FSIN Analyst Day 2008 - Bimetallic Products
-
Upload
fushicopperweld -
Category
Technology
-
view
1.838 -
download
1
description
Transcript of FSIN Analyst Day 2008 - Bimetallic Products
Bimetallic
Products
FUSHI COPPERWELD
Presented By
Dustin J. Fox
Global R&D Manager
Analyst-Investor Day
Tuesday, November 18, 2008
Fayetteville, TN
History of Copperweld
• Rankin, PA. (1915)
• Glassport, PA. (1927)
(Molten welding of copper to steel was the early process)
• Fayetteville, Tennessee– 1975 “green field facility” - CCA only
– 1979 Solid Cladding CCS Clad lines installed
• Fushi International acquires Copperweld, October 2007
Fushi Copperweld, Inc.
Manufacturing Locations
Telford, England
Dalian, China
Fayetteville, TN
Quality System
• Quality Management Systems
Certified to
ISO 9001• Fully equipped metallurgical laboratory with SEM
(scanning electron microscope)
Bimetallic Wire
• What is Bimetallic Wire?
– A Substitute for a single metal
– Outer metal is different from
inner metal
– Bond allows metals to act as
one when processing (drawing)
– Ratio of metal thickness
remains constant while drawing
– Metallurgical bond at interface
1.02mm CCS 40% 75X
5.83mm CCS 40% 14X
Metallurgical Bond
STEM-HAADF-XEDS
As tested by University of Alabama
Tuscaloosa, Alabama
0
20
40
60
80
100
0 100 200 300 400 500 600 700 800
Cu
Fe
Com
post
ion
, w
t%
Distance, nm
Interdiffusion zone spans ~ 80 nm
Copper-Clad Steel (CCS)
0
20
40
60
80
100
0 50 100 150 200
CuAl
Co
mp
os
tio
n, w
t%Distance, nm
Interdiffusion zone spans ~ 50 nm
Copper-Clad Aluminum (CCA)
Product Features
Bimetallic wires combine the features of dissimilar metals to achieve a cost and/or a performance advantage
Copper-Clad Aluminum
- Conductivity of copper
(high frequency applications) - Low weight of aluminum - Substantial weight savings versus copper - Low scrap value (theft resistance)
Copper-Clad Steel (Copperweld® Wire)
- Conductivity of copper
(high frequency applications) - Strength of steel - Corrosion resistance - Fusing current similar to copper - Durability - Low scrap value (excellent theft resistance)
Relative length of identical weights
of CCA and Copper wire
CCA Copper
Bimetallic Wire
• Production Methods
– Solid Metal Cladding (Fushi Copperweld Process)
– Electroplating
– Liquid Metal Dipping
– Molten Welding – Billet Extrusion
Solid Metal Cladding
Copper-Clad Steel (CCS) Process
Cooling
Take-up
Carbon steel rod
Two strips of high purity copper
Pressure & heat
Metallurgical Bond
Bimetallic Wire Quality
COPPERWELD (copper-clad steel) Low Carbon 21%
Poor Quality Producer (copper-plated steel) Low Carbon 21%
100X of Steel Core
100X of Steel Core
1500X of copper cladding on steel core
1500X of copper plating on steel core
Voids between copper
plating and steel core
Bimetallic Wire Quality
Poor Quality Producer Low Carbon 40%COPPERWELD® Low Carbon 40%
Bimetallic Wire Quality
COPPERWELD® Low Carbon 40% Poor Quality Producer - Low Carbon 40%
Copper-Clad Steel (CCS)
Applications
Telephone and CATV drop wire
Catenary wire for electrified railroads
Electronic lead wire
CCS
CCS Cable
CCS Catenary
CCS Lead Wires
Copper-Clad Steel (CCS)
Applications – Con’t
Grounding wire for electric power systems
Buried Counterpoise WireBuilding Ground
Lightning
Protection
Substation Grounding
Grid Wire
Fence Ground
Pole
Ground
Wire
Transformer
Ground
Transmission System
Distribution System
Copper-Clad Steel (CCS)
Applications – Con’t
Tracer Wire
Automotive Wiring Harness
Detonation Wire
Plastic Pipe
CCS
Wire
CCS Tracer Wire
Solid Metal Cladding
Copper-Clad Aluminum (CCA) Process
CleaningDrawing
Copper-Clad
Aluminum RodTube Forming
Tube Seam
Welding
DrawingPressure
Bonding
Die
Aluminum Rod
Copper Strip
Take-up
High Purity Aluminum rod
One Strip High Purity Copper
Extreme Pressure & Cleanliness
Metallurgical Bond
Copper-Clad Aluminum (CCA)
Applications
– Coaxial Distribution Cable
– Building Wire
– Power Cables
– RF Cables – Cellular Towers
– Braid Wire
– Data (LAN) Cables
– Wiring Harness (power leads)
– Magnet Wire
– Automotive Battery Cables
– Jumper/Booster Cables
High Frequency Signals
• Signal only travels on outer surface of center conductor
(skin effect)
• Copper Clad Aluminum & Copper Clad Steel exceeds
the minimum copper thickness for high frequency signals
High Frequency Signal
Copper CladdingSteel or Aluminum Core
Bimetallic Research and Development
• University of Alabama’s Materials Metrology Research Program – One-Year Agreement with Provisions for Extension
– Access to specialized materials experts and state-of-the-art research technology through UA’s Central Analytical Facility (CAF)
• Copper-Clad Stainless Steel– Applications in highly corrosive environments with sensitive
equipment
– Non-magnetic, high strength characteristics
• Copper-Clad Aluminum Tape (CCAT)
• CCA Bus Bar
• Copper-Clad Aluminum Magnesium Alloy (CCAM - Wire)
Copper-Clad Aluminum Tape (CCAT)
Solid Metal Cladding
One strip of high purity Aluminum
One strip of high purity Copper
Extreme Pressure and Cleanliness
Metallurgical Bond
RF Cables – Cellular Towers
CCA Bus Bar
• Electrical Power Distribution Systems
• 15%-20% Copper by Volume
• Patented Method
- Lower Cost vs. Molten Extrusion Method
• AC Skin Effect – Direct Substitution of Copper
• Typical Sizes (mm)
– 30X3
– 40X4
– 50X5
– 80X8
– 100X10
– 120X10
Copper-Clad Aluminum
Magnesium Alloy Wire (CCAM)
• High Tensile Strength CCA
–30-40% higher than Standard CCA
–New standards under development
– 15% Copper by Volume
• Use as Braid/Shielding Wire
• Other applications and markets being developed