Copper in the Automotive Industry

192 Pages·2007·1.083 MB·English

by  Dipl.?Ing. (TU) Hansjorg Lipowsky, Dr. Emin Arpaci(auth.)

HansjörgLipowsky
andEminArpaci
Copper
intheAutomotiveIndustry
CopperintheAutomotiveIndustry.HansjörgLipowskyandEminArpaci
Copyright©2007WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:978-3-527-31769-1
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Hansjörg Lipowsky and Emin Arpaci
Copper in the Automotive Industry
Physics, Technology, Applications
Mit Beispielen aus der Praxis
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ISBN978-3-527-31769-1
V
Contents
Preface XI
1 Raw Material Resources 1
1.1 Primary Raw Materials 1
1.2 Availability 1
2 Production 3
2.1 FromOre to CopperConcentrate 3
2.2 FromCopper Concentrate to Refined Copper 3
2.3 SecondaryCopper Production 5
2.4 Energy Consumption 5
2.5 Recycling 6
2.6 Environmental Protection 8
3 Classification of Copper Materials 11
3.1 Wrought Copper Materials 11
3.1.1 Copper 11
3.1.2 LowAlloyed Wrought Copper 13
3.1.3 Wrought Copper–Zinc Alloys 15
3.1.4 Wrought Copper–Tin Alloys 15
3.1.5 Wrought Copper–Nickel Alloys 18
3.1.6 Wrought Copper–Nickel–Zinc Alloys 18
3.1.7 Wrought Copper–Aluminum Alloys 18
3.2 Copper Casting Materials 20
3.2.1 Copper and Copper–Chromium Casting Materials 20
3.2.2 Copper–Zinc Casting Alloys 22
3.2.3 Copper–Tin Casting Alloys 22
3.2.4 Copper–Tin–Lead Casting Alloys 25
3.2.5 Copper–Aluminum Casting Alloys 25
3.2.6 Copper–Manganese–Aluminum and Copper–Nickel
Casting Alloys 25
3.3 Composites 27
3.4 PowderMetallurgical Materials 28
CopperintheAutomotiveIndustry.HansjörgLipowskyandEminArpaci
Copyright©2007WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:978-3-527-31769-1
VI Contents
4 Wrought Copper Materials 29
4.1 Manufacture ofSemi-finishedProducts 29
4.1.1 Smelting and Casting 29
4.1.2 HotForming 29
4.1.3 Cold Forming 30
4.1.4 Production ofSheet and Strip 30
4.1.5 Wire Production 31
4.1.6 Production ofRodsand Profiles 31
4.1.7 Production ofTubes 32
4.1.8 Forging 32
4.1.9 PowderMetallurgical Forming (Sintering) 33
4.2 Shapes and Dimensions 33
4.2.1 Strips, Sheets and Plates 34
4.2.2 Tubes 35
4.2.3 Rods 36
4.2.4 Wires 37
4.2.5 Drawn and Extruded Profiles 38
4.2.6 Forgings 38
4.2.7 Special Shapes 38
4.3 Classification and Designation 39
4.3.1 Designation by Material Number 39
4.3.2 Designation Accordingto Chemical Composition 40
4.3.3 Designation ofthe Conditionof the Material 41
4.3.4 Product Designation 42
4.3.5 Designation ofPowderMetallurgical (Sintered) Materials 43
5 Copper Casting Materials 45
5.1 Casting Procedures 45
5.1.1 LostMoldCasting 46
5.1.1.1 Sand Casting 46
5.1.1.2 Precision(Investment) Casting (Lost-waxProcess) 46
5.1.1.3 Exact Casting (Other Processes) 47
5.1.2 Permanent MoldCasting 47
5.1.2.1 Die Casting 48
5.1.2.2 PressureDie Casting 48
5.1.2.3 Centrifugal Casting 49
5.1.3 Continuous Casting 49
5.1.4 CompositeCasting 50
5.2 Shapes and Dimensions 50
5.3 Classification and Designation 51
5.3.1 Designation by Material Numberand Chemical Composition 52
5.3.2 Designation ofthe Casting Processand the Product 53
Contents VII
6 Properties of the Copper Materials 55
6.1 Physical Properties 55
6.2 Mechanical and Technological Properties 58
6.2.1 Strength Propertiesat Room Temperature 58
6.2.1.1 Rolled Products 60
6.2.1.2 Extruded Products 61
6.2.1.3 Drawn Products 67
6.2.1.3.1 Rods 67
6.2.1.3.2 Tubes 67
6.2.1.3.3 Wires 68
6.2.1.4 Forgings 69
6.2.1.5 Castings 70
6.2.1.6 Composites 70
6.2.1.7 SinteredMaterials 72
6.2.2 High Temperature Strength and Creep Properties 72
6.2.3 Relaxation 74
6.2.4 Behaviorat LowTemperatures 74
