Copper properties and applications

Copper is a highly conductive metal used in electrical, thermal, and RF applications. It offers excellent conductivity and corrosion resistance.

  • Electrical conductivity — excellent (second only to silver)
  • Thermal conductivity — excellent
  • Corrosion resistance — good
  • Machinability — fair (ductile, gummy)
  • Common grades — C110 (electrolytic), C101 (oxygen-free)
Engineering Note

Oxygen-free copper (C101) is preferred for applications requiring high conductivity, such as RF components.

Copper machining challenges

  • Ductility — copper is soft and tends to form built-up edges
  • Tool wear — copper is abrasive, causing tool wear
  • Burr formation — copper tends to form burrs
  • Heat generation — copper conducts heat away, but cutting still generates heat
  • Chip control — copper produces long, stringy chips
Buyer Tip

Choose a supplier with experience in copper machining. Copper requires specific tooling and techniques that not all shops have.

Best practices for copper machining

  • Use sharp tools — sharp tools reduce built-up edge formation
  • Maintain consistent feeds — avoid dwell and vibration
  • Use coolant — reduces heat and improves surface finish
  • High speeds, moderate feeds — reduces tool wear and improves finish
  • Consider chip breakers — helps control stringy chips
Common Mistakes

Using dull tools for copper machining. Dull tools increase built-up edge formation and reduce tool life.

Typical copper components

  • Electrical busbars — high-current applications
  • RF components — waveguides, antennas
  • Heat exchangers — thermal management
  • Electrical connectors — terminals, plugs
  • EDM electrodes — for electrical discharge machining

Frequently Asked Questions

Is copper difficult to machine?

Copper is challenging to machine due to its ductility and tendency to form built-up edges. However, with the right tooling and techniques, it can be machined effectively.

What is the best grade of copper for machining?

Tellurium copper (C145) is free-machining, but C110 and C101 are also commonly machined for electrical applications.

What tolerance can copper machining achieve?

Typical tolerance is ±0.01mm, with precision capability of ±0.005mm.

What applications use copper?

Electrical components, RF applications, heat exchangers, and EDM electrodes.