Copper sections for various applications

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Bruno Fields
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1 Copper sections

Copper sections for various applications Company portrait The Wieland Group, with headquarters in Ulm, Germany, is one of the world s leading manufacturers of semi-finished and special products in

2 Copper sections for various applications Company portrait The Wieland Group, with headquarters in Ulm, Germany, is one of the world s leading manufacturers of semi-finished and special products in copper and copper alloys. These include strip, sheet, tube, rod, wire and sections as well as slide bearings, finned tubes and heat exchangers. Sections Sections are semi-finished products from which functional parts are manufactured in the majority of cases at very low processing costs. With sections it is possible to reduce production costs, and consequently, total costs. Due to their excellent electrical and thermal conductivity, copper sections are mainly used in the electrical industry and in cooling systems. Wieland s history dates back to the early 19th century. Founder Philipp Jakob Wieland took over his uncle s Ulm art and bell foundry in 1820 and by 1828 he was producing brass sheet and wire. Today, the Wieland Group comprises manufacturing companies, slitting centres and trading subsidiaries in many European countries as well as in the USA, in South Africa, Singapore and the People s Republic of China. Wieland manufactures several hundred thousand tons of copper alloys every year, from the continuously cast to the semi-finished product. Production starts at Europe s largest foundry for copper alloys, at our plant in Vöhringen, Germany. The Wieland Group manufactures solid and hollow copper sections in a wide range of sizes. Our Technical Marketing can provide assistance from the concept to the construction of your copper section. Moreover, we supply copper sections which have undergone further processing. We offer all common methods of machining as well as surface coating. For further information please contact our Technical Marketing Extruded/Drawn Products. Copper Copper is one of the oldest natural materials known to man, yet today it remains amongst the most important and widely used non-ferrous metals in the world. Wieland semi-finished products form an indispensable link between the raw material copper and the wide variety of products made by our customers. Copper is suitable for a tremendous range of applications due to its unique combination of various properties such as high electrical and thermal conductivity outstanding corrosion resistance good forming and processing properties excellent suitability for surface coating Wieland copper sections are, therefore, used across a multitude of industries. 2

Solid copper sections Applications Solid sections are used in various shapes and sizes, mainly in the electrical industry, e.g.

Advantages of copper sections Technical solutions achieved through the use of copper sections are becoming increasingly important for cost-efficient production.

Copper sections offer additional advantages such as electrical optimization of conductor cross-sections thermal optimization (cooling) reduction of processing costs (optimization of process costs)

3 Solid copper sections Applications Solid sections are used in various shapes and sizes, mainly in the electrical industry, e.g. for busbars in switch cabinets terminals switches or commutators They are also used in cooling systems for the electronics industry. Advantages of copper sections Technical solutions achieved through the use of copper sections are becoming increasingly important for cost-efficient production. Ideally, it is sufficient to simply cut the section to length to produce the desired finished part. Copper sections offer additional advantages such as electrical optimization of conductor cross-sections thermal optimization (cooling) reduction of processing costs (optimization of process costs) ease of mounting and installation (efficiency) saving of material (less scrap) Shapes available The production of a section depends on its geometry. Shape and dimensions are usually defined in a drawing. Basic information on shapes available as well as process-related limits of copper sections are provided in EN Deviations from EN are possible by agreement. We are willing and able to assist you from the concept through every stage until the section becomes a reality. Copper section for busbar systems Photos above: copper sections 3

4 Solid copper sections Production capabilities We offer a wide range of production possibilities and shapes which is unique in the industry. Our equipment allows us to produce copper sections with weights of 0.02 kg/m to 30 kg/m (0.013 lbs/ft to lbs/ft). Advances in production processes and tool design make it possible to realize ever more complex shapes. Our competence in the production of sections is unsurpassed as a result of our own tool design and construction. Commutator sections DCC Circumscribed circle Production technologies To manufacture copper sections we apply extrusion technology which enables us to make significant structural changes and produce the finished cross-sections in a cost-effective way. The smallest sections with a weight of up to 0.25 kg/m (0.168 lbs/ft) are produced from casting wire by means of a section roll. A final drawing process can be added allowing the setting of specific tempers and tolerances. The table below shows an overview of our production process. Sections are usually supplied in straight lengths of up to 8 m. Small and medium-sized sections are also available in the form of wire for which additional information regarding the direction of coiling and the position of the crosssection in the coil is necessary. Process Diameter of circumscribed circle (DCC) Weight per meter max. Extruding / drawing mm (0.394 in in) 30 kg/m ( lbs/ft) Rolling / drawing mm ( in in) 0.25 kg/m (0.168 lbs/ft) 4

Hollow copper sections Applications Due to their excellent electrical and thermal conductivity hollow copper sections are also suitable for cooled electrical

Silver-containing copper has a better softening resistance.

available as symmetric and asymmetric sections as well as double-chamber sections.

Asymmetric hollow sections and double-chamber sections are our specialty. Extensive know-how is necessary for the production of these shapes.

Production possibilities Hollow sections are manufactured by extruding and drawing.

