Copper - Conductivity and Versatility at the Heart of Industry
Copper is one of the oldest and most fundamental metals of industrial civilization. Its electrical conductivity, second only to silver among affordable materials, and its exceptional thermal conductivity make it the indispensable material for the electrical, electronic and thermal industries. Added to this is natural corrosion resistance, excellent formability and complete recyclability that make it an economically and ecologically justified choice.
Industrial copper properties
Pure copper (grades C10100 to C11000 per ASTM standards) offers the best conductivity properties, with an electrical conductivity of 100% IACS (International Annealed Copper Standard) for oxygen-free electrolytic copper (ETP copper). Its thermal conductivity (401 W/m·K) is approximately 25 times higher than stainless steel, explaining its predominant use in heat exchangers, heat sinks and cooling systems.
Pure copper’s mechanical strength is moderate (yield strength of 70 MPa annealed, rising to 350 MPa after maximum cold working), making it adequate for many applications without demanding high mechanical strength. Its ductility is exceptional, allowing significant deformation without fracture, which facilitates forming, stamping and bending into complex shapes.
Applications in the electrical industry
The electrical and electronic industry is the world’s primary copper user. Electrical conductors (cables, wires), bus bars for power distribution in industrial facilities, electrical contacts and connectors, transformer and motor windings, and switchboard components are the most important applications.
ADI Laval fabricates copper bus bars and distribution plates according to our clients’ specifications. These components are used in industrial distribution panels, electrical substations, welding stations and electrolysis installations. Dimensional precision of bus bars is critical for ensuring the required quality electrical connections.
Heat exchangers and thermal systems
Copper’s exceptional thermal conductivity makes it the reference material for heat exchangers in applications where compactness and efficiency are paramount. Water-to-water heat exchangers, oil coolers, refrigeration condensers, industrial radiators and power electronics cooling systems commonly use copper tubes, fins and plates to maximize thermal transfer.
In industrial HVAC and refrigeration systems, copper coils are the industry standard. Copper’s compatibility with the vast majority of refrigerants, its high thermal conductivity and its formability that allows complex coil fabrication make it the ideal material for these applications.
Industrial plumbing and fluid distribution systems
Copper has been used for centuries in plumbing installations thanks to its natural corrosion resistance in potable water, its antibacterial capacity (which inhibits the growth of Legionella and other pathogenic bacteria) and its long service life. In industrial installations, copper piping is used for potable water distribution, cooling water, low-pressure steam, medical gases and compressed air.
For pharmaceutical applications and laboratories, copper piping systems serve to distribute technical gases (oxygen, nitrogen, argon) and certain process fluids. Copper’s compatibility with these fluids and its ease of welding make it a practical choice for these systems.
Antibacterial properties and food applications
An often-overlooked property of copper is its intrinsic antibacterial activity. Scientific research has demonstrated that copper surfaces eliminate a significant proportion of common pathogenic bacteria (E. coli, MRSA, Staphylococcus aureus, Listeria) in a short time, without additional chemical products. This property has led to the increasing use of copper in hospitals (door handles, staircase railings, contact surfaces), industrial kitchens and food establishments.
ADI Laval can fabricate surfaces, countertops and equipment in copper for applications where the material’s antibacterial properties represent a sanitary advantage. These applications include professional kitchens, healthcare facilities, food processing installations and laboratories.
Copper welding and assembly
Copper welding presents technical specificities related to its high thermal conductivity, which rapidly dissipates heat from the weld pool, and its tendency to absorb gases (particularly hydrogen) at high temperature. To compensate for high thermal conductivity, local preheating may be necessary for thick-section parts. The choice of welding process (TIG, MIG, brazing) and adequate parameters is important for obtaining porosity-free welds with maintained conductivity.
ADI Laval masters the welding and brazing processes for copper alloys. Our technicians apply adapted procedures to guarantee quality assemblies that maintain the material’s electrical and thermal properties in the assembly zones.
Common Grades
| Grade | Characteristic |
|---|---|
| C11000 (ETP) | Electrolytic tough pitch, 100% IACS conductivity |
| C10200 (OFHC) | Oxygen-free, premium conductivity |
Technical Specifications
Industries & Typical Uses
- Bus bars and electrical distribution
- Heat exchangers and cooling
- Plumbing and fluid distribution
- Antibacterial surfaces
- Transformer components
Frequently Asked Questions - Copper
How does copper react to contact with stainless steel in a mixed piping system?
Direct contact between copper and stainless steel in a piping system with an electrolyte (water) can create a galvanic cell. Generally, stainless steel being more noble than copper, copper would be the anode (corroding metal). However, in practice, copper is also relatively noble and galvanic corrosion between copper and stainless steel is generally slow. To minimize this risk, it is recommended to use dielectric fittings at copper/stainless steel junctions, especially in systems with municipal or salt water. Our team can advise on best assembly practices for your specific system.
Is the green patina that forms on copper harmful to water or food quality?
The green patina (verdigris) is malachite or brochantite, copper carbonate compounds that form naturally on the surface of copper exposed to moist air. In a potable water piping system or food equipment, this patina does not form the same way as it requires air exposure. Copper pipes in permanent contact with water instead form a copper oxide (CuO) layer that protects the metal and is generally harmless. Copper ion concentrations in potable water passing through copper pipes are well below regulatory limits. However, for direct food contact applications, we recommend verifying applicable standards (NSF/ANSI 61 for example) and ensuring the copper grade used is compliant.