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COPPERTODAY AND TOMORROW Motor rotors, wind turbines, and anti-microbial surfaces demonstrate some of the capabilities of and its alloys. Ken Geremia Copper Development Association New York, New York

or nearly ten millennia, copper applica- tions have been evolving and involving nearly every facet of our lives. From cook- ware and construction to nuclear waste Fcontainment and nanotechnology, the applica- tions of copper are manifold. This article looks at some of the exciting projects going on today, such as copper motor rotors, copper wound turbines, structured wiring, and anti-microbial alloys, then Over the next few years, copper- and that could considers what is likely for the future. last ten years will continue to penetrate the automotive industry. They are fully competitive with today’s aluminum counterparts. Based on CuproBraze Die-cast copper motor rotor and design innovations developed with research funding from the Interna- tional Copper Association (ICA), these radiators are 35% to 40% lower in Die-casting technology patented by the Copper weight than traditional, nonoptimized copper-brass radiators, and are also Development Association (CDA) to fabricate correspondingly lower in material costs. copper motor rotors is being applied by SEW Eu- rodrive, Bruchal, Germany, and FAVI S.A., Hal- veloped by Verdant Power, Arlington, Va., is lencourt, France. Both companies confirm that the slated for the project. When completed, the system technology is economical for manufacture. SEW will generate ten megawatts of power. The system, claims that the technology provides a 14% to 18% which reverses to take advantage of the six-mph production cost advantage, plus a weight reduc- tidal water flow, does no harm to aquatic life and tion between 19% and 22% for equivalent motors produces no . with aluminum rotors. • Wind power: In 2004, wind power accounted A key advantage to end-users is significantly for about 1% of the nation’s generating capacity, improved electric motor nameplate efficiency – and estimates place its growth rate at 20% per year. 1% to 5% beyond today’s NEMA Premium effi- Wind turbines also rely on copper windings. For ciency standards, depending on motor size (1 to example, Austin Energy, Texas, has committed 50 hp). In addition, the new rotor design enables to supply 20% of its energy needs from renewable reduced weight and size, cooler running, and resources by the year 2020. California, Texas, Min- longer life. nesota, Iowa, and Wyoming lead the nation with The U.S. Defense Logistics Agency has invested a combined total of nearly 5000 megawatts. $2.2 million in the Copper-Based Casting Tech- • Solar power: Because of the volatility of the nology project over the past two years to develop, oil markets, solar power is encountering renewed test, and optimize AC induction motors, largely interest. Passive solar applications are being re- for retrofit of legacy weapons systems. Ramco vived, and such companies as ECD Ovonics (the Motors and Reliance Electric are participating in same folks working with NiMH storage systems, the project. Manufacturers in Europe, Asia, South see below) are developing new copper-intensive America, and North America are also pursuing photovoltaic applications. the new motor rotor technology. CDA study projects Power generation Looking at power distribution, CDA’s Elevated • Water power: New York City has built a new Ambient Study (EATS) continues to generation of copper-wound water turbines in make its mark on the National Electrical Code. the East River to power portions of the city. A farm The ongoing study is quantifying the tempera- of up to 300 of the 15-foot diameter turbines, de- ture rises associated with wire bundling (mainly ADVANCED MATERIALS & PROCESSES/JANUARY 2006 49 copper.qxp 12/28/2005 10:51 AM Page 2

the home. The reliability and economy of hard- wired copper systems in the home are expected to offset any encroachment from optical fiber into the next decade.

