In the field of ultra-high-voltage transmission, copper rods with a diameter of 600mm need to meet
the harsh requirements of axial grain size ≤ 0.015mm; the surface roughness of copper rods for
semiconductor lead frames must be controlled within Ra0.1μm. Behind these extreme parameters
is the technological revolution of modern copper bar manufacturing equipment.
Melting revolution: purity control of nanoscale competition
A copper processing enterprise testing data show that the use of new vertical furnace melting system,
the oxygen content stabilized at less than 5ppm, the key technological breakthroughs include:
1. Melt purification third-order system
Electromagnetic stirring: 0.35T rotating magnetic field, inclusions uplift efficiency increased by 70
Ceramic filtration: 40ppi foam ceramic filter bed to intercept ≥ 10μm impurities
Vacuum degassing: reduce hydrogen content to 0.8ml/100g under 0.08Pa vacuum.
2. Intelligent temperature control matrix
Infrared thermometer: ±1℃ dynamic monitoring of melt temperature
Multi-stage gradient heating: the furnace body is divided into 8 zones of independent temperature control
Emergency cooling module: start liquid nitrogen emergency cooling within 3 seconds
Rolling process revolution: the art of deformation strengthening
A copper bar production line adopts three-roll planetary rolling technology to realize 85% deformation in a
single pass, with key technical features:
1. Roll dynamics innovation
Asynchronous rolling: the speed difference between the upper and lower rolls is maintained at 12-15%.
Curved roll design: 40% increase in contact arc length
Hydraulic adjustment of roll gap: precision ±0.01mm
2. Deformation heat treatment coupling
Online quenching: rolling outlet water temperature difference of ≤ 2 ℃
Strain induction: cumulative strain ε ≥ 4.2
Dynamic recrystallization: grain size refinement to 8μm
Finishing equipment matrix: the pinnacle of surface engineering
Aiming at the surface quality requirements of 5G heat dissipation copper rods, the latest finishing system
realizes three major breakthroughs:
1. Multi-modal joint drawing
Swimming core head technology: diameter reduction rate increased to 45%.
Ultrasonic assisted: pulling force reduced by 32%.
Nano-lubrication: coefficient of friction reduced to 0.03
2. Intelligent polishing system
Magnetorheological polishing: surface roughness Ra0.05μm
Visual inspection: 0.02mm defect recognition rate of 99.3%
Self-adaptive regrinding: 3 times longer life of abrasive belt
3. Stereoscopic heat treatment
Protective atmosphere annealing: oxygen content <3ppm
Multi-stage tension control: 92% residual stress relief
Grain boundary engineering: Σ3 grain boundary ratio＞65%
Energy efficiency and environmental protection: the way
to break the ice of green manufacturing
A demonstration base data show that the new production line tons of product energy consumption
reduced to 820kW-h, environmental protection technologies include:
Flue gas waste heat power generation: 31% recovery efficiency
Rolling oil regeneration system: 89% reuse rate
Closed loop copper chip recycling: 99.6% metal recovery rate
Electromagnetic shielding melting: noise reduced to below 75dB
Technology Foresight: Blueprint for Next-Generation Copper Rod Manufacturing
In the face of the extreme requirements for copper in 6G communications and fusion devices, the industry is advancing:
Ultra-fine crystal preparation: equal-channel corner extrusion technology
Composite reinforcement: graphene copper matrix composites
Digital Twin: Real-time optimization of process parameters
Hydrogen smelting: zero-carbon smelting technology development
Conclusion: When new energy automobile motors need copper conductors with a million times bending life, when
quantum computers are thirsty for zero-defect electromagnetic shielding copper rods, every evolution of
manufacturing equipment is breaking through the material limit. From plasma purification in melting furnaces
to ultrasonic vibration assistance in drawing machines, these technological innovations are reshaping the
technological landscape of the copper processing industry. Driven by both carbon neutrality and digital
transformation, copper rod manufacturing equipment will open a new era of precision, intelligence and green.