Comprehensive Overview of Premium High Conductivity Copper Castings
We are a specialised manufacturer and global supplier of premium High Conductivity Copper Castings, serving industries that demand exceptional electrical and thermal performance in complex component geometries. Our copper castings are manufactured from high-purity copper alloys including C10100 Oxygen-Free Copper for maximum conductivity and C11000 Electrolytic Tough Pitch Copper for balanced performance and cost-effectiveness. These castings leverage advanced foundry technologies including vacuum casting, continuous casting, and precision mold processes to deliver components with conductivity ratings exceeding 100% IACS while maintaining mechanical integrity in complex shapes. With state-of-the-art foundry capabilities and comprehensive quality control systems, we deliver copper castings that excel in electrical power transmission, heat transfer, and specialized industrial applications where maximum conductivity is paramount.
High Conductivity Copper Castings – Maximum Electrical & Thermal Performance
High Conductivity Copper Castings represent the pinnacle of electrical and thermal performance in manufactured components, providing unparalleled conductivity in complex geometries that cannot be achieved through machining or fabrication alone. These castings maintain the inherent high conductivity of copper while allowing for the production of intricate shapes, integrated features, and optimized designs that maximize performance in electrical and thermal management applications.
Applications of High Conductivity Copper Castings
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Electrical Power Systems: Bus bar systems, switchgear components, transformer parts, circuit breaker elements
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Power Electronics: Heat sinks, power semiconductor bases, IGBT coolers, rectifier housings
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Renewable Energy: Solar inverter components, wind turbine generators, power conditioning systems
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Industrial Heating: Induction heating coils, resistance heating elements, furnace components
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Transportation: Electric vehicle power distribution, rail traction systems, aerospace electrical components
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Telecommunications: RF components, waveguide elements, high-frequency circuit bases
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Medical Equipment: MRI components, X-ray equipment, electrosurgical device elements
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Research Equipment: Particle accelerator components, laboratory instrumentation, test equipment
Copper Alloy Specifications for High Conductivity Castings
| Copper Alloy | UNS Designation | Composition | Conductivity (% IACS) | Key Properties | Applications |
|---|---|---|---|---|---|
| Oxygen-Free Copper | C10100 | 99.99% Cu, 0.0005% O₂ | 101% min | Highest conductivity, excellent formability | Critical electrical, high vacuum applications |
| Electrolytic Tough Pitch | C11000 | 99.90% Cu, 0.04% O₂ | 100% min | Excellent conductivity, good strength | General electrical, bus bars, power distribution |
| Deoxidized Copper | C12200 | 99.90% Cu, 0.02% P | 98% min | Excellent brazing, good conductivity | Plumbing, heating, assembled components |
High Conductivity Copper Casting Technical Specifications
| Parameter | C10100 (Oxygen-Free) | C11000 (ETP) | C12200 (Deoxidized) |
|---|---|---|---|
| Electrical Conductivity (% IACS) | 101% min | 100% min | 98% min |
| Thermal Conductivity (W/m·K) | 391 | 388 | 378 |
| Tensile Strength (MPa) | 220 – 380 | 220 – 360 | 240 – 380 |
| Yield Strength (MPa) | 70 – 275 | 69 – 260 | 75 – 280 |
| Density (g/cm³) | 8.94 | 8.89 | 8.91 |
Casting Processes: Sand casting, investment casting, permanent mold casting, continuous casting
Maximum Cast Weight: 500kg for single castings
Dimensional Tolerance: ±0.5% or ±1.0mm, whichever is greater
Surface Finish: As-cast, machined, polished, plated finishes available
Quality Standards: ASTM B170, ASTM B224, ISO 9001, RoHS compliant
Product Range & Technical Specifications
Electrical Bus Bar Castings
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Design: Complex bus bar configurations with integrated features
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Applications: Power distribution, switchgear, transformer connections
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Features: Optimized current paths, integrated mounting points, custom geometries
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Benefits: Reduced assembly, improved conductivity, space optimization
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Size Range: 50mm to 2000mm length, various cross-sections
Heat Sink & Thermal Management Castings
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Design: Complex fin arrays, optimized thermal paths, integrated mounting
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Applications: Power electronics, LED lighting, computer systems
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Features: High surface area, optimized thermal mass, custom interfaces
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Benefits: Maximum heat dissipation, reduced thermal resistance
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Configurations: Natural convection, forced air, liquid cooled designs
Electrical Connector & Contact Castings
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Design: Precision contact surfaces, complex geometries
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Applications: High-current connectors, switch contacts, relay components
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Features: High conductivity paths, wear-resistant surfaces
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Benefits: Low contact resistance, long service life
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Casting Methods: Investment casting for detail resolution
Specialty Component Castings
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Induction Coils: Custom geometries for specific heating applications
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Waveguide Components: Precise RF components for telecommunications
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Vacuum Components: High-purity castings for vacuum applications
