Copper Alloy Casting Mold Thermal Conductivity
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Solution Overview
Problem
The existing casting methods for copper or copper alloys used in electrical applications result in high energy costs, environmental pollution, and reduced mechanical properties due to porosity and mold degradation from excessive heat, which limits the service life of the casting mold.
Innovation Solution
A method that maintains a low excess temperature of the casting material, achieving a cooling rate of at least 10^3 K/s with a thermally conductive mold, reducing porosity and extending mold life, while using a high thermal conductivity material and optional deoxidizing agents to prevent oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the temperature is increased well above the melting point of the cast material, then the porosity is reduced and electrical properties are improved, but energy costs increase and environmental pollution worsens
Solution Approach 1:
The invention changes the temperature parameter from conventional high superheat (well above melting point) to a controlled low excess temperature (melting point plus 15-20% only), achieving low porosity through optimized cooling rate rather than excessive heat input
Solution Approach 2:
The mold is pre-cooled to a temperature below ambient before casting, creating a temperature gradient that ensures rapid heat extraction from the melt, preventing porosity formation without requiring high casting temperatures
2Manufacturing precision
If the temperature is increased well above the melting point of the cast material, then the porosity is reduced and electrical properties are improved, but the service life of the casting mold decreases
Solution Approach 1:
The invention changes the temperature parameter from conventional high superheat to a controlled low excess temperature (melting point plus 15-20% only), achieving low porosity through optimized cooling rate rather than excessive heat input
Solution Approach 2:
The mold is pre-cooled to a temperature below ambient before casting, creating a temperature gradient that ensures rapid heat extraction from the melt, preventing porosity formation without requiring high casting temperatures that would damage the mold
3Manufacturing precision
If the temperature is increased to improve filling, then the wetting conditions and contact with mold surface are improved, but the stress on the mold increases
Solution Approach 1:
The invention changes the temperature parameter from conventional high superheat to a controlled low excess temperature (melting point plus 15-20% only), achieving low porosity through optimized cooling rate rather than excessive heat input
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces copper or copper alloy products with excellent mechanical and electrical properties, minimal porosity, and a long-lasting mold, achieving high thermal conductivity and fine grain structure without the need for additional cooling measures or oxidizing agents.
Implementation Method 1
The mold is made of a thermally conductive material with suitable mechanical properties... the mold can be filled well, with the casting material being of high quality
Data Source
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AI summary
The method for preparing products comprising copper or copper alloys for electrical applications, comprises melting the copper or copper alloy, adding the melt to a casting mold (7), and applying to the product. The copper alloy has a melting point of higher than 1035[deg] C. A cooling rate of the melt is greater than 102 K/s, and the molten material is overheated to 15-20% of its melting point. The deoxidation of the melt is carried out with a deoxidizer. The casting mold consists of materials having an average thermal conductivity of greater than 100 W/(m.K). The method for preparing products comprising copper or copper alloys for electrical applications, comprises melting the copper or copper alloy, adding the melt to a casting mold (7), and applying to the product. The copper alloy has a melting point of higher than 1035[deg] C. A cooling rate of the melt is greater than 102 K/s, and the molten material is overheated to 15-20% of its melting point. The deoxidation of the melt is carried out with a deoxidizer. The casting mold consists of materials having an average thermal conductivity of greater than 100 W/(m.K), where the thermal conductivity prevents a crack formation in the mold. The casting material is melted under a protective gas atmosphere. Inner sides in the mold coming into contact with the molten casting material are provided with a coating. A metallurgical connection between the material of the mold and the casting material is prevented. The molten casting material is introduced by a pressure casting process, centrifugal casting or sand or gravity die casting. The casting material is melted in an induction furnace, an electric resistance furnace or in a gas-heated furnace.