Copper sections

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Copper

Copper is one of the oldest natural materials known to man, yet today it remains amongst the most important and widely used non-ferrous metals in the world. Wieland semi-finished products form an indispensable link between the raw materi-al copper and the wide variety of products made by our cus-tomers.

Copper is suitable for a tremendous range of applications due to its unique combination of various properties such as

· high electrical and thermal conductivity· outstanding corrosion resistance · good forming and processing properties· excellent suitability for surface coating

Wieland copper sections are, therefore, used across a multi-tude of industries.

Copper sections for various applications

Sections

Sections are semi-finished products from which functional parts are manufactured – in the majority of cases at very low processing costs. With sections it is possible to reduce production costs, and consequently, total costs.

Due to their excellent electrical and thermal conductivity, copper sections are mainly used in the electrical industry and in cooling systems.

The Wieland Group manufactures solid and hollow copper sections in a wide range of sizes. Our Technical Marketing can provide assistance from the concept to the construction of your copper section.

Moreover, we supply copper sections which have undergone further processing. We offer all common methods of machin-ing as well as surface coating. For further information please contact our Technical Marketing Extruded/Drawn Products.

Company portrait

The Wieland Group, with headquarters in Ulm, Germany, is one of the world’s leading manufacturers of semi-finished and special products in copper and copper alloys. These include strip, sheet, tube, rod, wire and sections as well as slide bearings, finned tubes and heat exchangers.

Wieland’s history dates back to the early 19th century. Founder Philipp Jakob Wieland took over his uncle’s Ulm art and bell foundry in 1820 and by 1828 he was producing brass sheet and wire.

Today, the Wieland Group comprises manufacturing compa-nies, slitting centres and trading subsidiaries in many Europe-an countries as well as in the USA, in South Africa, Singapore and the People’s Republic of China.

Wieland manufactures several hundred thousand tons of copper alloys every year, from the continuously cast to the semi-finished product. Production starts at Europe’s largest foundry for copper alloys, at our plant in Vöhringen, Germany.

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Applications

Solid sections are used in various shapes and sizes, mainly in the electri-cal industry, e.g. for

· busbars in switch cabinets· terminals· switches or commutators

They are also used in cooling systems for the electronics industry.

Copper section for busbar systems

Solid copper sections

Advantages of copper sections

Technical solutions achieved through the use of copper sections are becom-ing increasingly important for cost-effi-cient production. Ideally, it is sufficient to simply cut the section to length to produce the desired finished part. Cop-per sections offer additional advantag-es such as

· electrical optimization of conductor cross-sections· thermal optimization (cooling)· reduction of processing costs (optimi- zation of process costs)· ease of mounting and installation (efficiency)· saving of material (less scrap)

Shapes available

The production of a section depends on its geometry. Shape and dimensions are usually defined in a drawing. Basic information on shapes available as well as process-related limits of copper sec-tions are provided in EN 13605. Devia-tions from EN 13605 are possible by agreement.

We are willing and able to assist you from the concept through every stage until the section becomes a reality.

Photos above: copper sections

DCC

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Production capabilities

We offer a wide range of produc-tion possibilities and shapes which is unique in the industry. Our equipment allows us to produce copper sections with weights of 0.02 kg/m to 30 kg/m (0.013 lbs/ft to 20.159 lbs/ft). Advanc-es in production processes and tool design make it possible to realize ever more complex shapes. Our compe-tence in the production of sections is unsurpassed as a result of our own tool design and construction.

Solid copper sections

Commutator sections

Production technologies

To manufacture copper sections we apply extrusion technology which ena-bles us to make significant structur-al changes and produce the finished cross-sections in a cost-effective way.

The smallest sections with a weight of up to 0.25 kg/m (0.168 lbs/ft) are pro-duced from casting wire by means of a section roll.

Process Diameter of circumscribed circle (DCC) Weight per meter max.

Extruding / drawing 10 - 200 mm (0.394 in - 7.874 in) 30 kg/m (20.159 lbs/ft)

Rolling / drawing 2.5 - 10 mm (0.0984 in - 0.394 in) 0.25 kg/m (0.168 lbs/ft)

A final drawing process can be added allowing the setting of specific tempers and tolerances. The table below shows an overview of our production process.

Sections are usually supplied in straight lengths of up to 8 m. Small and medi-um-sized sections are also available in the form of wire for which additional information regarding the direction of coiling and the position of the cross-section in the coil is necessary. Circumscribed circle

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Hollow copper sections

Applications

Due to their excellent electrical and thermal conductivity hollow copper sections are also suitable for cooled electrical conductors. Since hollow sections are often used at high temper-atures, silver-containing copper is used in addition to pure copper. Silver-con-taining copper has a better softening resistance. Typical applications are:

· induction heating and melting plants· generators· busbars· transformers· electromagnets

Shapes available

Seamless hollow sections are availa-ble as symmetric and asymmetric sec-tions as well as double-chamber sec-tions. We manufacture the sections in close cooperation with our customers according to drawings and specifica-tions.