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Research Equipment: Custom components for scientific instruments
Manufacturing Processes & Quality Control
Our High Conductivity Copper Castings are manufactured through precision-controlled processes:
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Material Selection: Certified copper cathodes and billets meeting ASTM specifications
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Melting Process: Controlled atmosphere melting to minimize oxidation
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Mold Preparation: Sand, investment, or permanent mold creation per design
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Pouring Process: Controlled temperature and rate pouring
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Solidification Control: Directional solidification for sound castings
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Heat Treatment: Stress relief and homogenization treatments
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Finishing Operations: Shot blasting, grinding, machining
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Quality Inspection: Comprehensive dimensional and NDT inspection
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Performance Testing: Conductivity and mechanical property verification
Quality Assurance Tests:
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Chemical Analysis: Spectrographic verification of composition
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Conductivity Testing: Eddy current or four-point probe measurement
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Radiographic Testing: X-ray inspection for internal soundness
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Dye Penetrant Testing: Surface defect detection
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Ultrasonic Testing: Internal quality assessment
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Dimensional Verification: CMM and manual inspection
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Metallographic Examination: Grain structure and purity assessment
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Mechanical Testing: Tensile, hardness, and impact testing
Technical Data & Performance Specifications
Electrical Performance Characteristics
| Casting Type | Minimum Conductivity | Maximum Current Density | Temperature Rise @ Rating | Applications |
|---|---|---|---|---|
| Bus Bar Castings | 100% IACS | 3.5 A/mm² | 45°C @ rated current | Power distribution, switchgear |
| Heat Sink Castings | 98% IACS | N/A | 25°C above ambient | Power electronics, LED systems |
| Connector Castings | 100% IACS | 5.0 A/mm² | 35°C @ rated current | High-current connectors |
| Induction Coils | 98% IACS | 6.0 A/mm² | 50°C @ rated current | Industrial heating systems |
Mechanical Performance Data
| Copper Alloy | As-Cast Tensile (MPa) | Heat Treated Tensile (MPa) | Hardness (HB) | Elongation (%) |
|---|---|---|---|---|
| C10100 | 220 – 280 | 240 – 320 | 45 – 65 | 25 – 40 |
| C11000 | 220 – 270 | 230 – 310 | 40 – 60 | 25 – 35 |
| C12200 | 240 – 300 | 260 – 340 | 50 – 70 | 20 – 30 |
Design Features & Benefits
High Conductivity Copper Casting Advantages
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Maximum Electrical Conductivity: 100%+ IACS rating for minimal energy loss
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Superior Thermal Performance: Excellent heat transfer capabilities
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Design Flexibility: Complex geometries impossible with other manufacturing methods
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Material Purity: Controlled composition for consistent performance
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Integrated Features: Reduced assembly through monolithic construction
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Cost Effectiveness: Lower tooling costs for complex components
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Material Utilization: Near-net shape casting minimizes waste
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Performance Optimization: Custom designs for specific application requirements
Performance Characteristics
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Low Electrical Resistance: Minimal voltage drop in power applications
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Efficient Heat Transfer: Rapid thermal equalization and dissipation
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Corrosion Resistance: Natural corrosion resistance in many environments
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Non-Magnetic Properties: Ideal for sensitive electrical applications
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Long Service Life: Maintains properties over extended service periods
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Reliability: Consistent performance in demanding applications
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Manufacturing Scalability: Suitable from prototype to production quantities
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Quality Consistency: Controlled processes ensure repeatable results
Industry Compliance & Certifications
International Standards Compliance
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ASTM B170: Standard Specification for Oxygen-Free Electrolytic Copper—Refinery Shapes
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ASTM B224: Standard Classification of Coppers
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ISO 9001:2015: Quality management systems
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RoHS 3: Restriction of hazardous substances
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REACH: Chemical safety regulations
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ASTM E1004: Standard Practice for Determining Electrical Conductivity
Quality Certifications
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ISO 9001:2015: Quality management system certification
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Material Certifications: Full traceability from raw material to finished casting
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NDT Certification: Qualified personnel for non-destructive testing
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Calibration Certification: Regular calibration of test equipment
Frequently Asked Questions (FAQ)
Q1: What is the difference between C10100 and C11000 copper for high conductivity applications?
