Hansjörg Lipowsky and Emin Arpaci

Copper in the Automotive Industry

B I C E N T E N N I A L

• I C E N T E N N I A L

WILEY-VCH Verlag GmbH & Co. KGaA

Contents

Preface XI

1 Raw Material Resources 1

1.1 Primary Raw Materials 1 1.2 Availability 1

2 Production 3

2.1 From Ore to Copper Concentrate 3 2.2 From Copper Concentrate to Refined Copper 3 2.3 Secondary Copper 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 Low Alloyed 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 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 Powder Metallurgical Materials 28

Copper in the Automotive Industry. Hansjörg Lipowsky and Emin Arpaci Copyright © 2007 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ISBN: 978-3-527-31769-1

VI Contents

4 Wrought Copper Materials 29 4.1 Manufacture of Semi-finished Products 29 4.1.1 Smelting and Casting 29 4.1.2 Hot Forming 29 4.1.3 Cold Forming 30 4.1.4 Production of Sheet and Strip 30 4.1.5 Wire Production 31 4.1.6 Production of Rods and Profiles 31 4.1.7 Production of Tubes 32 4.1.8 Forging 32 4.1.9 Powder Metallurgical 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 According to Chemical Composition 40 4.3.3 Designation of the Condition of the Material 41 4.3.4 Product Designation 42 4.3.5 Designation of Powder Metallurgical (Sintered) Materials 43

5 Copper Casting Materials 45

5.1 Casting Procedures 45 5.1.1 Lost Mold Casting 46 5.1.1.1 Sand Casting 46 5.1.1.2 Precision (Investment) Casting (Lost-wax Process) 46 5.1.1.3 Exact Casting (Other Processes) 47 5.1.2 Permanent Mold Casting 47 5.1.2.1 Die Casting 48 5.1.2.2 Pressure Die Casting 48 5.1.2.3 Centrifugal Casting 49 5.1.3 Continuous Casting 49 5.1.4 Composite Casting 50 5.2 Shapes and Dimensions 50 5.3 Classification and DesignatSpm 51 5.3.1 Designation by Material Number and Chemical Composition 52 5.3.2 Designation of the Casting Process and the Product 53

6 Properties of the Copper Materials 55

6.1 Physical Properties 55 6.2 Mechanical and Technological Properties 58 6.2.1 Strength Properties at Room Temperature 58 6.2.1.1 Roiled 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 Sintered Materials 72 6.2.2 High Temperature Strength and Creep Properties 72 6.2.3 Relaxation 74 6.2.4 Behavior at Low Temperatures 74 6.2.5 Behavior under Dynamic Load 75 6.2.6 Behavior under Cyclic Load 75

7 Worldng 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 Solid Forming 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 (Polished Turning, Grinding, Engrailing,

Thread Production) 90 7.1.3 Chemical Machining, Chemical and Electrochemical Polishing 7.1.4 Electrical Discharge Machining 93 7.1.5 Thermal Cutting 93 7.2 Joining 94 7.2.1 Soldering and Brazing 94 7.2.1.1 Soldering 95 7.2.1.2 Brazing 96 7.2.2 Welding 97 7.2.2.1 Are Welding and Shielding Gas Welding

(TIG and MIG Welding) 98 7.2.2.2 Resistance Welding 99 7.2.2.3 Recent Welding Processes 100 7.2.3 Platins 101

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 or Welding 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 Processes for Surface Treatment 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-dip Coating 114 7.4.3.4 Thermal Spraying 114 7.4.3.5 Deposition Welding 114 7.4.3.6 Roll-cladding 115 7.5 Safety Measures 115 7.6 Health Care 115

8 Design Notes 117

8.1 Design for Material 117 8.2 Design for Recycling 119 8.3 Limits of Application 120 8.4 Tolerances and Machining Allowances 120

9 Application 123

9.1 Areas of Application 323 9.2 Examples for Application 123

10 Usage Properties 127 10.1 Corrosion Behavior 127 10.1.1 Basics of Copper Corrosion 127 10.1.2 Types of Corrosion 128 10.1.3 Corrosion Behavior of Copper Alloys 130 10.1.4 Corrosion in Gases 132 10.1.5 Corrosion Protection 132

Contents I IX

10.2 Strips for Electrical Engineering and Electronics 133 10.3 Piain Bearings 137 10.4 Reliability 142 10.5 Repairability 143

References 145

A.l A.1.1 A.1.2 A.1.3 A.1.4 A.1.5 A.1.6 A.1.7 A.1.8 A.1.9 A.1.10 A.1.11 A.1.12 A.2 A.2.1 A.2.2 A.2.3 A.2.4 A.2.5 A.2.6 A.2.7 A.2.8 A.2.9 A.2.10 A.2.11 A.2.12 A.2.13 A.3 A.3.1 A.3.2 A.3.3 A.3.4 A.3.5 A.3.6 A.3.7

Appendix: Standards and Specifications 149 EN-Standards 149 Basic Standards 150 Testing Standards 150 Refinery Copper 151 Fiat Rolled Products 151 Tubes 151 Rods, Profiles and Wires 152 Forgings and Forging Stock 152 Semi-finished Products for Electrical Engineering Scrap, Master-alloys, Ingots and Castings 153 Bearing Materials 153 Soldering, Brazing and Welding 153 Other Technical Rules for Copper Materials 154 US-Standards (ASTM) 154 Basic Standards 154 Testing Standards 154 Refinery Copper 156 Fiat Rolled Products 156 Tubes 157 Wires 159 Rods, Bars and Shapes 160 Forgings and Extruded Profiles 162 Products for Electrical Engineering 162 Master Alloys, Ingots and Castings 163 Bearing Materials 164 Soldering, Brazing and Welding 164 Coatings 164 Japanese Standards (JIS) 165 Basic Standards 165 Testing Standards 165 Refinery Copper 165 Fiat Rolled Products 165 Tubes 166 Wires 166 Rods, Bars and Shapes 167

152

X I Contents

A.3.8 Master-alloys, Ingots and Castings 167 A.3.9 Soldering, Brazing and Welding 167 A.3.10 Products for Electrical Engineering 167 A.3.11 Coatings 267

Subject Index 269

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