivity of high-purity material is related with sintered density, by using injection molding technology, the density of parts can become close to original material, besides, they will have complex shape. Shropshire and Klatt from American Chenet Corporation, Lin from National Taiwan University and Chan from Far East College, Taiwan have put forward the application of copper powder on thermal management device. Except for the complex all-copper cooling fin and other heat-dissipation parts in the electronic products, they also discuss the application of loose copper powder on electronic parts cooling. Ullrich from ACu Powder International has studied the necessary conditions of achieving high electric conductivity and thermal conductivity and analyzed the requirement of conductivity on raw materials, extrusion pressure and sintering temperature of more than 90 percents of parts. As is the same with the growth of iron powder, copper powder that premixed with iron powder is expected to increase 5 percents. Copper powder can improve the performance of ironcarbon alloy as well as improve the density, strength, fatigue resistance and mechanical property. Engstrom from North America Hoganas has published a paper about how to add a
7 certain amount of copper powder in several kinds of iron base powder metallurgy parts so as to improve the performance and microstructure. The growth of copper and copper powder The application of copper powder on heat conduction equipment and powder metallurgy parts that have high electrical and thermal conductivity has rarely been developed. The potential application mainly includes electrical contact elements, short-circuiter and electric components (such as slip ring, commutator and rotor bar). Cooling fin and heat exchanger that have been used in electric parts field will also be used in electronic cooling system. The usage amount of copper powder that used in conductive and heat conduction parts will reach percents. The usage amount of copper powder will increase along with the increasing of iron powder mixture and infiltration agent. The annual consumption of copper powder will reach about 25 percents, besides, the consumption of copper-tin powder that used in oilless bearing, brass parts that used in locking piece and textile parts and bronze alloy powder in the world will reach percents. The development of bend that used in pipeline industry and other parts have become very mature. However, as the production cost of producing parts with pure copper powder will be very high, this economic problem should be reviewed once again. Due to the pretty color and good atmospheric resistance of copper powder, it can be largely used in decorations, such as furniture, building outer layer, wall and roofing material. Besides, copper powder metallurgy parts can also be used in these fields. Currently, some large parts that have high pressure made by copper powder and copper base alloy material have been able to be used in these fields.
8 Many kinds of forging and casting copper and copper alloy parts all need machining. In order to improve the machinability of copper, lead is often added in these kinds of products. As it is very difficult to process lead alloy bearing parts, many countries are exerting pressure so as to reduce the content of lead. Powder metallurgy part can be produced without any machining. Therefore, it can replace many forging and casting parts that contain lead. Besides, it also can be used in fuse carrier, welding electrode, valve, fastener and transmission part. In conclusion, copper powder will have promising development prospect in the future. Some traditional applications, such as oilless bearing, premixed powder, infiltration agent, brass and bronze alloy as well as friction material will continuously play important roles. The application of copper powder on heat conduction and conductive fields will continuously increase, which will in turn expand the use of copper powder. Most of powder metallurgy technologies are feasible in producing high density and high heat conductivity parts, while the new powder metallurgy technology still needs to be cognized and developed. In addition, it still needs to be developed by producing sanitary ware, high-speed cutting powder metallurgy alloy parts and decorative parts with powder metallurgy technology, in which only parts that made by copper powder can meet the feature requirement.
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