Copper C103 (TU2)

Introduction to Copper C103 (TU2)

Copper C103 (TU2) is a specific grade of oxygen-free copper that is known for its exceptionally high electrical conductivity and excellent corrosion resistance. This grade of copper contains a minimal amount of oxygen (less than 0.001%) and is often called Oxygen-Free High Conductivity (OFHC) copper. The TU2 designation indicates the copper's specific purity and oxygen-free quality, which is suitable for various industrial applications where high performance and minimal impurities are crucial.

Copper C103 (TU2) is commonly used in applications where high electrical conductivity and corrosion resistance are paramount. It is widely utilized in electrical power systems, telecommunications, and precision electronic components, where performance reliability is a key factor. The ability of Copper C103 (TU2) to maintain its conductivity over time, even in harsh environments, makes it an ideal material for components such as connectors, terminals, and electrical wiring in specialized industries.

Due to its high purity, Copper C103 (TU2) is well-suited for CNC Machining Service projects, particularly in creating CNC Machined Copper Parts for electrical systems, telecommunications, and precision electronic components.

Chemical, Physical, and Mechanical Properties of Copper C103 (TU2)

Chemical Composition (Typical)

Physical Properties

Mechanical Properties (Annealed Temper)

Note: These values are representative of annealed (soft) Copper C103 (TU2) at room temperature. Mechanical strength increases with cold working but may reduce elongation.

Key Characteristics of Copper C103 (TU2)

Superior Electrical Conductivity (≥101% IACS)

Copper C103 (TU2) stands out for its excellent electrical conductivity, reaching ≥101% International Annealed Copper Standard (IACS), according to ASTM B193. This high level of conductivity ensures that Copper C103 (TU2) is an excellent choice for high-performance applications where low resistive losses and efficient current flow are critical, such as in power systems, connectors, and electrical components.

Excellent Thermal Conductivity (398 W/m·K)

With a thermal conductivity of 398 W/m·K at 20°C, Copper C103 (TU2) excels in heat transfer applications. This makes it suitable for use in heat exchangers, electrical systems that require rapid heat dissipation, and components where temperature management is important. The high thermal conductivity ensures that Copper C103 (TU2) can efficiently manage the heat generated in electrical circuits or components.

High Ductility and Formability

Copper C103 (TU2) exhibits excellent ductility, with elongation values typically above 35% (ASTM E8/E8M), making it highly formable. This property is essential in CNC machining, as it allows Copper C103 (TU2) to be easily shaped into intricate components without compromising its structural integrity. The material can be cold-worked into various forms, including wire, thin sheets, and busbars, making it a versatile material for various applications.

Corrosion Resistance and Longevity

The low oxygen content in Copper C103 (TU2) enhances its resistance to corrosion, particularly in moist or saline environments. Unlike other copper alloys that may form a green oxide layer over time, Copper C103 (TU2) maintains its bright, metallic surface without degradation, ensuring longevity and durability in high-performance applications. Its resistance to corrosion makes it ideal for outdoor applications, marine environments, and power distribution systems.

Non-Magnetic and Stable Annealed State

Copper C103 (TU2) is non-magnetic, which is important for applications that require minimal interference from magnetic fields, such as telecommunications and sensitive electronic components. Additionally, being an annealed copper alloy, Copper C103 (TU2) maintains its excellent conductivity and dimensional stability even after extensive forming processes, ensuring that the material retains its mechanical and electrical properties over time.

CNC Machining Challenges and Solutions for Copper C103 (TU2)

Machining Challenges

Work Hardening

Copper C103 (TU2) is prone to work hardening, particularly when subjected to high cutting speeds. As the material deforms, its hardness increases, making it more challenging to machine, resulting in increased tool wear and potential part distortion.

• Solution: CNC machinists should use lower cutting speeds and optimize feed rates to reduce work hardening. Tool coatings like TiAlN can also reduce friction and prevent the material from hardening at the cutting edge.

Chip Formation

Due to its high ductility, Copper C103 (TU2) produces long, stringy chips that can become tangled in the machine, causing disruptions and damaging the workpiece.

• Solution: Using chip breakers or tools with positive rake angles improves chip flow and helps reduce chip buildup. Also, applying a steady coolant flow can enhance chip removal and prevent clogs.

High Thermal Conductivity

Copper C103 (TU2) has high thermal conductivity, which can lead to excessive heat buildup at the cutting interface. This can accelerate tool wear and affect the quality of the surface finish.

• Solution: A high-performance coolant system is essential for managing heat buildup. Carbide tools with higher thermal resistance are also recommended to reduce the effects of heat on the machining process.

Optimized Machining Strategies

Tool Selection

Copper C103 Cutting Parameters (ISO 513 Compliance)

Typical Machining Services for Copper C103 (TU2)

Copper C103 (TU2) is suitable for various machining processes but requires careful parameters management to ensure high-quality finishes and efficient production. Below are the typical machining services:

Surface Treatment for Copper C103 CNC Parts

• Electroplating: Coating copper with a layer of tin, nickel, or silver to enhance corrosion resistance and improve solderability for electrical contacts and connectors.

• Polishing: Achieves a glossy, smooth finish (Ra 0.1–0.6 µm), improving both aesthetic appeal and contact quality in electronic components.

• Brushing: Produces satin or matte surfaces, reducing glare and enhancing the appearance of visible parts in consumer products and electrical equipment.

• PVD Coating: Thin coatings (2–3 µm) that improve wear resistance, color stability, and durability for high-performance electrical components.

• Passivation: Chemical treatment that enhances corrosion resistance by removing residual oils and oxides from the copper surface.

• Powder Coating: A durable polymer coating ideal for components exposed to harsh environments, providing excellent protection against moisture, UV rays, and abrasion.

• Teflon Coating: Provides excellent chemical resistance and non-stick properties, making it ideal for components that will be exposed to aggressive substances.

• Chrome Plating: Adds a thin layer of chromium for improved wear resistance, surface hardness, and a glossy finish for high-end electrical parts.

Industry Applications of Copper C103 (TU2)

• Electrical & Power Distribution: Copper C103 (TU2) is widely used for busbars, power connectors, and cables due to its high electrical conductivity and corrosion resistance.

• Aerospace & Defense: Ideal for components that require low magnetic permeability, such as aircraft electrical systems and high-precision connectors.

• Medical Devices: Used for MRI machines and other equipment requiring non-magnetic, conductive components.

• Automotive: High-current connectors, electrical terminals, and fuse boxes.

• Consumer Electronics: Speaker terminals, high-performance connectors, and other electrical parts where conductivity is key.

FAQs

• What are the common applications for Copper C103 in electronics?

• How does Copper C103 perform in extreme temperature environments?

• What is the maximum conductivity achievable in Copper C103?

• What is the difference between Copper C103 and Copper C101 in terms of conductivity?

• How can Copper C103 be used in aerospace applications?