Copper Forging

Copper forging involves the plastic deformation of Copper billets and bars under controlled temperature and pressure conditions to produce near-net-shape components. This process leverages Copper’s exceptional malleability and ductility, enabling the creation of complex geometries with superior mechanical properties. Hot forging temperatures typically range from 750°C to 950°C, optimizing material flow while preventing grain growth. Cold forging operations performed at ambient temperatures achieve exceptional surface finish and dimensional accuracy. Our forging capabilities include open-die forging for large components, closed-die forging for precision parts, and seamless forging for hollow components. Advanced process control systems monitor temperature, pressure, and deformation rates to ensure consistent quality and optimal material utilization throughout the forging cycle.

Copper Forged Parts

Copper forged parts demonstrate superior mechanical properties compared to machined or cast alternatives, featuring enhanced grain flow alignment, improved fatigue resistance, and elimination of internal porosity. Our comprehensive range includes valve bodies, pipe fittings, electrical terminals, heat exchanger components, and marine hardware. Precision forging operations achieve dimensional tolerances of ±0.1mm with surface roughness values as low as Ra 1.6μm. Multi-stage forging sequences enable complex geometries while maintaining material integrity and optimizing production efficiency. Secondary operations including heat treatment, machining, and surface finishing ensure final components meet exact customer specifications. Quality assurance protocols include dimensional inspection, material testing, and performance validation according to relevant international standards.

Copper Stamped Components

Copper stamped components encompass a wide range of precision-formed parts produced through progressive stamping, deep drawing, and blanking operations. High-speed stamping presses operating at speeds up to 800 strokes per minute enable cost-effective production of complex geometries with exceptional repeatability. Advanced die design incorporating carbide cutting edges and precision guide systems ensures consistent edge quality and dimensional accuracy. Progressive stamping operations combine multiple forming stages within a single press cycle, optimizing material utilization and production throughput. Our stamping capabilities include thickness ranges from 0.1mm to 10mm with forming depths up to 150mm for deep-drawn components. Specialized tooling for perforating, coining, and embossing operations expands the range of achievable features and surface textures.

Copper Hot Forging

Copper hot forging operations utilize elevated temperatures between 750°C and 950°C to enhance material plasticity and reduce forming forces. Induction heating systems provide precise temperature control with uniform heat distribution throughout the workpiece. Hot forging enables the production of large, complex components with significant cross-sectional changes while maintaining excellent material properties. Controlled atmosphere furnaces prevent oxidation and decarburization during heating cycles. Automated material handling systems ensure consistent heating times and optimal temperature uniformity. Post-forging cooling rates are carefully controlled to achieve desired microstructures and mechanical properties. Hot forging operations are particularly effective for high-volume production of components requiring extensive material flow and complex three-dimensional geometries.

Copper Hot Stamped Parts

Copper hot stamped parts combine the benefits of elevated temperature forming with precision stamping operations to achieve complex geometries with enhanced material properties. Hot stamping temperatures typically range from 400°C to 700°C, optimizing formability while maintaining dimensional stability. Heated die systems ensure uniform temperature distribution and prevent premature cooling during forming operations. This process is particularly effective for high-strength Copper alloys that require elevated temperatures for optimal formability. Integrated heating and forming systems minimize handling time and maintain consistent part quality. Hot stamped components exhibit improved grain structure, reduced residual stresses, and enhanced fatigue performance compared to cold-formed alternatives. Applications include automotive electrical components, aerospace fittings, and high-performance heat exchanger elements.

Copper Hot Stamped and CNC Machined Parts

Copper hot stamped and CNC machined parts represent the pinnacle of precision manufacturing, combining the enhanced material properties of hot forming with the dimensional accuracy of computer-controlled machining. Initial hot stamping operations create near-net-shape blanks with optimized grain structure and reduced material waste. Subsequent CNC machining operations achieve final dimensions with tolerances as tight as ±0.025mm and surface finishes up to Ra 0.4μm. Multi-axis machining centers enable complex feature geometry including threaded holes, precision bores, and intricate surface profiles. Integrated manufacturing cells combine hot stamping and machining operations to minimize handling and optimize production flow. Advanced programming techniques optimize tool paths and cutting parameters for maximum efficiency and surface quality. Quality control systems include in-process measurement and statistical process control to ensure consistent dimensional accuracy throughout production runs.

Copper Impact Extrusion Parts

Copper impact extrusion parts are manufactured through high-velocity forming operations that combine the benefits of forging and extrusion processes. Impact extrusion utilizes a punch traveling at speeds up to 10 m/s to force Copper material through a shaped die, creating hollow components with exceptional wall thickness uniformity. This cold-forming process achieves remarkable dimensional accuracy with typical tolerances of ±0.05mm and excellent surface finish quality. Impact extrusion is particularly effective for producing thin-walled cylindrical components, complex internal geometries, and parts requiring superior material properties. The rapid deformation rates result in fine grain structure and enhanced mechanical properties compared to conventional forming methods. Applications include electrical enclosures, heat sink components, and precision fittings requiring leak-tight performance and dimensional stability under thermal cycling conditions.

Copper Forged Transformer Spades
These are engineered for the most demanding high-current applications within power transformers and heavy electrical switchgear. Unlike stamped alternatives, these components are manufactured through a hot forging process that subjects high-purity Electrolytic Tough Pitch Copper (CDA 110) to extreme pressure, aligning the metal’s grain flow to the contour of the spade. This process eliminates porosity and creates a denser, more robust part with superior mechanical strength and electrical conductivity. The inherent grain flow resulting from forging provides exceptional resistance to fatigue and stress cracking, which is critical for handling the immense electromagnetic forces and thermal cycling experienced in transformer applications. These forged spades often feature a tin-plated finish to prevent oxidation and ensure a stable, low-resistance connection, making them the preferred choice for permanent, ultra-reliable power connections in the electrical utility sector.

Copper Stamped Electrical Terminals
They represent the most common and versatile manufacturing method for producing a wide array of connector types, including spade, ring, and hook terminals. This high-volume process utilizes precision progressive dies mounted in high-tonnage presses to blank, pierce, and form sheets of copper alloy, such as CDA 110 Copper or CDA 220 Commercial Bronze, into the final desired shape. Stamping allows for excellent dimensional consistency, complex features, and very high production rates, making it extremely cost-effective for large orders of standard components. While the grain structure is cut rather than formed, these terminals are perfectly suited for the vast majority of electrical wiring applications in control panels, automotive harnesses, and consumer appliances. They can be easily tin-plated or selectively plated to enhance solderability and corrosion resistance, offering a reliable and economical solution for secure electrical connections.