C10100 Oxygen-Free Copper contains less than 0.0005% oxygen and offers the highest possible electrical and thermal conductivity (101% IACS minimum), making it ideal for critical applications where maximum conductivity is essential. C11000 Electrolytic Tough Pitch Copper contains approximately 0.04% oxygen and provides excellent conductivity (100% IACS minimum) at a more economical price point. The choice depends on your specific conductivity requirements and budget considerations.
Q2: What casting process is best for high conductivity copper components?
The optimal casting process depends on component size, complexity, quantity, and dimensional requirements. Sand casting is ideal for large components and low volumes, investment casting provides excellent detail resolution for complex shapes, permanent mold casting offers good surface finish and dimensional consistency for medium volumes, and continuous casting is optimal for simple cross-sections in long lengths. Our engineering team can recommend the most suitable process for your specific application.
Q3: How does casting affect the electrical conductivity of copper?
Properly executed copper casting can maintain 95-100% of the wrought material’s conductivity when using appropriate foundry practices. Key factors include controlled melting atmosphere to prevent oxidation, proper grain structure development, and suitable heat treatment. Our specialized processes are optimized to preserve the inherent high conductivity of copper while achieving the design benefits of the casting process.
Q4: Can high conductivity copper castings be used in vacuum applications?
Yes, particularly C10100 Oxygen-Free Copper castings are excellent for vacuum applications due to their very low gas content and minimal outgassing properties. The absence of oxygen and other volatile elements makes these castings suitable for high vacuum systems, space applications, and vacuum furnace components where material purity and stability are critical.
Q5: What are the size limitations for high conductivity copper castings?
Our capabilities include castings from a few grams to 500kg in weight, with maximum dimensions of approximately 1500mm x 1000mm x 800mm for single sand castings. Investment castings typically range from 1 gram to 50kg with high detail resolution. Continuous cast sections can be produced in lengths up to 6000mm with various cross-sectional profiles. Larger components may be produced as assemblies or using special processes.
Why Choose Our High Conductivity Copper Castings?
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Material Expertise: Deep knowledge of copper metallurgy and conductivity optimization
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Advanced Foundry Technology: State-of-the-art melting, molding, and casting equipment
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Comprehensive Quality Assurance: Rigorous testing and inspection protocols
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Technical Support: Engineering assistance from design to production
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Custom Solutions: Tailored casting solutions for specific application requirements
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Production Flexibility: Capability from prototype to production volumes
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Competitive Pricing: Cost-effective manufacturing without quality compromise
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Global Compliance: Products meeting international standards and certifications
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Reliable Delivery: Consistent on-time delivery performance
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Technical Documentation: Complete specifications and certification packages
Call to Action – Contact Us Today
Maximize your electrical and thermal performance with our premium high conductivity copper castings. Contact us for quotations, technical specifications, or application engineering support.
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Request a Quote: Email your requirements to sales@jambrass.com for comprehensive pricing
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Technical Consultation: +91-22-43449300 – Speak with our copper casting specialists
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Documentation Request: sales@jambrass.com – Request detailed specifications and capability information
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Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
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Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat – 361004
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Samples Available: Contact us for evaluation samples and technical data
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Design Support: Engineering assistance for component optimization
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OEM Partnerships: Comprehensive support for equipment manufacturers
We look forward to providing you with the highest quality high conductivity copper castings for your electrical and thermal management requirements.
