Copper in the Automotive Industry Book

Preface     XI
Raw Material Resources     1
Primary Raw Materials     1
Availability     1
Production     3
From Ore to Copper Concentrate     3
From Copper Concentrate to Refined Copper     3
Secondary Copper Production     5
Energy Consumption     5
Recycling     6
Environmental Protection     8
Classification of Copper Materials     11
Wrought Copper Materials     11
Copper     11
Low Alloyed Wrought Copper     13
Wrought Copper-Zinc Alloys     15
Wrought Copper-Tin Alloys     15
Wrought Copper-Nickel Alloys     18
Wrought Copper-Nickel-Zinc Alloys     18
Wrought Copper-Aluminum Alloys     18
Copper Casting Materials     20
Copper and Copper-Chromium Casting Materials     20
Copper-Zinc Casting Alloys     22
Copper-Tin Casting Alloys     22
Copper-Tin-Lead Casting Alloys     25
Copper-Aluminum Casting Alloys     25
Copper-Manganese-Aluminum and Copper-Nickel Casting Alloys     25
Composites     27
PowderMetallurgical Materials     28
Wrought Copper Materials     29
Manufacture of Semi-finished Products     29
Smelting and Casting     29
Hot Forming     29
Cold Forming     30
Production of Sheet and Strip     30
Wire Production     31
Production of Rods and Profiles     31
Production of Tubes     32
Forging     32
Powder Metallurgical Forming (Sintering)     33
Shapes and Dimensions     33
Strips, Sheets and Plates     34
Tubes     35
Rods     36
Wires     37
Drawn and Extruded Profiles     38
Forgings     38
Special Shapes     38
Classification and Designation     39
Designation by Material Number     39
Designation According to Chemical Composition     40
Designation of the Condition of the Material     41
Product Designation     42
Designation of Powder Metallurgical (Sintered) Materials     43
Copper Casting Materials     45
Casting Procedures     45
Lost Mold Casting     46
Sand Casting      46
Precision (Investment) Casting (Lost-wax Process)     46
Exact Casting (Other Processes)     47
Permanent Mold Casting     47
Die Casting     48
Pressure Die Casting     48
Centrifugal Casting     49
Continuous Casting     49
Composite Casting     50
Shapes and Dimensions     50
Classification and Designation     51
Designation by Material Number and Chemical Composition     52
Designation of the Casting Process and the Product     53
Properties of the Copper Materials     55
Physical Properties     55
Mechanical and Technological Properties     58
Strength Properties at Room Temperature     58
Rolled Products     60
Extruded Products     61
Drawn Products     67
Rods     67
Tubes     67
Wires     68
Forgings     69
Castings     70
Composites     70
Sintered Materials     72
High Temperature Strength and Creep Properties     72
Relaxation     74
Behavior at Low Temperatures      74
Behavior under Dynamic Load     75
Behavior under Cyclic Load     75
Working with Copper Materials     79
Mechanical Processing     79
Non-cutting Treatment     79
Forming Sheets and Strips     80
Solid Forming     84
Machining     85
Turning     88
Milling     89
Drilling     89
Cutting     90
Fine Finishing (Polished Turning, Grinding, Engrailing, Thread Production)     90
Chemical Machining, Chemical and Electrochemical Polishing     92
Electrical Discharge Machining     93
Thermal Cutting     93
Joining     94
Soldering and Brazing     94
Soldering     95
Brazing     96
Welding     97
Arc Welding and Shielding Gas Welding (TIG and MIG Welding)     98
Resistance Welding     99
Recent Welding Processes     100
Plating     101
Bonding     102
Heat Treatment     102
Homogenization     103
Soft Annealing (Recrystallization)     103
Thermal Stress-relieving      104
Age-hardening (Precipitation Hardening)     106
Surface Treatment     108
Pretreatment     108
Cleaning, Degreasing     108
Pickling and Etching     109
Chemical and Electrochemical Polishing     110
Pretreatment for Soldering, Brazing or Welding     110
Pretreatment for Bonding     111
Pretreatment for Coating     111
Shot Peening     111
Surface Design     112
Mechanical Processes for Surface Treatment     112
Non-metallic Coatings, Metal Coloring     112
Metallic Coatings     112
Electroplating     113
Electroless (Chemical) Deposition     114
Hot-dip Coating     114
Thermal Spraying     114
Deposition Welding     114
Roll-cladding     115
Safety Measures     125
Health Care     115
Design Notes     117
Design for Material     117
Design for Recycling     119
Limits of Application     120
Tolerances and Machining Allowances     120
Application     123
Areas of Application     123
Examples for Application     123
Usage Properties     127
Corrosion Behavior     127
Basics of Copper Corrosion     127
Types of Corrosion     128
Corrosion Behavior of Copper Alloys     130
Corrosion in Gases     132
Corrosion Protection     132
Strips for Electrical Engineering and Electronics     133
Plain Bearings     137
Reliability     142
Repairability     143
References     145
Standards and Specifications     149
EN-Standards     149
Basic Standards     150
Testing Standards     150
Refinery Copper     151
Flat Rolled Products     151
Tubes     151
Rods, Profiles and Wires     152
Forgings and Forging Stock     152
Semi-finished Products for Electrical Engineering     152
Scrap, Master-alloys, Ingots and Castings     153
Bearing Materials     153
Soldering, Brazing and Welding     153
Other Technical Rules for Copper Materials     154
US-Standards (ASTM)     154
Basic Standards     154
Testing Standards     154
Refinery Copper     156
Flat Rolled Products     156
Tubes     157
Wires     159
Rods, Bars and Shapes     160
Forgings and Extruded Profiles     162
Products for Electrical Engineering     162
Master Alloys, Ingots and Castings     163
Bearing Materials     164
Soldering, Brazing and Welding     164
Coatings     164
Japanese Standards (JIS)     165
Basic Standards     165
Testing Standards     165
Refinery Copper     165
Flat Rolled Products     165
Tubes     166
Wires     166
Rods, Bars and Shapes     167
Master-alloys, Ingots and Castings     167
Soldering, Brazing and Welding     167
Products for Electrical Engineering     167
Coatings     167
Subject Index     169