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Presentation On Copper, Cu
- 1. Presentation On Copper,Cu Craig S. Thames, PE
- 2. Introduction • History • Characteristics • Uses and Applications • Characteristics Of Alloys • UL Evaluations • What’s New 2
- 3. A Little AboutCopper § Distinctive Reddish Orange Color § Mostly Found In Ore Form § Density = 8.9 g/cm3 § Melting Point = 1083°C § Boiling Point =2595°C 3
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- 5. The Copper Age5000-3000 BC • Age Following The Stone Age • Believed First Used On Cypress 5
- 6. The Bronze Age3000-750 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
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- 8. Properties Of Copper •Excellent Electrical & Thermal Conductor 8
- 9. An Excellent ElectricalConductor • 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
- 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 10
- 11. An Excellent ThermalConductor • 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
- 12. Properties Of Copper •Excellent Electrical & Thermal Conductor • Excellent Corrosion Resistance 12
- 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 13
- 14. Patina Formation OfCopper 14
- 15. Corrosion Resistance • TarnishesAfter 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) 15
- 16. Corrosion Resistance Not RecommendedFor 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
- 17. Properties Of Copper •Excellent Electrical & Thermal Conductor • Excellent Corrosion Resistance • Excellent Workability 17
- 18. 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
- 19. Properties Of Copper • Excellent Electrical & Thermal Conductor • Excellent Corrosion Resistance • Excellent Workability • Antimicrobial 19
- 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 20
- 21. Antimicrobial • Great For High Touch Areas • Door Knobs, Hand Rails, Push Plates • Hospital Applications • Marine Applications (Barnacle Resistant) • HVAC Ductwork Improves IAQ 21
- 22. Kills Mold Spores Mold – Aspergillus Niger 22
- 23. Properties Of Copper • Excellent Electrical & Thermal Conductor • Excellent Corrosion Resistance • Excellent Workability • Antimicrobial • An Abundant Element 23
- 24. An Abundant Element •3.7 Billion Tons Known Worldwide • 8.3 Million Tons Mined Yearly Worldwide • Most Mining Western N & S. America 24
- 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 25
- 26. Consumers Of Copper •China: Single Leading Country • Big Spike In Last 10 Years • US: Steady For Last 30 Years 26
- 27. China’s Consumption Growth • Economic Growth: 10% YOY 10 Yrs • Explosion In Automotive Production • Electric Car Production 2X Copper • Expansion In Home Building 27
- 28. Recycling Copper • 100% Recyclable • 160,000 Tons = 10% Cu Consumption • Relied Upon For US Self Reliance • Meets 41% Of Global Yearly Demand 28
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- 31. Uses For Copper(2009) Manufacturing Consumers 49% - Wire Mills 50% - Building Construction 40% - Brass Mills 21% - Electrical & Electronic Products 7% - Foundries 10% - Consumer & General Products 1% - Powder Plants 11% - Transportation 3% - Other 8% - Industrial Machinery & Equipment 31
- 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% 32
- 33. POP QUIZ • Whyshould 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
- 34. Copper Alloys • TheMost Commonly Alloyed Metal • Over 475 Distinct Alloys • Wrought and Cast Products 34
- 35. Wrought Alloys ofCopper 7 Main Families (Wrought Alloys) • High Copper Alloys • Brasses • Bronzes, (Sn/P, Al, Si) • Copper-Nickels, Nickel Silvers 35
- 36. Effect Of AlloyingElements • 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
- 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) 37
- 38. Wrought Brass Alloys •Red Brass Cu, Zn (C2100-C28000) • Leaded Brass Cu, Zn, Pb (C31400-C38500) • Gun Metal Cu, Zn, Sn (C40500-C46700) 38
- 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 39
- 40. Mechanical Props. OfBrass • Highest Strength Brass Alloy • C36000 The Standard In Machinability 40
- 41. Machinability Comparables Titanium 6% 316 Stainless Steel(18/8) 12% Medium Carbon Steel 20% Aluminum Alloy 50% Copper 20% Leaded High Copper 80% 41
- 42. Wrought Bronze Alloys •Phosphor Bronze (Sn/P) C5xxxx • Aluminum Bronzes (Al) C60600-64200 • Silicon Bronzes (Si) C64700-C66100 42
- 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 43
- 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 44
- 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 45
- 46. Bronze Mechanical Properties •Highest Tensile Strength Bronze C52400 • Best Machinability Bronze C54400 46
- 47. 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
- 48. Cast Alloys OfCopper • High Copper • Brass 4 Main Families Of Bronze • Copper- Tin (Tin Bronze) • Copper-Leaded-Tin • Copper-Tin-Nickel • Copper-Aluminum 48
- 49. 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
- 50. How Does ULEvaluate Copper? 50
- 51. 10 Day MoistAmmonia Test • In More Than 50 UL Standards • Dezincification of Alloys (Brass) >15% Zn • Fire Protection, Gas & Oil § Valves, Pipe and Fitting § Sprinklers 51
- 52. Overcoming Dezincification • Arsenic(0.20%) Improves Resistance • Heat Treatment Processes 52
- 53. Copper Sulfate Test •Measures Zn Coating Thickness 53
- 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 54
- 55. HVAC • Disallowed ForAmmonia Refrigerants 55
- 56. What’s New? • LeveragingAnti Microbial • High Efficiency Electric Motors • Sprinklers 56
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- 59. CA, VT LeadLaw • 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
- 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 60
- 61. High Efficiency Motors •Greater Conductor Sizes • Attack 5 Areas For Losses • Electrically Commentated Motors 61
- 62. Sprinklers • Mandated: NewConstructions • Sprinkler Pipe, Fittings, & FPD Conn. 62
- 63. Summary Engineering Uses • High Electrical Conductivity • Excellent Conductor of Heat • High Strength Applications • Corrosion Resistant • Antimicrobial • Excellent Machinability & Workability 63
- 64. POP QUIZ • Name3 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 64
- 65. QUESTIONS? 65
- 66. Additional Resources • ASMMetals 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
- 67. THE END 67
- 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 68
- 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 69
- 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 70
- 71. Type L, Tubing •Intermediate Wall Thickness & Cost 71
- 72. Type M, Tubing • Thinnest Wall Thickness • Lightest Weight • Easiest To Bend • Cheaper Than K, or L Tubing • Underground. H20 Dist., Heating, Fire, 72
- 73. Type DWV, Tubing •Drainage Waste Venting 73
- 74. Type ACR, Tubing •Air Conditioning & Refrigeration 74