COLD FORGED COPPER
The electrolytic purity of copper parts used in electrical transmission mechanisms is as important as the processes they undergo during forming. The high conductivity that comes from the purity of the material must not be lost due to voluntary or involuntary changes made on the surface. These parts are currently produced by hot forging. This method seriously damages the electrical conductivity of the material and is expensive due to the thermal energy input. 1 During hot forging, when the material temperature is raised above 1000 Celsius and the material is allowed to cool down after forging, the material crystals grow. Due to the hot forging process, the mechanical force cannot support the crystal shrinkage. As a result, the surface hardness of the material remains low. This causes rapid wear on the friction surfaces of the part. 2 The separating media used during hot forging and the oxide burrs formed during forging are removed by sandblasting. Due to the softness of the copper, the much harder sand is embedded in the surface and reduces the average contact surface of the copper. This has a negative effect on electrical conductivity. 3 Surface roughness increases considerably after hot forging and post-processing. Although it causes a reduction in the overall contact surface area, it leads to rapid deformation due to the rapid melting of the roughness during the instantaneous arc transition.
By cold forging electrolytic copper, it is possible to get rid of all three main problems mentioned above. 1 Pure copper is not a material that hardens by heat treatment. This type of material requires “Cold Working” for hardening. For mechanical hardening, a considerable amount of pressure must be exerted on the material and the cross-sectional area of the material must be significantly changed. Cold forging meets all of these requirements during forming, eliminating the need for a post-process to harden the parts. In addition, the hardness of all the parts produced remains the same and the consistency in production quality is maintained. For parts produced by hot forging, parts that can be produced in the 65-75 HV hardness range can be hardened up to 100 HV by cold forging at Şuz Makine. 2 Since the electrolytic copper raw material is directly molded and shaped, the material produced directly retains the surface properties of the raw material. Receiving the product without any preliminary or additional processing ensures that the properties offered directly by the raw material are preserved in terms of electrical conductivity. 3 Since forging is done in a cold casting, the surface quality is directly equal to the casting surface quality. Thanks to the high forming properties of copper, with the proper casting design, it is possible to achieve fine processing quality without having to machining the contact surfaces
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