Copper impregnated graphite is a material with the qualities of both graphite and copper. It is a graphite material manufactured with a controlled amount of interconnected porosity which is then infiltrated with copper by capillary action in a furnace.
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Shops generally use copper to make electrodes when they have a need to provide a better surface finish and better flushing. They generally use graphite when they have a need to provide fine detail and a higher metal removal rate. Copper impregnated graphite is chosen for electrodes when qualities from both materials are warranted. A shop looking for a material that results in better surface finish and better flushing, while able to hold finer detail or provide a higher metal removal rate may find a copper-impregnated graphite to be a good choice.
Copper impregnated graphite offers the following features:
1. Increased electrical conductivity and mechanical strength
Electrical conductivity is the result of the movement of the electrically charged particles. In the case of the copper, a single valence electron moves with little resistance and causes a repelling reaction. Copper does not interact with carbon; the two elements are essentially immiscible. The copper is precipitated in ferrite, resulting in a hardening effect.
2. It is an electrode material with a low resistivity value that allows the maximization of the amount of energy.
Electrical resistance, is the total opposition to the passage of electrical current, or the flow of electrons. Resistance depends on current passing through. Copper impregnation reduces the graphite&#;s overall resistance, allow more energy to pass through more quickly.
3. Copper impregnated graphite offers the combined benefits of the ease of fabrication of graphite, and the burn stability and &#;safety&#; of copper.
Graphite is a material that is fairly easy to machine. Like carbon, graphite is a non-metallic substance with an extremely-high sublimation temperature which provides resistance to high- temperature arcs. It is a fine grain-sized material, and tends to have better erosion and wear performance. The impregnation of copper stabilizes the erosion and wear, producing burn safety.
4. Copper impregnated graphite can be used on carbide materials.
Carbide is extremely dense and is slow to machine. Carbide EDMing results in a higher wear ratio, and metal removal is slow. Electrodes made from copper impregnated graphite can be run in reverse polarity and high frequency allowing for the energy needed to burn carbide materials.
5. Copper impregnated graphite yields good surface finish.
Graphite and copper electrodes produce comparatively high surface roughness for the materials at higher values of pulse current. Copper impregnated graphite electrodes offer low values of surface roughness at high discharge current which yield good surface finish.
If you require the better finishes, impregnated graphites provide better finishes. Copper- impregnated grades also allow for stable machining when unfavorable conditions exist &#; such as poor flushing or when the operator is not very experienced with the application.
Copper impregnated graphite is a material with the qualities of both graphite and copper. It is a great alternative when qualities from both materials are warranted. It is when a shop needs an economical alternative requiring a good finish.
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Copper impregnation provides increased resistance to erosion and corrosion, making Copper Impregnated Graphite suitable for harsh operating conditions and chemically aggressive environments. Copper Impregnated Graphite, specifically EC-15C and HK6-C grades, offer several advantages that make them a preferred choice in various applications like electrodes.
Some reasons you should consider using EC-15C and HK-6C grades include:
Copper impregnation significantly improves the electrical conductivity of the graphite material. This makes it ideal for applications where high electrical conductivity is essential, such as in electrical discharge machining (EDM), electrical contacts, and other electrical applications.
Flexural strength is a crucial aspect to consider when evaluating electrodes. Unlike other materials, copper graphite is suitable for wire EDM to cut at higher speeds and provide finer finishes. EC-15C and HK-6C is an excellent choice for EDMing carbide and exotic alloys, as well as work pieces with limited flushing conditions.
Copper impregnation also enhances the thermal conductivity of the graphite material. This property enables efficient heat dissipation, making it suitable for applications that require effective thermal management, such as heat sinks, thermal interfaces, and electronic cooling systems.
Copper impregnation strengthens the graphite matrix, resulting in improved mechanical strength and stability. This makes Copper Impregnated Graphite more resistant to chipping when machining thin ribs and sharper detail, ensuring better durability and resistance to wear or deformation in demanding applications.
Copper impregnation provides increased resistance to erosion, making copper graphite suitable for harsh operating conditions and chemically aggressive environments. Utilizing this metal is less prone to DC arcing in poor flush conditions.
Copper graphite used on common metal substrates have higher metal removal rates in roughing applications than standard graphite. Properties of copper graphite offer lower resistivity, higher flexural strength, high conductivity, and better finish with lower amperage settings which improves electrode wear.
Copper Impregnated Graphite finds applications across various industries, including automotive, aerospace, electronics, power generation, and more. It can be used in EDM electrodes, current-carrying components, thermal management solutions, seals, gaskets, and other high-performance applications.
It is important to note that when selecting the appropriate electrode material for an EDM job, several factors come into play. Copper impregnated graphite has proven to be a suitable choice for EDM electrodes in various applications. However, the decision to opt for this material depends on specific application requirements and the desired outcomes. It is crucial to evaluate these variables carefully in order to make an informed choice regarding the use of copper impregnated graphite as the electrode material.
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