The copper extrusion process combines several phases to produce a high quality, customized, precision-oriented extrusions using state of the art machinery. From alloy selection through final reduction the process only works if it’s governed by the strictest quality control procedures available. Here’s an overview of the process.
In-House Copper Bar Mill
The extrusion process begins with billets produced in an controlled environment then cut to a precise size. The billet then goes into a high-speed induction billet heater. Once heated to temperature, the billet is placed into a 900-ton Loewy hydraulic extrusion press with a shuttle press capable of automatic bar pointing. Coming out of the press, the billet goes into an in-line cooling system to reduce copper oxide formation during the extrusion process. The next step is a 45-foot cold draw bench which allows for straightening and reduction of the extruded bar to their final sizes with precise hardness. The final steps are cleaning and packaging the bars for final delivery.
Guaranteed Quality and Production Control
Every chemical composition used is first assessed in the laboratory. If it doesn’t meet quality thresholds, it is rejected. This process makes sure the desired alloy composition is present before anything is extracted and because standard quality thresholds are high, it’s almost guaranteed that the client’s expectations will always be exceeded.
There’s also a check system utilized in the manufacturing process. This entails a physical and chemical check of every component. Finally, a Certificate of Compliance is available with every shipment, or if requested, that guarantees the quality standards of the materials used, alloy mixes and the final product. Additionally, full metal testing is available upon request.
To ensure that every job meets customer expectations in terms of cost and delivery, a computerized monitoring system allows for monitoring of scheduling, production cycle, overall and per unit costs and quality assurance check results. This ensures that every job is completed on time, on budget, and possesses the quality clients expect.
Depending on a client’s need, this process can produce full bar lengths, cut to precision lengths or fully machined pieces ready for an assembly process.
Specific shapes that can be fabricated include various angles, rectangular, round, square and hex bars as well as half rounds while guaranteeing quality and production consistency. Because it’s highly customizable, every client leaves satisfied with the custom shaped bars that are extruded to their precise measurements and requirements.
With their extremely high melting point of 4000° F, refractory metals are uniquely capable of withstanding heavy use under severe conditions. This property, as well as their high density and chemically inert characteristics, make refractory metals ideally suited for a number of industrial applications. Here are just a few instances of the way in which these remarkable materials can be utilized.
Refractory Metal Contacts
Any industrial use that requires constant wear at low to medium voltages is an ideal circumstance for refractory metals. Motor controls, power transfer switches, circuit breakers, push-button switches, wiring devices, and countless other examples of electrical contact assemblies make good use of the refractory metals’ toughness and durability.
Refractory Metals in Powder Form
The advantages of refractory metals – such as their exceedingly high melting points – means manufacturing can be a challenge. One technique to better utilize their characteristics while reducing cost is to apply refractory metals in powder form onto a base metal. By bonding an extremely thin layer of refractory metals onto a surface area of a cheaper metal, manufacturers can cut back on the amount of precious metal required to achieve the same advantages that come with standalone refractory metals. These powder metal contacts are only necessary at critical points, so the cost is reduced without any reduction in quality.
Silver has a high conductivity, so it’s perfect for electrical contacts. Besides the better conductivity, contacts made of silver alloys such as silver nickel, silver tin oxide, silver graphite, and silver tungsten are highly durable and low in environmental toxicity, making silver alloys the preferred contact used in many industrial situations.
Cadmium, unfortunately, is highly toxic and has gone out of fashion of late due to environmental concerns. Composed mostly of alloys such as silver cadmium oxide, the more reliable and safer alternative silver alloys are replacing cadmium in most modern applications.
The durability, reliability, and low cost of refractory metal contacts – as well as the decreased environmental impact of new silver alloys – has led to their increased demand in the world of industry and manufacturing for the present and for the indefinite future.