Raw Materials Choice
Alloying Elements: Small amounts of certain alloying constituents including silver, tellurium, or phosphorus can be added in certain conditions. Silver can be employed to strengthen strength in high temperatures and conductance, whereas tellurium can be used to achieve better machinability.
Extrusion process
Pre - heating: Pre-heating is done to pre-warm the copper billet to between temperatures of 700 to 900°C. This is done to soften the copper to an extent that can be processed through an easier process in an attempt to smoothen the process.
Die Design: Special shape dies are created in accordance with desired power-related copper extrusions' desired shape. Die is manufactured by making use of high-strength tool steel and is finely ground to obtain final shape accuracy. As an illustration, in case where the extrusion is to have an intricate multi-cavitated or irregular shape with respect to cross-sections, die design becomes complicated.
Extrusion Force & Velocity: Optimum speed & force in this process is employed. Level of extrusion force is in proportion to shape complexity, physical & sizes & characteristics of copper & billets. Optimum speed is employed to prevent defect generation in shape in the form of cracks & irregular deformation.
Heat Treatment
Annealing: After extruding, annealing is generally carried out to relieve internal stress and to improve ductility and electric conductance in copper extrusions. Annealing time and temperature can be adjustable in accordance with final products requirements and final composition of alloys. As an example, an approximate annealing temperature in pure copper extrusions can be between 400 to 600°C over a prolonged duration.
Surface Treatment
Cleaning: The lubricants or oxides in the surface get purified by stripping. This is achieved through processes such as alkaline cleaning or acid pickling.
Coating or Plating: Protective plating or coating is included in some cases to support anti-corrosion strength in the copper extrusions. One can put an overlayer of tin plating or nickel plating to prevent oxidation and gain improved power performance in the future.
Quality Assurance
Dimensional Inspection: Highly accurate equipment such as calipers, micrometers, and computerized coordinate measuring equipment (CMM) inspect to ensure that these unique shape copper extrusions fit requirements in design.
Electrical Property Testing: Electrical conductance in extrusions is conducted to ensure that it is in accordance with power requirements. This is achieved through testing with conductance meters.
Non - destructive Testing: Ultrasonic testing or eddy-current testing can be used to check internal faults in the shape of cracks or voids in the copper extrusions.
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