Our Copper Die Casting Services
Di Yigu Technology, kami Copper Die Casting solutions deliver unmatched performance for applications demanding high conductivity, kekuatan, dan rintangan kakisan. With deep copper alloy expertise, lanjutan Pemutus Precision keupayaan, dan ketat jaminan kualiti, we transform durable aloi tembaga menjadi kompleks, dimensionally accurate components for electrical, Automotif, dan industri marin. Sama ada anda perlukan Pengeluaran volum tinggi or custom-designed parts, we combine technical innovation with reliable service to meet your most demanding requirements.
What Is Copper Die Casting?
Copper Die Casting adalah khusus metal forming proses yang menggunakan tekanan tinggi untuk memaksa cair copper alloy ke dalam acuan keluli (mati), producing parts with exceptional conductivity, kekuatan, dan ketahanan. As a key branch of die casting basics, it addresses the unique challenges of copper’s high melting point (1,085° C.) by using specialized equipment and techniques.
Jelas Gambaran keseluruhan proses menyoroti kecekapannya: Molten copper alloy (heated to 1,100–1,200°C) is injected into a preheated die at pressures ranging from 80–150 MPa. The metal cools and solidifies under pressure to minimize porosity, Kemudian mati dibuka untuk mengeluarkan bahagian siap. Jadual 1 compares copper die casting to other common die casting metals:
| Jenis pemutus mati | Logam digunakan | Titik lebur | Faedah utama | Kes penggunaan yang ideal |
| Copper Die Casting | Copper Alloys | 1,085–1,200°C | Kekonduksian yang tinggi, kekuatan, Rintangan kakisan | Penyambung elektrik, plumbing valves |
| Aluminium mati pemutus | Aloi aluminium | 650-750 ° C. | Ringan + kos efektif | Bahagian struktur automotif |
| Zink mati pemutus | Aloi zink | 380-420 ° C. | Kos rendah, ketepatan sebahagian kecil | Perumahan elektronik, Perkakasan |
Yigu Technology’s Copper Die Casting Capabilities
Kami Copper Die Casting Capabilities are engineered to handle the unique demands of copper alloys, from simple electrical components to complex industrial parts.
Pecahan Keupayaan Utama
| Kawasan keupayaan | Perincian |
| Pengeluaran volum tinggi | 30,000–300,000 units/month (optimized for electrical and plumbing components) |
| Pembuatan bahagian kompleks | Ability to produce parts with intricate features (thin walls down to 1mm, lubang kecil) |
| Pemutus Precision | Mencapai toleransi yang ketat as low as ±0.05mm for critical features |
| Custom Die Casting | Reka bentuk acuan yang disesuaikan, Pengadunan aloi, dan rawatan permukaan untuk keperluan projek yang unik |
| Copper Alloy Expertise | 12+ years of experience working with brass, gangsa, and custom copper alloys |
| Jaminan kualiti | ISO 9001 & IATF 16949 diperakui; 100% pemeriksaan (dimensi, kekonduksian, cek kecacatan) |
The Copper Die Casting Process
The Copper Die Casting Process follows a structured workflow optimized for copper’s high melting point and thermal properties.
- Persiapan mati: The steel die (made from heat-resistant H13 or H11 steel) is preheated to 250–350°C and coated with a high-temperature lubricant to prevent metal sticking.
- Suntikan logam: Cair copper alloy is transferred from a holding furnace to the die’s cold chamber, then injected into the cavity at high speed (1–4 m/s) dan tekanan (80-150 MPa) to ensure full filling.
- Cooling and Solidification: The metal solidifies under pressure (15-40 saat, bergantung pada saiz bahagian) to reduce porosity and maintain ketepatan dimensi. Saluran penyejuk di mati mempercepatkan proses ini sambil menghalang warping.
- Letakkan: Mati dibuka, and ejector pins push the finished part out—copper’s moderate shrinkage rate (1.2-1.5%) Memastikan bahagian mengekalkan bentuknya.
- Trimming and Finishing: Bahan berlebihan (kilat) dikeluarkan melalui alat pemangkasan automatik, and parts undergo optional machining or surface treatment.
