Copper C194 (Alloy 194)
Introduction to Copper C194 (Alloy 194)
Copper C194 (Alloy 194) is a high-strength copper alloy, enhanced with chromium and zirconium, providing superior mechanical properties such as increased strength, wear resistance, and fatigue resistance. Its high electrical and thermal conductivity combination makes it ideal for CNC machining applications, where precision and durability are critical. This material is commonly used in manufacturing components like electrical connectors and aerospace parts, ensuring high performance in both electrical and mechanical systems.
Due to its strength and conductivity, Copper C194 (Alloy 194) is a popular choice for industries requiring high-quality parts. CNC machined Copper C194 parts are utilized in various applications such as power distribution, automotive, and telecommunications, offering an excellent balance between electrical performance and structural integrity.
Chemical, Physical, and Mechanical Properties of Copper C194 (Alloy 194)
Chemical Composition (Typical)
Element | Composition Range (wt.%) | Key Role |
|---|---|---|
Copper (Cu) | 98.5% | Forms the base material, ensuring excellent conductivity |
Chromium (Cr) | 0.25–0.35% | Enhances strength and resistance to oxidation |
Zirconium (Zr) | 0.05–0.15% | Increases strength, improves resistance to wear and fatigue |
Other Elements | ≤0.5% | Residual elements with minimal impact on properties |
Physical Properties
Property | Value (Typical) | Test Standard/Condition |
|---|---|---|
Density | 8.92 g/cm³ | ASTM B311 |
Melting Point | 1,083°C | ASTM E29 |
Thermal Conductivity | 300 W/m·K at 20°C | ASTM E1952 |
Electrical Conductivity | 92% IACS at 20°C | ASTM B193 |
Coefficient of Expansion | 17.5 µm/m·°C | ASTM E228 |
Specific Heat Capacity | 380 J/kg·K | ASTM E1269 |
Elastic Modulus | 120 GPa | ASTM E111 |
Mechanical Properties (Annealed Temper)
Property | Value (Typical) | Test Standard |
|---|---|---|
Tensile Strength | 550–700 MPa | ASTM E8/E8M – full-section test specimens |
Yield Strength (0.2%) | 400–550 MPa | ASTM E8/E8M – offset method |
Elongation | 20–30% | ASTM E8/E8M – gauge length = 50 mm |
Hardness | 80–100 HB | ASTM E10 – Brinell hardness, 10 mm ball/500 kg load |
Fatigue Strength | ~350 MPa | ASTM E466 – rotating bending fatigue at 10⁷ cycles |
Impact Resistance | Moderate | ASTM E23 – Notched, room temperature |
Note: These values are typical for annealed Copper C194 (Alloy 194) and can vary based on specific processing conditions.
Key Characteristics of Copper C194 (Alloy 194)
High Electrical Conductivity (92% IACS)
Copper C194 (Alloy 194) retains excellent electrical conductivity (92% IACS), making it ideal for applications that require high conductivity, such as electrical connectors, switchgear, and components used in power generation and distribution systems. Its conductivity and strength provide a balanced solution for electrical systems needing both performance and durability.
Enhanced Strength and Fatigue Resistance
The addition of chromium and zirconium increases Copper C194’s tensile strength. It improves its resistance to fatigue, making it suitable for demanding applications like the aerospace and automotive industries, where parts are subjected to high mechanical stress over time.
Superior Resistance to Wear and Corrosion
Copper C194 (Alloy 194) demonstrates excellent wear and corrosion resistance in various environments, including those exposed to moisture and corrosive elements. This makes it an ideal material for manufacturing long-lasting parts such as electrical terminals, switchgear, and other components subjected to mechanical wear and corrosion.
Good Machinability
Despite its high strength, Copper C194 is relatively easy to machine, making it an excellent choice for CNC machining. The alloy’s ability to hold tight tolerances and take on complex geometries ensures high-quality finished parts with smooth surfaces and precise dimensions.
Stable Performance at High Temperatures
Copper C194 is highly stable at elevated temperatures. It is suitable for high-temperature applications such as components used in engines, turbines, and electrical equipment, where other materials may fail due to heat-induced degradation.
CNC Machining Challenges and Solutions for Copper C194 (Alloy 194)
Machining Challenges
Work Hardening
Copper C194 (Alloy 194) can work-harden during machining, which may lead to increased tool wear and difficulties in further processing.
