A Handy Book For Metal Sheet Fabrication For Copper

Many copper parts you see today have passed through one or more fabrication processes. There are different ways to turn a copper metal stock into functional end products. It involves cutting, bending, and welding the metal sheets to create various shapes and sizes. 

Before fabricating metal sheets using any technique, it is important to understand how it works and why you should use it. This article will be your guide in everything metal sheet fabrication for copper. It will explain what it is, the various techniques you can use, and the application of copper sheet fabricated parts. 

What is Copper Sheet Metal Fabrication and How Does it Work?

Copper sheet metal fabrication is a wide range of processes that turns copper metal into useful components. It involves cutting, bending, and rolling sheets of copper metals. The first step of copper sheet metal fabrication is to obtain the appropriate grade of copper you want to work with. The raw material is usually large and may be chunky. 

Thereafter, sketch out what you want the final part to look like and transform this design into a language the computer understands. You then mount the workpiece and load all necessary tools. Now, you can carry out the required fabrication process. If the part needs more than one technique, you do this simultaneously to avoid interruptions. The final step involves applying appropriate finishing operations and assembling the finished product. 

Why Use Copper for Sheet Metal Fabrication?

Copper is found in nature in its usable form. It has many benefits that make it suitable for the sheet metal fabrication process. Below are a few reasons you should make copper your first option in metal fabrication

• Copper has excellent formability properties as it can undergo plastic deformation without breaking or cracking. 
• It is highly ductile making it possible for you to stretch it into thin sheets easily. 
• Copper metal can withstand corrosion as a result of atmospheric oxidation and corrosive fluids.
• Copper is an antimicrobial agent as it deactivates bacteria, viruses, and fungi that come in close contact with it. 
• Its thermal and electrical conductivity stands out. Copper conducts electricity and transfers heat faster than most metals. 

Types of Copper Sheet Metal 

Copper is one of the few metals that occur naturally in its metallic form. There are different types available to meet the diverse needs of the manufacturing industry. You can either use copper in its pure form or as an alloy. 

Pure Copper Sheet

This is the highest grade of copper and one of the most widely used for sheet metal fabrication. It contains up to 99% of copper with about 0.7% of impurities. Pure copper has remarkable electrical and thermal conductivity. It is also very easy to work with and weld pure copper sheets. 

Copper Alloy Sheet

They have copper as their primary element with other metals added for various reasons. The following are common copper alloys in sheet metal fabrication

High Copper Alloy

As the name implies, this type has a high copper content compared to most other copper alloys. It contains an average of 96% copper. The additional element can either be beryllium, chromium, cadmium, zinc, aluminum, or zirconium, alone or in combination. They have low hardness and are very ductile.

Brass

Brass is an alloy of copper and zinc. The zinc content is as high as 34% leaving 66% copper. Brass sheets are highly malleable and you can easily form them into various shapes. These sheets have applications in casings, gears, and locks. 

Bronze

Bronze contains mainly copper, 12-15% tin, and traces of other metals and sometimes nonmetals. Bronze is hard and has a low friction. However, it comes with a melting point as high as 913 C. This may make welding bronze sheets time-consuming. 

Copper-Nickel

This alloy is composed mainly of copper and nickel with a small amount of other metals such as iron or manganese. Copper-nickel has good mechanical properties and it is easy to stamp and bend to create various designs. 

Nickel-Silver

Nickel-silver is an alloy of copper, nickel, and zinc. Note that it does not contain silver. However, it has an attractive silver luster hence the name. You can fabricate nickel-silver alloy by shearing, blanking, and forming. The resultant sheet metal can be used for jewelry and ornamental metalwork. 

Techniques for Fabricating Copper Sheets

‘Industrial welding process of copper metal using a filler material’

This section will discuss the key processes you can use to make useful components out of copper metal sheets.

Cutting

Cutting is a common process of copper sheet fabrication. It is usually the first step and is most of the time not used alone. Cutting involves placing the copper sheet between two blades; one is movable while the other is stationary. As the movable blade comes in contact with the sheet metal, it splits it using a shear force. This technique is fast and makes clean cuts. 