- Kawalan proses: Sensor masa nyata memantau suhu, tekanan, and injection speed to ensure consistency and minimize defects.
Rata -rata, the total cycle time for a medium-sized copper part (Mis., an electrical connector) ranges from 25–45 seconds.
Materials Used in Copper Die Casting
Memilih hak copper die casting materials sangat penting untuk prestasi bahagian, Dan kami menawarkan pakar Pemilihan aloi Sokongan untuk memenuhi keperluan projek anda.
Copper Alloy Properties & Aplikasi
| Jenis aloi | Gred biasa | Kunci Sifat bahan | Aplikasi biasa |
| Aloi tembaga | C36000 (Free-Cutting Brass) | Kekonduksian yang tinggi (45% IACS), kebolehkerjaan yang baik, Rintangan kakisan | Penyambung elektrik, plumbing fittings |
| Bronze Alloys | C93200 (Leaded Tin Bronze) | Kekuatan tinggi (350-450 MPa), Pakai rintangan, geseran rendah | Industrial bearings, gear, Komponen Marin |
| Specialty Copper Alloys | C17200 (Beryllium Copper) | Kekuatan tinggi (600-700 MPa), excellent conductivity (25% IACS), non-magnetic | Komponen Aeroangkasa, high-precision electrical parts |
| Custom Copper Alloys | Dicampur ke spesifikasi | Tailored for enhanced conductivity, kekuatan, or corrosion resistance | Peranti perubatan, bahagian perindustrian suhu tinggi |
Semua kita aloi tembaga menjalani ujian yang ketat untuk kekonduksian (via four-point probe testing), kekuatan (tensile and yield tests), dan Rintangan kakisan (salt spray and immersion tests). Di samping itu, copper’s Kitar semula (100% recyclable with no loss of quality) supports sustainable manufacturing goals.
Surface Treatment for Copper Die Cast Components
Copper Die Casting Surface Treatment enhances both functionality and aesthetics, addressing industry-specific needs from conductivity preservation to corrosion protection.
| Kaedah rawatan | Tujuan | Kelebihan | Sesuai untuk |
| Penyaduran | Adds a protective/conductive metal layer (Mis., Nikel, perak, emas) | Meningkatkan kekonduksian, prevents tarnishing, enhances solderability | Penyambung elektrik, Elektronik mewah |
| Menggilap | Mewujudkan lancar, permukaan reflektif | Meningkatkan rayuan estetik, removes surface defects | Decorative components, Perkakasan seni bina |
| Anodizing | Membentuk lapisan oksida pelindung (for specialty copper alloys) | Meningkatkan rintangan kakisan, warna yang disesuaikan | Komponen Marin, outdoor electrical parts |
| Salutan | Applies a specialized layer (Mis., epoksi, Ptfe) | Meningkatkan rintangan kakisan, mengurangkan geseran | Injap perindustrian, Perkakasan Marin |
| Pemesinan | Refines critical features (penggerudian, threading) | Mencapai toleransi yang ketat, improves part fit | Precision electrical parts, mechanical components |
| Lukisan | Adds color and basic protection | Kos rendah, Julat warna yang luas | Non-conductive decorative parts, barang pengguna |
Our surface treatment processes are designed to preserve copper’s inherent kekonduksian dan kekuatan, ensuring no compromise on performance.
Tolerances in Copper Die Casting
Copper Die Casting Tolerances dan ketepatan dimensi dicapai melalui reka bentuk acuan ketepatan, advanced process control, dan ketat kawalan kualiti langkah -langkah.
Typical Tolerance Ranges for Copper Die Casting
| Ciri bahagian | Toleransi standard | Toleransi yang ketat (Adat) | Tahap Toleransi Rujukan |
| Dimensi bahagian (≤100mm) | ± 0.1mm | ± 0.05mm | ISO 8062:2018 Kelas CT6 |
| Kedudukan lubang | ± 0.15mm | ± 0.08mm | EN 13920 anda |
| Kebosanan | 0.1mm/m | 0.06mm/m | IATF 16949 |
Pengukuran is conducted using coordinate measuring machines (CMMS) and laser scanners to verify compliance, while secondary pemesinan refines critical features to meet even the most demanding specs.