Solution: Use sharp, carbide tools and apply moderate cutting speeds. Ensure proper coolant application to minimize heat buildup and reduce work hardening effects.
Chip Formation
The alloy tends to produce long chips, which can become tangled and interfere with the machining process, slowing down operations.
Solution: Utilize chip breakers to create shorter, manageable chips. Apply a consistent flow of coolant to improve chip removal and prevent obstruction.
Tool Wear
Copper C194’s high strength and hardness can result in excessive tool wear during machining, particularly when using inadequate tooling or cutting speeds.
Solution: Use high-quality carbide or coated tools designed for tough materials. Controlling the cutting speed and using the appropriate coatings can reduce tool wear significantly.
Optimized Machining Strategies
Tool Selection
Parameter | Recommendation | Rationale |
|---|---|---|
Tool Material | Carbide tools with TiAlN coating | Enhances tool life and reduces wear in tough materials |
Geometry | Positive rake, sharp edges | Improves chip flow and reduces material buildup |
Cutting Speed | 150–250 m/min | Prevents excessive heating and enhances tool longevity |
Feed Rate | 0.10–0.20 mm/rev | Ensures smooth cutting and reduces risk of work hardening |
Coolant | Flood coolant or air blast | Reduces heat buildup and helps in chip removal |
Copper C194 Cutting Parameters (ISO 513 Compliance)
Operation | Speed (m/min) | Feed (mm/rev) | Depth of Cut (mm) | Coolant Pressure (bar) |
|---|---|---|---|---|
Roughing | 150–200 | 0.10–0.15 | 2.0–4.0 | 25–40 (Flood coolant) |
Finishing | 200–250 | 0.05–0.10 | 0.5–1.0 | 30–50 (Flood coolant) |
Functions for Copper C194 (Alloy 194)
Below are the specific functions of various machining processes for Copper C194 (Alloy 194), highlighting the benefits for this material:
Machining Process | Function and Benefit for Copper C194 (Alloy 194) |
|---|---|
CNC machining offers high precision for electrical components like connectors and terminals, retaining strength and conductivity while providing tight tolerances. | |
Milling is ideal for creating flat surfaces and complex shapes for Copper C194 components while maintaining structural integrity and smooth finishes. | |
CNC turning is suitable for machining cylindrical parts such as rods and tubes, enabling precise geometry and high-quality finishes. | |
Drilling provides accurate hole dimensions for Copper C194, ensuring the correct fit for connectors and other critical components. | |
Boring ensures the enlargement of holes with high precision and smooth internal surfaces, ideal for Copper C194 used in aerospace and electrical components. | |
Grinding achieves fine surface finishes and tight tolerances on Copper C194, improving part performance and appearance. | |
Multi-axis machining allows for creating complex geometries in Copper C194, ensuring accuracy and reducing setup times. | |
Precision machining delivers high-tolerance parts, ensuring Copper C194 components meet exact specifications for use in demanding applications. | |
Electrical Discharge Machining (EDM) creates intricate details and fine features in Copper C194 components, providing superior precision. |
Surface Treatment for Copper C194 CNC Parts
Electroplating: Enhances wear resistance and corrosion protection by applying a thin coating of metals such as nickel, silver, or gold.
Polishing: Achieves a smooth, reflective finish that enhances the appearance and functionality of components.
Brushing: Provides a satin or matte finish that reduces surface glare and enhances the appearance of decorative components.
PVD Coating: Adds superior durability and wear resistance for visible parts.
Passivation: Improves corrosion resistance by removing contaminants from the surface.
Powder Coating: Provides durable protection from wear and harsh environmental conditions.
Teflon Coating: Ideal for parts that need to resist chemicals and wear.
Chrome Plating: Adds a shiny, durable, and corrosion-resistant finish.
Industry Applications of Copper C194 (Alloy 194)
Aerospace Industry: Copper C194 (Alloy 194) is ideal for components in aerospace applications that require both high strength and conductivity, such as connectors and electrical terminals.
Electrical & Power Distribution: Used for high-performance electrical contacts and connectors, ensuring reliable power distribution in critical systems.
Automotive Industry: Suitable for electrical components, terminals, and connectors used in electric and hybrid vehicles.
FAQs
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