Copper in the Automotive Industry

Copper in the Automotive Industry......Page 5
Contents......Page 7
Preface......Page 13
1.2 Availability......Page 15
2.2 From Copper Concentrate to Refined Copper [1, 4]......Page 17
2.4 Energy Consumption [12]......Page 19
2.5 Recycling [8–10]......Page 20
2.6 Environmental Protection [12]......Page 22
3.1.1 Copper [1, 14]......Page 25
3.1.2 Low Alloyed Wrought Copper [14, 15]......Page 27
3.1.4 Wrought Copper–Tin Alloys [14, 17]......Page 29
3.1.7 Wrought Copper–Aluminum Alloys [14, 20]......Page 32
3.2.1 Copper and Copper–Chromium Casting Materials [1, 21]......Page 34
3.2.3 Copper–Tin Casting Alloys [21, 22]......Page 36
3.2.6 Copper–Manganese–Aluminum and Copper–Nickel Casting Alloys [18, 21]......Page 39
3.3 Composites......Page 41
3.4 Powder Metallurgical Materials [24]......Page 42
4.1.2 Hot Forming......Page 43
4.1.4 Production of Sheet and Strip......Page 44
4.1.6 Production of Rods and Profiles......Page 45
4.1.8 Forging......Page 46
4.2 Shapes and Dimensions......Page 47
4.2.1 Strips, Sheets and Plates [25–27]......Page 48
4.2.2 Tubes [28]......Page 49
4.2.3 Rods......Page 50
4.2.4 Wires......Page 51
4.2.7 Special Shapes......Page 52
4.3.1 Designation by Material Number......Page 53
4.3.2 Designation According to Chemical Composition......Page 54
4.3.3 Designation of the Condition of the Material......Page 55
4.3.4 Product Designation......Page 56
4.3.5 Designation of Powder Metallurgical (Sintered) Materials......Page 57
5.1 Casting Procedures [21, 30]......Page 59
5.1.1.2 Precision (Investment) Casting (Lost-wax Process)......Page 60
5.1.2 Permanent Mold Casting......Page 61
5.1.2.2 Pressure Die Casting......Page 62
5.1.3 Continuous Casting [31]......Page 63
5.2 Shapes and Dimensions......Page 64
5.3 Classification and Designation......Page 65
5.3.1 Designation by Material Number and Chemical Composition......Page 66
5.3.2 Designation of the Casting Process and the Product......Page 67
6.1 Physical Properties [1, 14, 24]......Page 69
6.2.1 Strength Properties at Room Temperature [1, 15–22, 32]......Page 72
6.2.1.1 Rolled Products [25, 26, 39]......Page 74
6.2.1.2 Extruded Products......Page 75
6.2.1.3.2 Tubes......Page 81
6.2.1.3.3 Wires [38]......Page 82
6.2.1.4 Forgings......Page 83
6.2.1.6 Composites......Page 84
6.2.2 High Temperature Strength and Creep Properties [21, 40–44]......Page 86
6.2.4 Behavior at Low Temperatures......Page 88
6.2.6 Behavior under Cyclic Load [21, 32, 43, 49]......Page 89
7.1.1 Non-cutting Treatment [14, 26, 27]......Page 93
7.1.1.1 Forming Sheets and Strips [14, 26, 27, 38, 51]......Page 94
7.1.1.2 Solid Forming [14, 53]......Page 98
7.1.2 Machining [53]......Page 99
7.1.2.1 Turning......Page 102
7.1.2.3 Drilling......Page 103
7.1.2.5 Fine Finishing (Polished Turning, Grinding, Engrailing, Thread Production)......Page 104
7.1.3 Chemical Machining, Chemical and Electrochemical Polishing......Page 106
7.1.5 Thermal Cutting......Page 107
7.2.1 Soldering and Brazing [37]......Page 108
7.2.1.1 Soldering......Page 109
7.2.1.2 Brazing......Page 110
7.2.2 Welding [14, 59, 60]......Page 111
7.2.2.1 Arc Welding and Shielding Gas Welding (TIG and MIG Welding)......Page 112
7.2.2.2 Resistance Welding......Page 113
7.2.2.3 Recent Welding Processes......Page 114
7.2.3 Plating......Page 115
7.3 Heat Treatment......Page 116
7.3.2 Soft Annealing (Recrystallization)......Page 117
7.3.3 Thermal Stress-relieving......Page 118
7.3.4 Age-hardening (Precipitation Hardening)......Page 120
7.4.1.1 Cleaning, Degreasing......Page 122
7.4.1.2 Pickling and Etching......Page 123
7.4.1.4 Pretreatment for Soldering, Brazing or Welding......Page 124
7.4.1.7 Shot Peening......Page 125
7.4.3 Metallic Coatings......Page 126
7.4.3.1 Electroplating......Page 127
7.4.3.5 Deposition Welding [68]......Page 128
7.6 Health Care......Page 129
8.1 Design for Material......Page 131
8.2 Design for Recycling......Page 133
8.4 Tolerances and Machining Allowances......Page 134
9.2 Examples for Application......Page 137
10.1.1 Basics of Copper Corrosion [1, 14, 24, 70]......Page 141
10.1.2 Types of Corrosion......Page 142
10.1.3 Corrosion Behavior of Copper Alloys [70]......Page 144
10.1.5 Corrosion Protection......Page 146
10.2 Strips for Electrical Engineering and Electronics......Page 147
10.3 Plain Bearings [14, 72]......Page 151
10.4 Reliability......Page 156
10.5 Repairability......Page 157
References......Page 159
Appendix: Standards and Specifications......Page 163
A.1.2 Testing Standards......Page 164
A.1.5 Tubes......Page 165
A.1.8 Semi-finished Products for Electrical Engineering......Page 166
A.1.11 Soldering, Brazing and Welding......Page 167
A.2.2 Testing Standards......Page 168
A.2.4 Flat Rolled Products......Page 170
A.2.5 Tubes......Page 171
A.2.6 Wires......Page 173
A.2.7 Rods, Bars and Shapes......Page 174
A.2.9 Products for Electrical Engineering......Page 176
A.2.10 Master Alloys, Ingots and Castings......Page 177
A.2.13 Coatings......Page 178
A.3.4 Flat Rolled Products......Page 179
A.3.6 Wires......Page 180
A.3.11 Coatings......Page 181
Subject Index......Page 183