Copper C194 (High Strength Copper)
Introduction to Copper C194 (High Strength Copper)
Copper C194 is a high-performance copper alloy known for its excellent combination of high strength, good electrical conductivity, and enhanced mechanical properties. It incorporates controlled amounts of alloying elements that provide excellent strength, wear resistance, and ductility. Copper C194 is ideal for precision CNC machining services where both high strength and excellent electrical performance are required.
Copper C194 is widely used in applications within industries such as aerospace, electrical, and telecommunications. CNC machined Copper C194 parts are typically used in connectors, switchgear, terminals, and other electrical components that require high conductivity combined with strength and durability.
Chemical, Physical, and Mechanical Properties of Copper C194 (High Strength Copper)
Chemical Composition (Typical)
Element | Composition Range (wt.%) | Key Role |
|---|---|---|
Copper (Cu) | 98.0% | Provides excellent electrical and thermal conductivity |
Phosphorus (P) | 0.015–0.045% | Enhances strength and improves machinability |
Other Elements | ≤0.1% | 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 | 220 W/m·K at 20°C | ASTM E1952 |
Electrical Conductivity | 70% IACS at 20°C | ASTM B193 |
Coefficient of Expansion | 17.0 µm/m·°C | ASTM E228 |
Specific Heat Capacity | 390 J/kg·K | ASTM E1269 |
Elastic Modulus | 125 GPa | ASTM E111 |
Mechanical Properties (Annealed Temper)
Property | Value (Typical) | Test Standard |
|---|---|---|
Tensile Strength | 600–750 MPa | ASTM E8/E8M |
Yield Strength (0.2%) | 450–600 MPa | ASTM E8/E8M |
Elongation | 10–25% | ASTM E8/E8M |
Hardness | 150–220 HB | ASTM E10 |
Fatigue Strength | ~250 MPa | ASTM E466 |
Impact Resistance | Moderate | ASTM E23 |
Note: These values are typical for annealed Copper C194 and can vary based on specific processing conditions.
Key Characteristics of Copper C194 (High Strength Copper)
High Strength and Durability
Copper C194 exhibits tensile strength up to 750 MPa, making it an ideal material for applications requiring high mechanical strength and resistance to wear.
Moderate Electrical Conductivity
With 70% IACS electrical conductivity, Copper C194 is well-suited for electrical components with high strength and moderate conductivity.
Excellent Machinability
The alloy's balanced composition of copper and phosphorus enhances its machinability, allowing for precision CNC machining without compromising strength.
Good Corrosion Resistance
Copper C194 has good corrosion resistance in most environments, making it ideal for parts exposed to moisture and mild chemicals.
Improved Fatigue Strength
The alloy’s fatigue strength of around 250 MPa ensures that it can withstand repeated stress, making it suitable for dynamic applications.
CNC Machining Challenges and Solutions for Copper C194 (High Strength Copper)
Machining Challenges
High Hardness and Tool Wear
Due to its high strength, Copper C194 can cause significant tool wear during machining, especially in high-speed operations.
Solution: Use carbide tools with TiN or TiAlN coatings to reduce wear and extend tool life.
Work Hardening
Copper C194 tends to work harden quickly, making subsequent machining operations difficult.
Solution: Maintain moderate cutting speeds and use sharp tools to avoid work hardening.
Chip Formation
The material’s high strength can cause long, stringy chips that can interfere with machining efficiency.
Solution: Employ chip breakers and increase coolant flow to ensure smooth chip removal and improve surface finish.
Optimized Machining Strategies
Tool Selection
Parameter | Recommendation | Rationale |
|---|---|---|
Tool Material | Carbide tools with TiN coating | Enhances tool life and reduces wear |
Geometry | Positive rake, sharp edges | Improves chip flow and reduces material buildup |
Cutting Speed | 100–180 m/min | Prevents excessive heating and extends tool life |
Feed Rate | 0.08–0.12 mm/rev | Ensures smooth cutting and reduces risk of work hardening |
Coolant | Flood coolant or air blast | Reduces heat buildup and assists 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 | 100–150 | 0.10–0.15 | 2.0–3.0 | 25–40 |
Finishing | 150–200 | 0.05–0.10 | 0.5–1.0 | 30–50 |
Key Features and Applications for Copper C194 (High Strength Copper)
Machining Process | Function and Benefit for Copper C194 (High Strength Copper) |
|---|---|
Achieves ±0.01 mm precision for high-strength electrical connectors and components. | |
Ideal for producing complex features like slots, grooves, and shapes in electrical parts. | |
Suitable for turning cylindrical components like connectors and terminals with tight tolerances. | |
Used for drilling holes with high precision in electrical components, including connectors. | |
Used for precise internal bore machining, ideal for electrical housings and connectors. | |
Provides fine surface finishes, ensuring high-quality electrical parts. | |
Ideal for producing complex, high-precision parts for electrical and aerospace components. | |
Achieves ultra-tight tolerances for high-performance electrical parts in aerospace and industrial uses. | |
Used for creating intricate features and micro-components, especially in electrical connectors. |
Surface Treatment for Copper C194 CNC Parts
Electroplating: Adds a 5–10 µm nickel coating for enhanced corrosion resistance and durability in electrical contacts.
Polishing: Achieves smooth, glossy finishes with Ra 0.2–0.4 µm, improving electrical conductivity and aesthetic appeal.
Brushing: Provides a uniform satin finish for decorative and mechanical applications, enhancing part appearance.
PVD Coating: Adds a 2–5 µm hard, durable coating to protect parts from wear and corrosion.
Passivation: Improves corrosion resistance, extending the lifetime of parts in harsh environments.
Powder Coating: Provides a 50–100 µm protective coating for durability and enhanced UV resistance.
Teflon Coating: Adds a low friction, chemical-resistant layer ideal for sliding and high-wear applications.
Chrome Plating: Adds a shiny, durable finish (10–20 µm thickness) for corrosion protection and high-load performance.
Industry Applications of Copper C194 (High Strength Copper)
Aerospace Industry: Copper C194 is used in aerospace for high-strength electrical contacts and connectors exposed to high stress.
Electrical & Power: Ideal for power connectors, terminals, and switches that require high strength and excellent conductivity.
Automotive Industry: Used in automotive systems for high-performance electrical parts, such as connectors and terminals in electric vehicles (EVs).
FAQs
What makes Copper C194 suitable for high-strength electrical applications?
How does Copper C194 compare to other copper alloys regarding machinability and strength?
Can Copper C194 be used in high-performance automotive electrical connectors?
What surface treatments are most effective for Copper C194 to enhance its properties?
How does Copper C194 perform under high-stress conditions in aerospace applications?
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