Custom Copper Tubing

Fabmann is committed to providing custom copper tubing fabrication service, and our production mainly involved in three different production solutions such as cold drawing, cold rolling and extrusion, and our experienced engineering team can achieve very tight tolerance and smooth inner surface for maximum conductivity performance with extended service life span for your projects. Plus, we also provide insulation service for hollow conductors, and all production is fully traceable with complete quality documents like MTC, chemical analysis, electrical conductivity and full measurement control.

Custom Copper Tubing

Section Dimension Tolerance

To meet demanding technical requirement, Fabmann engineers work very closely with tooling and production division teammates, and we implement very strict pilot run control, also called first article inspection control before mass production starts. Fabmann can supply all kind of copper tubing from thin wall (0.1mm) upto wall thickness 35mm.

 Quality Control

Hydrogen and Oxygen Analyzer

Our team takes full control from smelting, casting, peeling, cold rolling, cold drawing, annealing and packing, and each process is taken good care of by our experienced operators. Our production control mainly covers following aspects:

√ Chemical Analysis

√ Section Dimension & tolerance

√ Eddy Current Test

√ Grain Size if Required

√ Mechanical Property (hardness, tensile and yield strength, elongation)

√ Electrical Conductivity

√ Thermal conductivity if required

√ Inner surface roughness if required

√ Hydrogen and Oxygen content if required, and this is mainly required.

√ Hydrogen Embrittlement.

√ 90 degree bending test at different temperature.

Application

Our custom copper tubing is mainly used as hollow conductors which offers a unique combination of high current-carrying capacity, efficient cooling, and reduced weight, making them suitable for various demanding applications below:

√ Power Transformers, used in transformer windings minimize energy losses, improving the overall efficiency of the transformer. A smaller size of hollow conductors allows for more compact transformer designs, reducing space requirements and installation costs. The efficient cooling of hollow conductors helps maintain optimal operating temperatures, extending the lifespan of the transformer.

√ Electric Vehicles (stator direct cooling), it has lightweight and compact design of electric vehicle battery packs and charging systems, and they facilitate efficient and rapid charging of electric vehicle batteries, reducing charging times and improving user experience. The reduced weight of hollow conductors contributes to increased driving range for electric vehicles.

√ Aerospace, the light weight is crucial for aircraft and spacecraft, where every gram saved translates to increased fuel efficiency and payload capacity meanwhile hollow conductors can handle the high power requirements of onboard electrical systems, supporting critical functions like navigation, communication, and propulsion. Additionally, efficient cooling of hollow conductors ensures reliable operation in the harsh thermal conditions encountered during flight.

√ Pulse Magnets, it's ideal for generating high-intensity magnetic pulses in research and industrial applications due to their ability to handle large currents without overheating, meanwhile the efficient cooling of hollow conductors allows for rapid repetition rates of magnetic pulses, essential for various applications. The smaller size of hollow conductors enables the design of more compact and efficient pulse magnet systems.

√ Military Applications, it can be used in high-power radar systems due to their ability to handle the high currents required for generating powerful radar signals, and the high current-carrying capacity and efficient cooling of hollow conductors make them suitable for powering lasers and other directed energy weapons.

Our custom copper tubing is also widely used in following applications:

√ MRI devices / gradient coils

√ Particle accelerators

√ Generators

√ Induction furnaces / induction heating and melting

√ Plasma research devices

√ Electrodynamic vibration test systems

√ Ion implantation units for the microcircuit industry

√ High gradient separators

√ Waveguides

√ Liquid cooled transformers

Fabmann custom copper tubing offers significant advantages in various applications requiring high power, efficient cooling, and weight reduction. Their unique properties make them a valuable asset in power transmission, electric vehicles, aerospace, pulse magnets, military applications, and other demanding fields. Fabmann can assist you to develop the suitable hollow conductor design for your specific needs.

Drawing of Copper Tube

Copper and Copper Alloy Equivalences

Benefits of Using Copper and Copper Alloy Equivalences:

Copper and copper alloy equivalences are very useful because it will speed up the product development process, and each country has its own national material classification. Most countries are referring to US or European material standards, and equivalences allow for the consistent use of materials across different industries and applications. Plus, it allows for the substitution of one material for another without significantly affecting the performance of the product.

As a result, your designers and engineers can choose the most cost-effective material for the needs if they know the equivalents. Fabmann has a wide supply net work of different copper and copper alloy grades both in western and Chinese equivalent copper materials. Below is the most used copper materials and their chemical compositions:

Copper Material Equivalences

Copper and Copper Alloy Material Options

There are hundreds of different copper and copper alloys which are used tubing, and each serves different application.

The table below short lists the most common copper materials with their main chemical composition. In particular, copper and oxygen content is very critical final product performance and reliability.

Copper Designation & Chemical Composition

In all other elements (other than copper) are defined as the sum of Ag, As, Bi, Cd, Co, Cr, Fe, Mn, Ni, O, P, Pb, S, Sb, Se, Si, Sn, Te, And Zn, with the exclusion of any item whose value this indicated individually.

a. Including silver, to a maximum of 0.015%. b Up to 0.060% of oxygen content is permitted, subject to an agreement between buyer and supplier. c Oxygen content must be such that the material complies with the requisites for embrittlement by heating in a hydrogen atmosphere as in Norm EN 1976.

Mechanical Test of Copper Tube

Why copper tube mechanical and temper is important?

As we all know that mechanical & electrical properties are crucial for copper tubes like hollow conductors, which are widely used in various applications including MRI devices, generators, particle accelerator and waveguides. Therefore, the mechanical properties play a significant role in ensuring the performance, reliability, and safety for the relevant applications. Most of the time, the copper tubes are subjected to repeated stress cycles during operation, which can lead to fatigue failure, and this is why we shall have a thorough understanding of both mechanical and electrical properties with different tempers. Below is the a general guideline information of copper tubes with different tempers for copper tubes:

Copper Tube Mechanical Property

 Copper Electrical Property

NOTE 1

The IACS % values are calculated as percentages of the normalized value of high conductivity annealed copper, according to those established by the International Electrotechnical Commission. Copper whose volume resistivity is of 0,017 24 Ω x m, at 20ºC, is defined as that corresponding to a conductivity of 100%.

Custom Copper Tube Type

 

Fabmann's custom copper tubing is primarily designed for green energy, power transmission, power generation, MRI, radar and particle accelerator, and the following is our main copper tube range:

 

√ Hollow conductor

√ Custom hollow conductor for furnace

√ Standard waveguide tube & custom waveguide tube

√ Finned copper tube

√ Inner grooved copper tube

√ Level Wounded Copper (LWC) Tube

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