FSIN Analyst Day 2008 - Bimetallic Products
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Transcript of FSIN Analyst Day 2008 - Bimetallic Products
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Bimetallic
Products
FUSHI COPPERWELD
Presented By
Dustin J. Fox
Global R&D Manager
Analyst-Investor Day
Tuesday, November 18, 2008
Fayetteville, TN
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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
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Fushi Copperweld, Inc.
Manufacturing Locations
Telford, England
Dalian, China
Fayetteville, TN
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Quality System
• Quality Management Systems
Certified to
ISO 9001• Fully equipped metallurgical laboratory with SEM
(scanning electron microscope)
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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
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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)
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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
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Bimetallic Wire
• Production Methods
– Solid Metal Cladding (Fushi Copperweld Process)
– Electroplating
– Liquid Metal Dipping
– Molten Welding – Billet Extrusion
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Solid Metal Cladding
Copper-Clad Steel (CCS) Process
Cooling
Take-up
Carbon steel rod
Two strips of high purity copper
Pressure & heat
Metallurgical Bond
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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
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Bimetallic Wire Quality
Poor Quality Producer Low Carbon 40%COPPERWELD® Low Carbon 40%
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Bimetallic Wire Quality
COPPERWELD® Low Carbon 40% Poor Quality Producer - Low Carbon 40%
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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
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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
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Copper-Clad Steel (CCS)
Applications – Con’t
Tracer Wire
Automotive Wiring Harness
Detonation Wire
Plastic Pipe
CCS
Wire
CCS Tracer Wire
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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
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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
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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
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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)
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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
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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
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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
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