There have been many theories written on how copper graphite is created, many of which are completely untrue.
According to Eben Walker, president of Graphite Metallizing, the creation of copper graphite relies upon the unique structure of manufactured graphite, which includes a controlled amount of open porosity. This open porosity provides the pathways for copper to reach inside the graphite. The objective of metal impregnation is to fill these pores completely.
The impregnation process is performed at 2400oF (1300oC) in a controlled atmosphere to eliminate oxidation. The graphite must be heated first and then completely submerged in molten metal. Once completely surrounded by molten copper, several hundred atmospheres of pressure are applied to force the metal into the pores of the graphite. After the pores are fully infiltrated, the excess metal is removed and the graphite is allowed to cool in an inert atmosphere.
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.
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.
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.
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.
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.
A graphite material impregnated with copper suitable as a structural member exposed to a high temperature, for example, plasma opposing members in a plasma thermonuclear reactor is obtained. In the present invention, 70vol% or more of a constitutionally dense isotropic graphite material having a porosity and an average cell diameter of from 5 to 18vol% and from 0.1 to 2.5μm respectively as measured by a mercury penetration method is impregnated with a copper alloy defined by following conditions. Namely, the copper alloy comprises from 1 to 7wt% of an element selected from the group of elements having a standard enthalpy (ΔHdeg) obtained by the reaction with each of graphite and copper of up to -50kJ per 1 mol respectively and the substantial balance of copper. The bulk density thereof after the impregnation is determined to 3.0Mg/m3 or lower. Then, the graphite material can be impregnated with a copper uniformly thereby capable of providing a copper impregnated-graphite material excellent in handleability upon impregnating operation
Exotic workpiece metals are often chosen with considerations for strength and heat resistance. Because EDM is a thermal process the melting temperature and thermal conductivity of the metal will have the biggest effects.
Effectively EDMing exotic metals such as Beryllium Copper, Titanium Alloys, and Carbides is greatly benefited by a switch to copper impregnated graphite.
Infusing copper with porous graphite lowers the resistivity of the electrode and allows for more power to pass through to your work metal. Because of Copper on its own is relatively soft, tight tolerances on small details can be very difficult to machine.
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.
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.
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.
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