Copper and its alloys as the second (following silver) most electrical conductive metal, due to significantly lower cost is the preferred choice for applications demanding high electrical conductivity. Copper is basic material in variety of high conductivity products including: power transmission cables, communication cables, bus bars, electrical machinery, electrical contacts and connectors as well as a conductive material in a wide range of electronic components. In order to fulfill high electrical proprieties requirements for these applications, copper processing technologies are designed in a more advanced manner than in the case of copper-based construction materials. Basic requirements for copper products intended for electrical purposes include increased chemical purity and tailored microstructure, which have a direct impact on copper electrical properties. On the other hand the design of processing route should provide minimum production costs and number of technological steps.

1. Copper Academy:
Processing high conductivity materials
Piotr Osuch, PhD
AGH University of Science and Technology
Faculty of Non-Ferrous Metals
Krakow, January 2015

2. 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

3. 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

4. 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

5. 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

6. 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/m17,9 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

7. 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

8. 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

9. IFLUENCE OF IMPURITIES ON COPPER ELECTRICAL CONDUCTIVITY

10. Copper CathodeCopper Ore
2. ELECTROREFINING PROCESS – CHEMICAL PURITY OF CATHODE
METALLURGY OF COPPER

11. 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 TECHNOLOGYORE EXTRACTION TECHNOLOGY
ORE ENRICHMENT TECHNOOGYORE ENRICHMENT TECHNOOGY
SMELTING TECHNOLOGYSMELTING TECHNOLOGY
REFINING TECHNOLOGYREFINING TECHNOLOGY
Refined copper
99% Cu
Refined copper
99% Cu
REFINING TECHNOLOGYREFINING TECHNOLOGY Pb, Zn, Fe, S
As, Sb, Bi, Ni
Ag, Au
Pb, Zn, Fe, S
As, Sb, Bi, Ni
Ag, Au
SS
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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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.)

20. 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

21. 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

22. 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

23. 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

24. 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

25. 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

26. 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

27. 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

28. 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

29. 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

30. 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

31. 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

32. 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

33. 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

34. 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

35. 4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
CROSS-SECTION MACROSTRUCTURE – ETP CAST

36. DENSITY= 8,77 g/cm3
~4mm
~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

37. 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

38. 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

39. Cu2OCu2O
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

40. 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

41. 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
ELECTRICALCONDUCTIVITY[MS/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

42. Cu-ETP
ELECTROLYTIC TOUGH PITCH COPPER
Cu-OF
OXYGEN FREE COPPER
Cu2OCu2O
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

43. 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, [%]
UTS,[MPa]
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

44. 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

45. 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

46. 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

47. 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

48. 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

49. Fig. Drawing machine

50. Fig. Drawing machine

51. 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

52. 4. TWO MOST IMPORTANT PROCESSING TECHNOLOGIES FOR HIGH CONDUCTIVITY SEMI-FINIHED PRODUCTS
COPPER UTP CABLE – SIGNAL ATTENUATION
Signalattenuation[dB]
Signalattenuation[dB]
Signalattenuation[dB]
Signalattenuation[dB]
Frequency [MHz] Frequency [MHz]
Frequency [MHz] Frequency [MHz]
PAIR 1 PAIR 2
PAIR 3 PAIR 4

53. 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
Propagationspeed[-]
Propagationspeed[-]
Propagationspeed[-]
Propagationspeed[-]

54. Cu-ETP ϕ = 0,58 mm
Cu-OF ϕ = 0,56 mm
COPPER UTP CABLE (UNSHIELDED TWISTED PAIR)
𝑮 = 𝝈
𝑨
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

55. 5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
II. ROLLING PROCESS
Metal Rolling; Fig. 131; http://www.thelibraryofmanufacturing.com/metal_rolling.html

56. 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

57. 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/

58. 5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
III. EXTRUSION PROCESS
Direct Extrusion; Figure 209; http://thelibraryofmanufacturing.com/extrusion.html

59. 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

60. 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

61. 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

62. 5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
CONTINUOUS EXTRUSION PROCESS
continuous extrusion
cooling
finished
product cleaningtransport

63. 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

64. 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

65. 5. WROUGHT PROCESSING OF SEMI-FINISHED PRODUCTS FOR ELECTRICAL APPLICATIONS
MACHINES USED IN SHEET METAL FORMING PROCESS

66. 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

67. 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

68. 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

69. 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

70. CHOICE OF HIGH QUALITY COPPER CATHODECHOICE OF HIGH QUALITY COPPER CATHODE
25 COUNTRIES25 COUNTRIES
44 PRODUCERS44 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}

71. 200
250
300
350
400
450
500
100 120 140 160 180 200 220 240 260 280 300 320 340 360
TEMPERATURE, °C
UTS,MPa
1 2 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

72. 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
!!!

73. 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

74. 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

75. Thank you for your attention