Small-sized copper flat wires (thickness 0.05mm and above, width 2mm to 10mm) face many technical challenges in the production process, mainly in terms of material property control, precision rolling, surface quality, dimensional accuracy, mechanical properties, etc. The following are the main difficulties in producing small-sized copper flat wires:<\/p>
(1) High purity requirements for copper materials<\/p>
High-purity oxygen-free copper (OFC) or T2 copper is required to ensure good conductivity and ductility.<\/p>
The impurity content needs to be strictly controlled, especially the oxygen content, sulfur, phosphorus, etc., to avoid affecting the toughness and processability of the copper strip.<\/p>
(2) Surface quality of raw materials<\/p>
The copper surface must not have oxidation, cracks, inclusions or bubbles, otherwise it will cause defects during the rolling process.<\/p>
The uniformity of the copper billet is required to be high, otherwise it may lead to uneven thickness and unstable mechanical properties after rolling.<\/p>
Small-sized copper flat wires need to go through multiple rolling processes to achieve the required thickness and width. The difficulties in rolling include:<\/p>
(1) Difficulty in controlling ultra-thin specifications<\/p>
Small-sized copper flat wires are extremely thin (up to 0.05mm), and are prone to problems such as uneven size, breakage, and warping during the rolling process.<\/p>
High-precision four-roll mills, six-roll UC mills, twenty-roll Sendzimir mills, etc. are required to control thickness uniformity.<\/p>
(2) Complex plate shape control<\/p>
Due to the uneven force on the copper strip during the rolling process, defects such as wavy shape, curling, and side bending are prone to occur.<\/p>
A precise tension control system is required to ensure that the copper strip is evenly stressed during rolling.<\/p>
(3) Rolling lubrication and temperature control<\/p>
Too high temperature during rolling will affect the plasticity of copper materials, resulting in decreased mechanical properties or scratches on the surface.<\/p>
High-performance rolling oil is required to ensure good lubrication and cooling effects.<\/p>
(1) Precise control of annealing temperature<\/p>
Small-sized copper flat wires need to undergo precise annealing to adjust the hardness and ductility of the copper material.<\/p>
If the annealing temperature is too high, the copper strip will have coarse grains and affect its mechanical strength; if the temperature is too low, the copper strip will be too hard and its machinability will be reduced.<\/p>
(2) Yield strength and elongation control<\/p>
It is necessary to ensure that the copper strip has good ductility and tensile strength while meeting the hardness requirements to prevent cracking or breaking during subsequent processing.<\/p>
(1) Surface defect control<\/p>
Small-sized copper flat wires have extremely high requirements for surface quality, and the following defects are prone to occur during the production process:<\/p>
Scratches: Insufficient lubrication or entry of foreign matter during the rolling process will cause scratches.<\/p>
Oxidation discoloration: If the copper strip is exposed to high temperature for too long, an oxide layer will form, affecting conductivity.<\/p>
Black stripes, white spots, and dirt: mainly caused by rolling oil residue, incomplete cleaning, or foreign matter during the rolling process.<\/p>
(2) Surface treatment and anti-oxidation protection<\/p>
After production, it needs to be passivated or coated with anti-oxidation oil to prevent the surface of the copper strip from discoloring or oxidizing during long-term storage.<\/p>
When packaging, use vacuum packaging or nitrogen filling packaging to reduce contact with air and prevent oxidation.<\/p>
(1) Thickness tolerance control<\/p>
The thickness tolerance requirements for small-sized copper flat wires are extremely strict, and are generally required to be controlled within \u00b10.005mm.<\/p>
During the rolling process, a high-precision thickness gauge is required for real-time monitoring to ensure uniform thickness.<\/p>
(2) Width tolerance control<\/p>
The width tolerance is generally within the range of \u00b10.05mm, and a high-precision slitting process is required to ensure accurate cutting.<\/p>
The quality of trimming needs to be strictly controlled to prevent burrs or irregular edges from affecting subsequent processing.<\/p>
(1) Prevent wire jams caused by uneven tension<\/p>
Small-sized copper flat wires are easily affected by uneven tension during the winding process, resulting in inconsistent coil tightness or even breakage.<\/p>
A constant tension winding system is required to ensure that the copper strip is wound evenly.<\/p>
(2) Prevent deformation during transportation<\/p>
Because the copper belt is thin, it is easy to bend or deform during transportation.<\/p>
It is necessary to use a precise winding process and fix it with shock-proof packaging materials to prevent the copper tape from being damaged by transportation vibration.<\/p>
Summary: High-precision technology + strict quality control is the key<\/p>
The production difficulties of small-sized copper flat wires are mainly reflected in material purity, precision rolling, surface quality control, dimensional accuracy, annealing treatment, etc. To produce high-quality copper flat wires, you need to:<\/p>
\u2705 High purity copper material, ensuring good conductivity and ductility<\/p>
\u2705 Precision rolling mill to ensure uniform thickness and surface defects<\/p>
\u2705 Advanced annealing process, precise control of mechanical properties<\/p>
\u2705 High-precision testing, strict control of tolerance and surface quality<\/p>
\u2705 Optimize winding and packaging to prevent damage during transportation<\/p>
in the country,Raytron<\/a>\uff08Raytron<\/a>\uff09<\/strong>We are a leader in the industry with leading technology in the production of small-sized copper flat wires, and possess high-precision rolling and high-standard quality control capabilities.<\/p>","protected":false},"excerpt":{"rendered":" Small-sized copper flat wires (thickness 0.05mm and above, width 2mm to 10mm) face many technical challenges in the production process, mainly reflected in the material characteristics [\u2026]<\/p>","protected":false},"author":1,"featured_media":9053,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[19],"tags":[],"class_list":["post-33462","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog"],"_links":{"self":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/posts\/33462","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/comments?post=33462"}],"version-history":[{"count":0,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/posts\/33462\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/media\/9053"}],"wp:attachment":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/media?parent=33462"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/categories?post=33462"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/tags?post=33462"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}