Asymmetric hollow sections and dou-ble-chamber sections are our special-ty. Extensive know-how is necessary for the production of these shapes. We would be pleased to examine and determine whether the hollow section you require can be manufactured.

Production possibilities

Hollow sections are manufactured by extruding and drawing. Asymmet-ric hollow sections and double-cham-ber sections are extruded by means of bridge dies.

Hollow sections are usually supplied in soft temper. Their excellent cold work-ing properties resulting from the soft temper ensure a smooth adjustment to existing mounting conditions. Of course, other tempers are available, too. Due to the production process an eccentricity of +/- 10 % may result.

Diameter of circumscribed circle (DCC) Wall thickness / webs min. Weight per meter max.

Max. 200 mm (7.874 in) 3 mm (0.118 in) 30 kg/m (20.159 lbs/ft)

Two-duct hollow sections for generators

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Applications

As manufacturers of semi-finished products we also supply finished com-ponents. Your advantage: you receive your product from a single manufac-turer who is competent in the produc-tion and processing of semi-finished products.

Fabricated products from cop-

per sections

Switch gear for power distribution

Production capabilities

We offer the following value-added operations:

· cutting to length· drilling· milling· bending· stamping· plating

We provide assistance from the con-cept to the realization of your compo-nent. Please contact us and benefit from our experience and know-how.

From the concept …

… to the design …

… to the section.

Additional machining …

… and surface coating …

… are all part of our production programme.

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Materials and semi-finished products available

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Copper grade

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Symbol Number Number Number

Oxygen-con-taining copper grades

K16K34

Cu-ETP1 CW003A C11000 C1020 • • ≥ 385 ≥ 98Oxygen-containing copper grades with high purity, high electrical conductivity

Busbars, general appli-cations in the electrical industry if there are no requirements regarding hydrogen embrittlement

K18K32

Cu-ETP CW004A C11000 C1100 • • ≥ 385 ≥ 98Oxygen-containing copper grades, high electrical con-ductivity

Busbars, gripper arms, general applications in the electrical industry if there are no require-ments regarding hydro-gen embrittlement

Oxygen-free copper grades

K08K10

Cu-OFE CW009A C10100 C1011 • • ≥ 394 ≥ 101P ≤ 3 ppm, resistant to hydro-gen embrittlement, no volatile particles enter the vacuum.

High-vacuum technol-ogy, magnetrons and electronic tubes

K17K30

Cu-OF CW008A C10200 - • • ≥ 394 ≥ 100High electrical conductivity, resistance to hydrogen embrit-tlement

Switch gear, instru-ments in reducing gas environments, general applications in the elec-trical industry

Deoxidized copper grades

K12 Cu-HCP CW021A C10300 - • • ≥ 385 ≥ 98

Deoxidized copper grade, high electrical conductivity, resistance to hydrogen embrit-tlement, good weldability and solderability

Square-wave gen-erators, switching ele-ments, induction coils

K20 K21 K28

Cu-DHP CW024A C12200 C1220 • • ≥ 330 ≥ 77

Deoxidized copper grades, low electrical conductivity, resistance to hydrogen embrit-tlement, good weldability and solderability

Cooling panels

Copper grades containing silver

K35CuAg0,10 (OF)

CW019A - - - • ≥ 380 ≥ 100

Oxygen-free copper grade containing silver, resistance to hydrogen embrittlement, increased resistance to soften-ing with high conductivity

Commutators

K07CuAg0,04 (OF)

CW017A C10500 - - • ≥ 380 ≥ 100

Oxygen-free copper grade containing silver, resistance to hydrogen embrittlement, increased resistance to soften-ing with high conductivity

Commutators

K43 CuAg0,2** - C11600 - • • ≥ 380 ≥ 96Copper grade containing silver, increased resistance to soften-ing with high conductivity

Anode hangers

KA1KA4

CuAg0,1P CW016A C11600 - • • ≥ 380 ≥ 94

Deoxidized copper grades containing silver, resistance to hydrogen embrittlement, increased resistance to soften-ing with high conductivity

Moulds, two-duct hollow sections for generators

** not standardized

Other copper grades, high-copper alloys and dispersion-hardened copper alloys on request

WIELAND-WERKE AG buntmetall amstetten GmbH (A company of the Wieland Group)

www.wieland.com www.buntmetall.at

Graf-Arco-Str. 36, 89079 Ulm, Germany, tel. +49 (0)731 944-0, fax +49 (0)731 944-2772, e-mail: info@wieland.deFabrikstraße 4, 3300 Amstetten, Austria, tel +43 ((0)7472 606-0, fax: +43 (0)7472 616 04, e-mail: office@buntmetall.at 05

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