Copper And Copper Alloy Forging

The original definition of forging is the "mechanical deformation of metal when heated to a plastic state". However, in recent years it has come to include similar operations done in the cold or room temperature state as well. There are two types of forgings: open end forging and close end forging.

Pure copper is a joy to forge. It has a very long working range, essentially from cold to yellow. Because of its malleability it is rare for copper to crack during forging or bending. When worked hot there is no need to anneal because there is no work hardening occurring and when finish working thicker sections cold there is usually no need to anneal. For sheet, anneal by heating through to red, then quenching in cold water. For thin sections cold planishing to work harden effectively adds stiffness and strength. Because of its softness, careful planning of the work sequence is necessary to prevent deformation of previously worked areas. Even when cold it is possible to easily bend 1" x 1 " sections, especially when working in the vise. Copper can of course be soldered or brazed, but these methods lack the strength necessary for joining larger sculptural shapes. Copper can be mig welded using pure copper wire with a special gas mix trade named blue shield #5. Preheating is absolutely essential as the copper conducts the heat so quickly and has a high melting temperature (1980f). For tapping threads into copper a thread forming tap rather than cutting tap works better. Copper can be quite "gummy" due to its softness when machining. When sawing use higher blade speeds (270 fpm) with a coarse blade. Copper is very reactive and receives patinas wonderfully, both hot and cold. Copper and copper alloy forgings are quality parts, comparing favorably in material integrity, dimensional tolerance and surface finish with products made using other major metalworking processes. As a result of hot working, forged materials have superior density and freedom from flaws. Forming under heat and pressure in precise closed dies produces dimensional accuracy-always repeatable, part to part and lot to lot.

This material will help design engineers and purchasing departments maximize the utility and cost advantages inherent in the specification of copper alloy and copper forgings. It reviews competitive processes, comparing their advantages and disadvantages with forging. A tabular guide to the tolerances commonly specified for forgings of different types is included. An extensive glossary of terms used in the industry and information required for ordering are included to improve communication between user and supplier. Copper, copper alloy and bronze forgings offer the designer unique combinations of properties that other metals cannot match. Alloys can be selected to utilize the following unique characteristics: high electrical and thermal conductivity, superior corrosion resistance, high ductility, outstanding machinability, excellent joining and plating characteristics, superior polishing and finishing characteristics, non-magnetic properties, non-sparking characteristics, attractive solid colors-not just surface.

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