5 Hollow copper sections Applications Due to their excellent electrical and thermal conductivity hollow copper sections are also suitable for cooled electrical conductors. Since hollow sections are often used at high temperatures, silver-containing copper is used in addition to pure copper. Silver-containing copper has a better softening resistance. Typical applications are: induction heating and melting plants generators busbars transformers electromagnets Shapes available Seamless hollow sections are available as symmetric and asymmetric sections as well as double-chamber sections. We manufacture the sections in close cooperation with our customers according to drawings and specifications. Asymmetric hollow sections and double-chamber sections are our specialty. Extensive know-how is necessary for the production of these shapes. We would be pleased to examine and determine whether the hollow section you require can be manufactured. Production possibilities Hollow sections are manufactured by extruding and drawing. Asymmetric hollow sections and double-chamber sections are extruded by means of bridge dies. Hollow sections are usually supplied in soft temper. Their excellent cold working properties resulting from the soft temper ensure a smooth adjustment to existing mounting conditions. Of course, other tempers are available, too. Due to the production process an eccentricity of +/- 10 % may result. Two-duct hollow sections for generators Diameter of circumscribed circle (DCC) Wall thickness / webs min. Weight per meter max. Max. 200 mm (7.874 in) 3 mm (0.118 in) 30 kg/m ( lbs/ft) 5

Fabricated products from copper sections From the concept Applications As manufacturers of semi-finished products we

Your advantage: you receive your product from a single manufacturer who is competent in the production and processing

Production capabilities We offer the following value-added operations: cutting to length drilling milling bending

6 Fabricated products from copper sections From the concept Applications As manufacturers of semi-finished products we also supply finished components. Your advantage: you receive your product from a single manufacturer who is competent in the production and processing of semi-finished products. Production capabilities We offer the following value-added operations: cutting to length drilling milling bending stamping plating We provide assistance from the concept to the realization of your component. Please contact us and benefit from our experience and know-how. to the design to the section. Additional machining and surface coating Switch gear for power distribution are all part of our production programme. 6

7 Materials and semi-finished products available Material Copper grade Wieland EN designation UNS JIS Symbol Number Number Number Forms of semi-finished products Hollow section Solid section Thermal conductivity in W/(m*K) Electrical conductivity (reference value) in % IACS Other characteristics Application examples Oxygen-containing copper grades K16 K34 Cu-ETP1 CW003A C11000 C Oxygen-containing copper grades with high purity, high electrical conductivity Busbars, general applications in the electrical industry if there are no requirements regarding hydrogen embrittlement K18 K32 Cu-ETP CW004A C11000 C Oxygen-containing copper grades, high electrical conductivity Busbars, gripper arms, general applications in the electrical industry if there are no requirements regarding hydrogen embrittlement Oxygen-free copper grades K08 K10 Cu-OFE CW009A C10100 C P 3 ppm, resistant to hydrogen embrittlement, no volatile particles enter the vacuum. High-vacuum technology, magnetrons and electronic tubes K17 K30 Cu-OF CW008A C High electrical conductivity, resistance to hydrogen embrittlement Switch gear, instruments in reducing gas environments, general applications in the electrical industry Deoxidized copper grades K12 Cu-HCP CW021A C Deoxidized copper grade, high electrical conductivity, resistance to hydrogen embrittlement, good weldability and solderability Square-wave generators, switching elements, induction coils K20 K21 K28 Cu-DHP CW024A C12200 C Deoxidized copper grades, low electrical conductivity, resistance to hydrogen embrittlement, good weldability and solderability Cooling panels Copper grades containing silver K35 CuAg0,10 (OF) CW019A Oxygen-free copper grade containing silver, resistance to hydrogen embrittlement, increased resistance to softening with high conductivity Commutators K07 CuAg0,04 (OF) CW017A C Oxygen-free copper grade containing silver, resistance to hydrogen embrittlement, increased resistance to softening with high conductivity Commutators K43 CuAg0,2** - C Copper grade containing silver, increased resistance to softening with high conductivity Anode hangers KA1 KA4 CuAg0,1P CW016A C Deoxidized copper grades containing silver, resistance to hydrogen embrittlement, increased resistance to softening with high conductivity Moulds, two-duct hollow sections for generators ** not standardized Other copper grades, high-copper alloys and dispersion-hardened copper alloys on request 7

WIELAND-WERKE AG www.wieland.com buntmetall amstetten GmbH (A company of the Wieland Group) www.buntmetall.at Graf-Arco-Str. 36, 89079 Ulm, Germany, tel.

8 WIELAND-WERKE AG buntmetall amstetten GmbH (A company of the Wieland Group) Graf-Arco-Str. 36, Ulm, Germany, tel. +49 (0) , fax +49 (0) , Fabrikstraße 4, 3300 Amstetten, Austria, tel +43 ((0) , fax: +43 (0) , /10.06 Al 0,2 BD (GWW/En)

Wieland Components 2

Wieland Components 2 Wieland Components Wieland-Werke AG is an innovative manufacturer of prefabricated components: Wieland Components The Complete Solution. Wieland is able to provide, on request, a complete