Advantages of Copper Die Casting
The Copper Die Casting Advantages make it the top choice for applications requiring conductivity, kekuatan, dan ketahanan.
- Kekonduksian yang tinggi: Copper alloys offer electrical conductivity up to 60% IACS (International Annealed Copper Standard)—critical for electrical and telecommunications parts.
- Kekuatan tinggi: Bronze and specialty copper alloys deliver tensile strength up to 700 MPA, suitable for structural and high-load applications (Mis., gear industri).
- Rintangan kakisan: Brass and bronze resist rust and chemical damage, making them ideal for marine, paip, and outdoor applications.
- Rayuan Estetik: Polished copper parts have a premium, timeless look—perfect for architectural hardware and decorative consumer goods.
- Ketepatan: Ketat toleransi and consistent part geometry ensure seamless integration into assemblies, mengurangkan kerja semula.
- Keberkesanan kos: Untuk pengeluaran volum tinggi, die casting eliminates the need for expensive machining of solid copper, lowering per-unit costs by 20–30%.
- Fleksibiliti reka bentuk: Copper flows into complex molds, membolehkan ciri -ciri yang rumit (Dinding nipis, lubang kecil) that would be difficult to achieve with other processes.
Recyclabality: Copper is 100% boleh dikitar semula, dengan kitar semula yang memerlukan 85% less energy than producing primary copper—supporting sustainability goals.
Industry Applications of Copper Die Casting
Copper Die Casting Applications Span pelbagai industri, thanks to copper’s unique combination of conductivity, kekuatan, dan rintangan kakisan.
| Industri | Aplikasi utama | Aloi pilihan | Why Copper Die Casting? |
| Industri Elektrik | Penyambung, terminals, Pemutus litar, transformer components | C36000 Brass, C17200 Beryllium Copper | Kekonduksian yang tinggi, ketepatan |
| Industri automotif | Electrical system parts (wiring harness connectors), komponen brek, penukar haba | C36000 Brass, Bronze Alloys | Kekonduksian, kekuatan, Rintangan kakisan |
| Plumbing Industry | Injap, kelengkapan, pipe connectors, faucet components | C36000 Brass, Bronze Alloys | Rintangan kakisan, ketahanan |
| Telekomunikasi | Antenna components, signal connectors, 5Bahagian stesen pangkalan g | C36000 Brass, C17200 Beryllium Copper | Kekonduksian yang tinggi, kestabilan dimensi |
| Industri Marin | Propeller components, badan injap, hull fittings | Bronze Alloys (C93200) | Superior corrosion resistance in saltwater |
| Jentera Perindustrian | Galas, gear, Perumahan pam, valve stems | Bronze Alloys (C93200) | Pakai rintangan, kekuatan tinggi |
Manufacturing Techniques for Copper Die Casting
Kami Copper Die Casting Manufacturing Techniques combine specialized methods with innovation to overcome copper’s high melting point and deliver consistent quality.
- Cold-Chamber Die Casting: The primary method for copper (95% of our copper projects), it uses a separate holding furnace to heat copper alloy—preventing damage to the machine’s injection system from copper’s high temperature.
- Hot-Chamber Die Casting: Used only for low-melting-point copper alloys (Mis., 某些 brass grades with high zinc content), it integrates a molten metal pool to reduce cycle time for high-volume runs.
- Perkakas: We use heat-resistant H13 or H11 steel for molds, engineered to withstand copper’s high temperature and repeated use (150,000+ kitaran). Mold cooling channels are optimized to reduce cycle time and prevent mold warping.
- Reka bentuk acuan: Custom molds are designed with CAD/CAM software, featuring optimized gating and venting to ensure uniform metal flow and minimize porosity.
- Automasi: Lengan robot mengendalikan pemindahan logam, bahagian pelepasan, dan trimming and finishing, reducing human error and increasing production efficiency by 25%.