6.2.5 Behaviorunder Dynamic Load 75
6.2.6 Behaviorunder Cyclic Load 75
7 Working with Copper Materials 79
7.1 Mechanical Processing 79
7.1.1 Non-cutting Treatment 79
7.1.1.1 Forming Sheets and Strips 80
7.1.1.2 SolidForming 84
7.1.2 Machining 85
7.1.2.1 Turning 88
7.1.2.2 Milling 89
7.1.2.3 Drilling 89
7.1.2.4 Cutting 90
7.1.2.5 Fine Finishing (PolishedTurning, Grinding, Engrailing,
Thread Production) 90
7.1.3 Chemical Machining, Chemical and ElectrochemicalPolishing 92
7.1.4 Electrical DischargeMachining 93
7.1.5 Thermal Cutting 93
7.2 Joining 94
7.2.1 Solderingand Brazing 94
7.2.1.1 Soldering 95
7.2.1.2 Brazing 96
7.2.2 Welding 97
7.2.2.1 Arc Welding and Shielding Gas Welding
(TIGand MIG Welding) 98
7.2.2.2 ResistanceWelding 99
7.2.2.3 RecentWelding Processes 100
7.2.3 Plating 101
VIII Contents
7.2.4 Bonding 102
7.3 Heat Treatment 102
7.3.1 Homogenization 103
7.3.2 Soft Annealing (Recrystallization) 103
7.3.3 Thermal Stress-relieving 104
7.3.4 Age-hardening (Precipitation Hardening) 106
7.4 Surface Treatment 108
7.4.1 Pretreatment 108
7.4.1.1 Cleaning, Degreasing 108
7.4.1.2 Pickling and Etching 109
7.4.1.3 Chemical and Electrochemical Polishing 110
7.4.1.4 Pretreatment for Soldering, Brazing orWelding 110
7.4.1.5 Pretreatment for Bonding 111
7.4.1.6 Pretreatment for Coating 111
7.4.1.7 Shot Peening 111
7.4.2 Surface Design 112
7.4.2.1 Mechanical ProcessesforSurfaceTreatment 112
7.4.2.2 Non-metallic Coatings,Metal Coloring 112
7.4.3 Metallic Coatings 112
7.4.3.1 Electroplating 113
7.4.3.2 Electroless(Chemical) Deposition 114
7.4.3.3 Hot-dipCoating 114
7.4.3.4 Thermal Spraying 114
7.4.3.5 DepositionWelding 114
7.4.3.6 Roll-cladding 115
7.5 Safety Measures 115
7.6 Health Care 115
8 Design Notes 117
8.1 Designfor Material 117
8.2 Designfor Recycling 119
8.3 Limits ofApplication 120
8.4 Tolerancesand Machining Allowances 120
9 Application 123
9.1 Areasof Application 123
9.2 Examples forApplication 123
10 Usage Properties 127
10.1 CorrosionBehavior 127
10.1.1 BasicsofCopper Corrosion 127
10.1.2 Types of Corrosion 128
10.1.3 CorrosionBehaviorofCopper Alloys 130
10.1.4 Corrosionin Gases 132
10.1.5 CorrosionProtection 132
Contents IX
10.2 Strips for Electrical Engineering and Electronics 133
10.3 Plain Bearings 137
10.4 Reliability 142
10.5 Repairability 143
References 145
Appendix: Standards and Specifications 149
A.1 EN-Standards 149
A.1.1 BasicStandards 150
A.1.2 Testing Standards 150
A.1.3 Refinery Copper 151
A.1.4 Flat Rolled Products 151
A.1.5 Tubes 151
A.1.6 Rods,Profiles and Wires 152
A.1.7 Forgings and Forging Stock 152
A.1.8 Semi-finished Productsfor Electrical Engineering 152
A.1.9 Scrap, Master-alloys, Ingots and Castings 153
A.1.10 Bearing Materials 153
A.1.11 Soldering, Brazing and Welding 153
A.1.12 Other Technical Rules forCopper Materials 154
A.2 US-Standards (ASTM) 154
A.2.1 BasicStandards 154
A.2.2 Testing Standards 154
A.2.3 Refinery Copper 156
A.2.4 Flat Rolled Products 156
A.2.5 Tubes 157
A.2.6 Wires 159
A.2.7 Rods,Barsand Shapes 160
A.2.8 Forgings and Extruded Profiles 162
A.2.9 Products forElectrical Engineering 162
A.2.10 MasterAlloys, Ingots and Castings 163
A.2.11 Bearing Materials 164
A.2.12 Soldering, Brazing and Welding 164
A.2.13 Coatings 164
A.3 Japanese Standards (JIS) 165
A.3.1 BasicStandards 165
A.3.2 Testing Standards 165
A.3.3 Refinery Copper 165
A.3.4 Flat Rolled Products 165
A.3.5 Tubes 166
A.3.6 Wires 166
A.3.7 Rods,Barsand Shapes 167
X Contents
A.3.8 Master-alloys, Ingots and Castings 167
A.3.9 Soldering, Brazing and Welding 167
A.3.10 Products forElectrical Engineering 167
A.3.11 Coatings 167
Subject Index 169