Presentation On Copper, Cu

Presentation On Copper, Cu Craig S. Thames, PE

Introduction• History• Characteristics• Uses and Applications• Characteristics Of Alloys• UL Evaluations• What’s New 2

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 3

History Of Copper 4

The Copper Age 5000-3000 BC• Age Following The Stone Age• Believed First Used On Cypress 5

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 6

Characteristics of Copper 7

Properties Of Copper• Excellent Electrical & Thermal Conductor 8

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 9

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 10

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 11

Properties Of Copper• Excellent Electrical & Thermal Conductor• Excellent Corrosion Resistance 12

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 13

Patina Formation Of Copper 14

Corrosion Resistance• Tarnishes After Air Exposure (Dull Tan), CuO• After Few Years Dark Orange Color• Corrosion Rate Slows After Patina FormationAvg. Corrosion Rates• 0.05 mil/yr (Industrial), 0.02 mil/yr (Marine) 15

Corrosion ResistanceNot 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) 16

Properties Of Copper• Excellent Electrical & Thermal Conductor• Excellent Corrosion Resistance• Excellent Workability 17

Excellent Workability• Easily Workable, Molded Without Cracking• Malleable - Easily Hammered Into Shapes• Ductile - Easily Drawn (Wire & Tubes)• Machinability – Easy Threading, Cutting, Bending• Surface Can Be Highly Polished 18

Properties Of Copper• Excellent Electrical & Thermal Conductor• Excellent Corrosion Resistance• Excellent Workability• Antimicrobial 19

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 20

Antimicrobial• Great For High Touch Areas• Door Knobs, Hand Rails, Push Plates• Hospital Applications• Marine Applications (Barnacle Resistant)• HVAC Ductwork Improves IAQ 21

Kills Mold Spores Mold – Aspergillus Niger 22

Properties Of Copper• Excellent Electrical & Thermal Conductor• Excellent Corrosion Resistance• Excellent Workability• Antimicrobial• An Abundant Element 23

An Abundant Element• 3.7 Billion Tons Known Worldwide• 8.3 Million Tons Mined Yearly Worldwide• Most Mining Western N & S. America 24

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 25

Consumers Of Copper• China: Single Leading Country• Big Spike In Last 10 Years• US: Steady For Last 30 Years 26

China’s Consumption Growth• Economic Growth: 10% YOY 10 Yrs• Explosion In Automotive Production• Electric Car Production 2X Copper• Expansion In Home Building 27

Recycling Copper• 100% Recyclable• 160,000 Tons = 10% Cu Consumption• Relied Upon For US Self Reliance• Meets 41% Of Global Yearly Demand 28

Cost Of Copper 29

Uses For Copper 30

Uses For Copper (2009)Manufacturing Consumers49% - Wire Mills 50% - Building Construction40% - Brass Mills 21% - Electrical & Electronic Products7% - Foundries 10% - Consumer & General Products1% - Powder Plants 11% - Transportation3% - Other 8% - Industrial Machinery & Equipment 31

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% 32

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. 33

Copper Alloys• The Most Commonly Alloyed Metal• Over 475 Distinct Alloys• Wrought and Cast Products 34

Wrought Alloys of Copper7 Main Families (Wrought Alloys)• High Copper Alloys• Brasses• Bronzes, (Sn/P, Al, Si)• Copper-Nickels, Nickel Silvers 35

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 36

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) 37

Wrought Brass Alloys• Red Brass Cu, Zn (C2100-C28000)• Leaded Brass Cu, Zn, Pb (C31400-C38500)• Gun Metal Cu, Zn, Sn (C40500-C46700) 38

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 39

Mechanical Props. Of Brass• Highest Strength Brass Alloy• C36000 The Standard In Machinability 40

Machinability ComparablesTitanium 6%316 Stainless Steel(18/8) 12%Medium Carbon Steel 20%Aluminum Alloy 50%Copper 20%Leaded High Copper 80% 41

Wrought Bronze Alloys• Phosphor Bronze (Sn/P) C5xxxx• Aluminum Bronzes (Al) C60600-64200• Silicon Bronzes (Si) C64700-C66100 42

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 43

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 44

Silicon Bronze (C64700-C66100)• Great Strength• Great Inert Chemical Properties• Gets Stronger More Its Worked• Harder To Fabricate, (Machine)• Pumps, Boilers, Chemical Vessels, Marine 45

Bronze Mechanical Properties• Highest Tensile Strength Bronze C52400• Best Machinability Bronze C54400 46

Copper Nickels, (C7XXXX)• Silvery In Color• Excellent Salt Water Corrosion Resistance• Seawater App, Auto, Pipe & Fittings, etc.• 90% -10%, 70%-30%• Among Highest Tensile Strength Alloy 47

Cast Alloys Of Copper• High Copper• Brass4 Main Families Of Bronze• Copper- Tin (Tin Bronze)• Copper-Leaded-Tin• Copper-Tin-Nickel• Copper-Aluminum 48

Bronze Vs. Brass• Bronze, Increased Tensile & Hardness• Bronze More Costly Than Brass• Bronze More Corrosion Resistant• Sn Decreases Elec. & Therm. Conductivity• Zn<15% Doesn’t Reduce Conduct. Props.• Zn No Decrease in Corrosion Properties 49

How Does UL Evaluate Copper? 50

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 51

Overcoming Dezincification• Arsenic (0.20%) Improves Resistance• Heat Treatment Processes 52

Copper Sulfate Test• Measures Zn Coating Thickness 53

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 54

HVAC• Disallowed For Ammonia Refrigerants 55

What’s New?• Leveraging Anti Microbial• High Efficiency Electric Motors• Sprinklers 56

Antimicrobial Uses 57

Antimicrobial Uses 58

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 59

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 60

High Efficiency Motors• Greater Conductor Sizes• Attack 5 Areas For Losses• Electrically Commentated Motors 61

Sprinklers• Mandated: New Constructions• Sprinkler Pipe, Fittings, & FPD Conn. 62

Summary Engineering Uses• High Electrical Conductivity• Excellent Conductor of Heat• High Strength Applications• Corrosion Resistant• Antimicrobial• Excellent Machinability & Workability 63

POP QUIZ• Name 3 Features of BronzeIncrease 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 64

QUESTIONS? 65

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 66

THE END 67

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 68

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 69

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 70

Type L, Tubing• Intermediate Wall Thickness & Cost 71

Type M, Tubing• Thinnest Wall Thickness• Lightest Weight• Easiest To Bend• Cheaper Than K, or L Tubing• Underground. H20 Dist., Heating, Fire, 72

Type DWV, Tubing• Drainage Waste Venting 73

Type ACR, Tubing• Air Conditioning & Refrigeration 74

Presentation On Copper, Cu

by cthame1 on Feb 16, 2011

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