- Pengoptimuman proses: Sensor berkuasa AI memantau suhu, tekanan, dan kelajuan suntikan dalam masa nyata, adjusting parameters to minimize defects like shrinkage and porosity.
Pemeriksaan Kualiti: Every part undergoes multi-stage testing, including conductivity measurements, Pemeriksaan dimensi, and visual inspections for defects.
Kajian kes: Yigu Technology’s Copper Die Casting Success Stories
Kami Copper Die Casting Case Studies Mempamerkan bagaimana kita menyelesaikan cabaran dunia sebenar untuk pelanggan di seluruh industri.
Kajian kes 1: Electrical Connector Components
- Cabaran: A global electrical manufacturer needed 200,000 brass connectors monthly, with high conductivity (≥40% IACS), toleransi yang ketat (±0.06mm), dan rintangan kakisan untuk kegunaan luaran.
- Penyelesaian: Digunakan C36000 brass alloy in our cold-chamber die casting process, dengan penyaduran nikel for corrosion protection and automated quality inspection.
- Hasil: Connectors achieved 45% Kekonduksian IAC, 99.8% Kadar bebas kecacatan, and met IEC 60947 electrical standards. Production costs were reduced by 22% vs. the client’s previous machining process.
Kajian kes 2: Marine Valve Bodies
- Cabaran: A marine equipment firm required durable bronze valve bodies with superior saltwater corrosion resistance and strength (≥350 MPa).
- Penyelesaian: Digunakan C93200 leaded tin bronze and added a specialized Salutan Epoxy for enhanced protection. Designed custom molds to integrate internal flow channels, menghapuskan penggerudian sekunder.
- Hasil: Valves passed 5,000+ jam ujian semburan garam, bertahan 400 MPa of pressure, and met ABS (American Bureau of Shipping) marine standards.
Kajian kes 3: Automotive Electrical Harness Connectors
- Cabaran: An automotive client needed lightweight, high-conductivity connectors for EV wiring harnesses, with fast production turnaround (4-Masa memimpin minggu).
- Penyelesaian: Digunakan C36000 brass alloy and implemented cold-chamber die casting with automated assembly. Ditambah silver plating to improve solderability.
Hasil: Connectors were 15% lighter than previous steel designs, dicapai 44% Kekonduksian IAC, dan 100,000 units were delivered on time—supporting the client’s EV launch.
Why Choose Us for Copper Die Casting?
Apabila anda bekerjasama dengan Yigu Technology untuk Copper Die Casting, you gain a trusted collaborator with the expertise to deliver exceptional results. Inilah sebabnya pelanggan memilih kami:
- Kepakaran: 12+ years of focused experience in copper die casting, dengan pengetahuan yang mendalam mengenai copper alloy properties and process optimization.
- Pengalaman: We’ve successfully delivered 500+ copper die casting projects for clients in electrical, Automotif, and marine industries—solving complex challenges like high-temperature molding and conductivity preservation.
- Kualiti: Ketat kita jaminan kualiti proses (ISO 9001, IATF 16949) ensure every part meets or exceeds your specs, dengan 100% inspection for critical features.
- Penyesuaian: We offer end-to-end custom die casting penyelesaian, from alloy blending to surface treatment—tailored to your unique application needs.
- Perkhidmatan: Pengurus akaun khusus menyediakan 24/7 sokongan, dari perundingan reka bentuk untuk susulan selepas penghantaran. We offer DFM (Reka bentuk untuk pembuatan) Ulasan untuk mengoptimumkan bahagian anda untuk kos dan prestasi.
- Inovasi: Kami melabur dalam r&D to improve processes—like AI-powered mold temperature control—that reduce defects and cycle time by 15–20%.
- Kebolehpercayaan: Kami mengekalkan 98% kadar penghantaran tepat pada masanya, Terima kasih kepada Skala kami Pengeluaran volum tinggi capacity and proactive supply chain management.
Keberkesanan kos: Our automated processes and material efficiency reduce per-unit costs by 20–30% vs. machining or other casting methods—without compromising quality.