Copper Casting, High Conductivity Copper Casting – Conex Casting
Conex Casting is a leading manufacturer of Copper Castings and High Conductivity Copper Castings in India. Specializing in Permanent Mold Casting (also known as Gravity Die Casting), we produce precision copper components for electrical, industrial, and engineering applications. Our copper castings offer exceptional electrical conductivity, thermal conductivity, corrosion resistance, and long-term durability at a competitive price of US$ 18.90/Kg.
What is Copper Permanent Mold Casting?
Permanent mold casting (gravity die casting) is a process in which molten copper is poured into a reusable metal mold under gravity. This method produces copper castings with superior dimensional accuracy, smoother surface finish, and better mechanical properties compared to sand casting. The permanent mold casting process is ideal for medium to high volume production of high-conductivity copper components requiring consistent quality.
High Conductivity Copper Casting – Properties & Applications
High Conductivity Copper (HC Copper) contains a minimum of 99.9% pure copper, delivering outstanding electrical and thermal conductivity. Conex Casting produces HC copper castings conforming to international standards including ASTM B505, IS 191, BS 1400, and DIN standards. Our high conductivity copper castings are used in:
- Electrical switchgear components and busbars
- Transformer terminals and connectors
- Motor and generator rotor bars
- Heat exchangers and cooling systems
- Induction heating coils and electrodes
- Rail traction components
- Marine and offshore electrical equipment
- Welding equipment nozzles and tips
Copper Casting Grades – Material Specifications
Conex Casting works with a wide range of copper alloys for permanent mold casting, including pure copper and copper-based alloys. The most commonly cast grades include:
| Alloy | Copper % | Key Properties | Typical Applications |
|---|---|---|---|
| HC Copper (C11000) | ≥99.9% | Highest electrical & thermal conductivity | Electrical contacts, busbars, connectors |
| Oxygen-Free Copper (C10100) | ≥99.99% | Ultra-high purity, excellent ductility | High-vacuum electronics, waveguides |
| Phosphor Deoxidized Copper (C12200) | ≥99.9% | Good weldability, no hydrogen embrittlement | Plumbing, refrigeration, heat exchangers |
| Tellurium Copper (C14500) | ≥99.5% | Free-machining, good conductivity | CNC-machined electrical components |
Copper Casting Price – US$ 18.90 per Kg
Conex Casting offers high conductivity copper castings at US$ 18.90 per Kg (ex-works, Mumbai, India). Pricing may vary depending on alloy grade, casting complexity, order quantity, and surface finish requirements. Contact us for a customized quote for your copper casting requirements.
Why Choose Conex Casting for Copper Permanent Mold Castings?
- Decades of Experience: Over 25 years of expertise in copper and copper alloy casting in India.
- Precision Manufacturing: Permanent mold casting ensures tight dimensional tolerances and consistent quality.
- International Standards: Castings conforming to ASTM, BS, DIN, IS, and JIS standards.
- Competitive Pricing: Cost-effective copper castings at US$ 18.90/Kg with flexible MOQ.
- Custom Copper Castings: Cast to your drawing, pattern, or sample for bespoke copper components.
- Export Ready: Supplying copper castings globally to USA, UK, Europe, Australia, and the Middle East.
- Quality Tested: All castings undergo chemical composition, hardness, dimensional, and pressure testing.
Copper Permanent Mold Casting Process at Conex Casting
Our copper permanent mold casting process follows a systematic, quality-controlled workflow:
- Pattern & Mold Design: Engineering team reviews customer drawings and designs precision metal dies for permanent mold casting.
- Metal Melting: High-purity copper ingots are melted in induction furnaces at controlled temperatures to ensure alloy integrity.
- Mold Preparation: Metal molds are preheated and coated with release agents to ensure smooth casting ejection and extended mold life.
- Gravity Pouring: Molten copper is poured into the preheated permanent mold under gravity, filling cavities uniformly.
- Solidification & Cooling: Controlled cooling ensures minimal porosity and optimal grain structure in the casting.
- Ejection & Fettling: Solidified castings are ejected, gates and risers are removed, and rough surfaces are cleaned.
- Machining (Optional): CNC machining, drilling, and finishing are offered to achieve final dimensional requirements.
- Quality Inspection: Dimensional inspection, chemical analysis, hardness testing, and pressure testing as required.
Frequently Asked Questions (FAQ) – Copper Casting
Q1. What is the minimum order quantity for copper castings from Conex Casting?
Conex Casting accepts small batch orders starting from as low as 50 kg for sample or prototype copper castings. For regular production, the minimum order quantity is typically 100 kg or as negotiated based on casting complexity and tooling requirements.
Q2. What is the price of copper casting per kg?
Conex Casting offers high conductivity copper castings at US$ 18.90 per kg (ex-works). The final price may vary based on order quantity, alloy grade, casting complexity, and any secondary operations such as machining or plating. Please contact our sales team for an exact quotation.
Q3. What copper grades are available for permanent mold casting?
We cast a wide range of copper grades including High Conductivity Copper (C11000/ETP Copper), Oxygen-Free Copper (C10100), Phosphor Deoxidized Copper (C12200), and Tellurium Copper (C14500). Custom alloy formulations are also available on request.
Q4. What are the typical tolerances for copper permanent mold castings?
Permanent mold copper castings from Conex Casting typically achieve dimensional tolerances of ±0.5 mm for standard castings, with tighter tolerances achievable through CNC machining. Surface finish typically ranges from Ra 3.2 to Ra 6.3 µm depending on the casting geometry.
Q5. Does Conex Casting export copper castings internationally?
Yes, Conex Casting exports high conductivity copper castings worldwide, including to the United States, United Kingdom, Germany, Australia, UAE, and Southeast Asia. We provide export documentation, material test reports (MTR), and compliance certificates as required by international buyers.
Q6. How long does it take to produce copper castings after tooling?
Once tooling (permanent mold die) is ready, standard production lead times for copper castings are 3–5 weeks depending on order quantity and complexity. Tooling fabrication typically takes 4–6 weeks for new patterns. We also offer expedited production for urgent requirements.
Q7. What quality certifications does Conex Casting hold for copper castings?
Conex Casting is an ISO-certified foundry. Our copper castings are produced in compliance with ASTM, IS, BS, and DIN standards. We provide material test reports (MTR), chemical analysis certificates, dimensional inspection reports, and third-party inspection (TPI) support as required.
Q8. Can Conex Casting produce copper castings from customer-supplied drawings?
Absolutely. Conex Casting manufactures copper castings to customer drawings, 3D CAD models (STEP/IGES), or physical samples. Our engineering team provides design for manufacturability (DFM) feedback to optimize casting design for the permanent mold process and reduce costs.
Contact Conex Casting for Copper Casting Enquiries
For copper casting quotes, technical queries, or to discuss your permanent mold copper casting requirements, please contact Conex Casting:
Conex Casting
1406 / 1414 Dalamal Towers, Nariman Point, Mumbai – 400 021, India.
Phone: +91-22-43449300 | +91-22-43449323
Mobile: +91 99677 86663
Email: sales@conex-casting.com