In addition to shearing, there are other advanced cutting operations such as laser cutting, plasma cutting, and waterjet cutting. These processes are more efficient and accurate. However, they may be expensive for small-scale businesses. 

Punching

The metal punching process uses specialized tooling called a punch die to remove material from a copper sheet. The tool applies a great cutting force to create a circular cut in the form of a hole. Punching is inexpensive and the cuts do not need secondary finishes. 

Blanking 

Blanking involves cutting out circular discs known as blanks from the copper sheet. It uses a punch and die set to carry out this operation. The die is usually stationary and placed beneath while the movable punch exerts force to perform the cut. Blanking produces less scrap when compared to punching. However, it may be more expensive to set up and maintain.

Bending

Bending is a process that creates a U or V-shaped contour from a sheet of copper metal using a brake press. Bending is accurate and has low tooling costs. However, it comes with thickness limitations. Bending works best with copper sheets that are 0.2 to 10mm thick. 

Rolling

Rolling involves passing the copper stock into two rollers moving in opposite directions. Rolling aims to reduce thickness and make the thickness of the metal sheet uniform. Rolling can either be hot rolling or cold rolling. Cold rolling occurs at or near room temperature while hot rolling shapes the copper sheet at elevated temperatures. 

Hemming 

Hemming is the process of rolling a copper sheet over itself. This helps to conceal defects and make the part safer for you to handle. Hemming can be opened or closed. Open hems have a space in between the bend while closed hems do not. 

Welding 

Welding is a joining process that uses heat and pressure to fuse two or more copper sheets. Copper has a high thermal conductivity so transfers heat readily. For this reason, it is necessary to employ methods that localize heat input. You can use either gas metal arc welding (GMAM) or gas tungsten arc welding (GTAW) to join copper and its alloys. 

Brazing 

Brazing is similar to welding. However, it occurs at a lower temperature. It uses a filler material that has a lower melting point than the copper sheet. By heating the joint and the filler material at a predetermined temperature, the material melts, flows in, and fuses the sheets. This technique produces strong welds while preserving the properties of the base copper metal. 

Applications of Copper Fabricated Parts

Many industries utilize copper-fabricated parts extensively. You can use it for both indoor and outdoor uses. The following are some common applications 

Architecture 

The use of copper in architecture is nothing new. You can find it in roofing systems, guttering, and exterior cladding. Copper alloys are aesthetically pleasing and have different shades of color. In addition, they resist corrosion and are long-lasting. 

Transportation

Copper has remarkable use in the automotive industry. It is the material of choice when producing heat exchangers and radiators in car cooling systems. Copper prevents overheating and sudden breakdown. You can also use copper sheets in electric vehicle systems. Its excellent electrically conductive makes it indispensable when manufacturing electric car batteries. 

Renewable Energy

When manufacturing components of renewable energy systems, copper should be your go-to metal. It is used for manufacturing solar panels and components for wind turbines. 

Medical Devices

Copper sheets are critical components in the medical industry because of many reasons. It has remarkable antibacterial properties and does not corrode when in prolonged contact with body fluids and tissues. Henc, they reduce the risk of infection and improve healthcare. 

Decorative Uses

The beautiful and shiny appearance of copper sheets cannot be overemphasized. You can also use it for decorative and artistic purposes such as railings, home decor, and backsplashes. 

Marine

Copper also has uses in marine applications. It can survive in marine and seawater environments. You will find it in heat exchangers, boat hulls, and piping systems. 

Challenges in Copper Sheet Metal Fabrication

Despite the numerous benefits you can get from using copper for sheet metal fabrication. It comes with a few challenges. Some of these include 

• When compared to some metals, copper has limited strength and may be unsuitable in high-stress applications.
• Copper is costly and the price continues to rise because it is energy-intensive to mine and refine. However, there are ways you can employ to cut sheet metal fabrication costs. 
• The weight of copper is also a limitation. Copper is dense and heavy which can make handling difficult. 

Conclusion 

Copper sheets undergo different processes before they can be used in manufacturing industries. Some techniques stand alone while others are just starting points. Copper is a good choice for sheet metal fabrication because it is soft, ductile, and malleable. However, its cost and weight have limited its use in applications where fuel efficiency is a determining factor.