Copper Sheet Metal Fabrication
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About Copper Sheet Metal Fabrication
Commercial copper sheet metal has a high purity grade and is usually available in two variants. Both variants contain more than 99 percent copper, with the rest being impurities such as oxygen, lead, or silver. It is very malleable and it is easier to use copper to make sheet metal parts than other low-malleable materials.
Copper has excellent thermal and electrical conductivity and is highly malleable, making it an outstanding material for sheet metal applications. Because of these properties, the aerospace, automotive and chemical industries often use copper to make metal sheets.
Aluminum is a material widely used in sheet metal parts. The right alloy can be formed very easily and produce low-cost, high-strength and lightweight parts. Aluminum sheet metal parts can be found in the aerospace and transportation industries, as well as many other industries.
Copper Sheet Metal at a Glance
| Sheet Metal Applications | Welding fixtures, grounding strips, electrical components |
| Advantages | Good corrosion resistance, good electrical and heat conduction, excellent formability, antimicrobial |
| Disadvantages | Expensive manufacturing material, can work-harden during cold working |
| Minimum Lead Time | 3 days |
| Price Range | High ($$$) |
| Standard Tolerances | +/- 1.0 degree tolerances are possible on bent features and a cutout accuracy of +/- 0.020” (0.508 mm) |
| Sheet Thickness | Maximum of 3/8” (9.525mm) and a minimum of 0.0126” (0.32 mm) |
Copper 101
Copper 101 or oxygen-free copper is a highly refined metal (99.99% copper). Its high purity gives it excellent electrical conductivity, so it is often referred to as HC(highly conductive) copper. It has very high malleability, and although it hardens easily, it hardens slowly. C101 is easier to form after annealing. Its conductivity and ductility make it ideal for electrical sheet metal applications such as bus bars, anodes, and circuit breakers.
Aluminum 5052 Standard Gauges
| Tensile Strength, Yield (MPa) | Fatigue Strength (MPa) | Elongation at Break (%) | Hardness (Brinell) | Density (g/cm^3) |
|---|---|---|---|---|
| 69 | 0.020”, 0.025”, 0.032”, 0.040”,0.050”, 0.063”, 0.080”, 0.090”, 0.100”, 0.125”, 0.160”, 0.188”, 0.250”, 0.375”, 0.500” | 55 | 81 | 8.9 |
Copper 101 Standard Gauges
| Material | Standard Sheet Thickness |
|---|---|
| Copper 101, H00 to H01 | 0.025”, 0.032”, 0.040”, 0.050”, 0.063” |
Copper C110
Copper 110 or ETP copper is a high purity copper alloy containing 99.90% copper, which is slightly less pure than copper 101. It is the most important commercial copper alloy and is widely used in electrical and heat transfer applications such as heat exchanger fins and electrical switches. In short, copper 110 is a high purity copper alloy, containing 99.90% copper, not as pure as copper 101.
Copper C110 Properties
| Tensile Strength, Yield (MPa) | Fatigue Strength (MPa) | Elongation at Break (%) | Hardness (Brinell) | Density (g/cm^3) |
|---|---|---|---|---|
| 365 | 76 | 8055 | 57 | 8.93 |
Copper 110 Standard Gauges
| Material | Standard Sheet Thickness |
|---|---|
| Copper 110, Annealed | 0.005”, 0.010”, 0.021”, 0.043”, 0.063”, 0.093”, 0.125” |
| Copper 110, H01 | 0.016” |
| Copper 110, H02 | 0.020”, 0.040”, 0.050”, 0.063”, 0.080”, 0.093”, 0.125”, 0.188”, 0.250” |
Finishes
Copper’s electrical conductivity makes it a good material for making sheet metal. Here are some surface treatments for copper:
Electropolishing: The copper surface can be made very smooth and shiny by electropolishing, which can further improve the corrosion resistance of sheet metal parts.
Paint: Copper oxidizes easily and turns green. If only for aesthetics, paint or clear coatings can be applied to maintain the appearance, even when exposed to corrosive environments. However, it must be noted that this removes electrical properties and impedes heat conduction.
Cost-saving Design Tips
Copper is an expensive material, so it should be used optimally in sheet metal manufacturing.
Use only when necessary: If possible, use copper only when necessary for sheet metal processing. If only a small part needs the properties of this material, the cost of manufacturing the entire part from copper can be high. It may be better to solder the copper sheet in areas where it is needed, and use low-cost materials in other areas.
Choose the right grade: Ultra-pure copper is commonly used in electrical applications due to its high electrical conductivity. Therefore, it is only used when there is a special need for efficient transmission of power.
Copper 110 Standard Gauges
| Tensile Strength, Yield (MPa) | Fatigue Strength (MPa) | Elongation at Break (%) | Hardness (Brinell) | Density (g/cm^3) |
|---|---|---|---|---|
| 365 | 76 | 8055 | 57 | 8.93 |