Automotive components Hybrid electric are taking off in the market place. Such vehicles include as much as 100 pounds of copper, and are doubling the amount of the red metal found in a typical , most of it in wiring and motors. Hybrid buses from GM’s Allison Division include copper rotors in the induction motors of their hybrids for greater efficiency. Nickel-metal-hydride batteries with copper negative electrodes offer improved per- formance for onboard storage systems. Meanwhile, the first phases of a study on the performance of copper alloys and plating systems during high-temperature exposure to transmis- Copper windings in wind turbines enable power generation. In 2004, wind sion and brake fluids have been completed. The power accounted for about 1% of the nation’s generating capacity, and estimates study should provide the auto industry and con- place its growth rate at 20% per year. nector suppliers with the information necessary residential applications) and wire inside conduits to specify plated copper alloys for service in these exposed to sunlight (mainly commercial applica- environments. tions). Study results recommend a derating of the conductors (moving to a larger size) under con- Antimicrobial properties ditions calculated to be unsafe for the insulation Recent studies have shown that copper alloys on a smaller conductor. containing 65% or more copper can eradicate CDA is in the midst of a multiyear study eval- harmful bacteria in a matter of hours. This is ex- uating underground of electrical pected to have a dramatic effect on the touch sur- grounding electrodes. Again, the study’s objec- faces and HVAC equipment specified for health- tive is to determine if Code requirements are suf- care and other public facilities. ficient. The degree of corrosion can raise Hospital-acquired infections are on the rise, re- grounding resistance and allow it to rise above portedly accounting for more than 90,000 deaths acceptable levels. This is especially important for annually. CDAstudies suggest that combining facilities operating sensitive equipment, such as good hygienic practice with copper or selected al- medical diagnostics or emergency communica- loys for such items as door hardware, bed rails, tions. Five sites around the nation are being used bed trays, IV stands, countertops, and other work for this multiyear study. surfaces, could dramatically reduce cross- contamination. Structured wiring Similar studies indicate that copper in the coils, Gone are the days of the four-conductor wiring fins, and condensate drain pans in HVAC systems for telephones. The FCC now requires a minimum have a similarly dramatic effect in reducing air- of Category 3 wiring for home telecommunica- borne pathogens and significantly improving in- tions. All category wiring contains four twisted door air quality. As a bonus, copper’s higher pairs of copper conductors. The latest iteration, would provide for improved Cat5E and Cat6 structured wiring, is now finding energy efficiency. its way into more than half of all new homes in CDA is currently validating its research with a the United States, and that proportion is increasing series of required tests at a U.S. EPA-certified lab- yearly. Coupled with RG-6 coax cable, this wiring oratory to complete registration of health claims offers broadband service to outlets throughout under the Federal Insecticide, Fungicide, and Ro- Total U.S. Copper Consumption in 2004: 7822 million pounds Major Markets Wire and Brass Mill Products Building Construction 49.0% Wire & Cable 47.0% Electrical and Electronic Products 20.8% Rod, Bar & Mechanical Wire 15.9% Transportation Equipment 10.8% Strip, Sheet & Plate 15.5% Consumer and General Products 10.7% Plumbing Tube 10.2% Industrial Machinery and Equipment 8.7% Commercial Tube 8.3% Foundry, Casting & Powder Products 3.1% Source: Copper Development Association Inc. The complete CDA Annual Data Report can be found at www.copper.org. Click on Resources & Tools > Market Data > CDAAnnual Data 2005. 50 ADVANCED MATERIALS & PROCESSES/JANUARY 2006 copper.qxp 12/28/2005 10:51 AM Page 3

denticide Act. It would be the only metal to achieve such recognition. NEW BOOK RELEASE The future with copper Copper applications will continue to grow in ASM Handbook Volume 14A: critical areas such as energy efficiency, alternative energies, healthcare, communications, transporta- Metalworking: tion, security, and the environment. • Electronics: Microchip and nanotechnology Bulk Forming applications are also areas where we expect fur- ther developments that will take advantage of copper’s high thermal and electrical conductivity. Further into the future, we may even see specially strengthened copper components in advanced nuclear fusion equipment as an alternative en- ergy source. Yet another avenue of investigation is increasing the wear resistance of copper-based electrical contacts to ensure the smooth flow of energy and increased product reliability. • Transportation: Hybrid electric vehicles with highly conductive and compact copper-wound motors will become more efficient and ubiqui- tous. Light rail vehicles, with copper in motors and cabling, will also grow in popularity to sup- port commuters who want to avoid high gas prices. • Security: Elsewhere, copper is at the heart of the radio frequency identification (RFID) tech- nology for security, tracking, and purchasing sys- tems in retail, manufacturing, transportation, and distribution. For example, RFID allows customers at gas stations to pay at the pump by waving a small wand that holds their credit card informa- ASM Member: $178 tion. Copper increases the distance at which this Non-Member: $220 “invisible” technology will work. • Environment: Copper will continue to con- Order #06957G tribute in environmentally sound ways. Its long Volume 14A is an indispensable reference for life cycle and high recycling rate make copper the manufacturing, materials, and design engineers. Providing greenest of metals in architecture and building coverage of the process-design relationships that are needed construction. The ability of copper to remove con- to select and control metalworking operations that produce taminants from petroleum is being researched, as shapes from forging, extrusion, drawing well as its ability to detect potential bacterial and rolling operations. agents in aboveground water supplies. Some of the new topics and coverage include: • Architecture: Inventive fabrication and ap- • Innovations with forming processes: plication methods will enable architectural copper Equal-channel angular extrusion & advanced roll-forming to enhance exteriors in an array of colors and tex- techniques tures. Interiors will benefit from copper’s allure • Forming of special-purpose materials: in kitchen appliances, countertops and other sur- Intermetallic alloys faces – residential and commercial. Today, to- and composites morrow and well into the future, copper will con- • Advanced thermomechanical processes tinue to reveal its timeless beauty as well as its (ferrous & non-ferrous alloys) extraordinary range of inherent physical and me- • Process and material behavior models, process chanical attributes. optimization, and the properties of workpiece and die materials TO ORDER, CONTACT: ASM International Customer Service Center 9639 Kinsman Road Materials Park, OH 44073-0002 1-800-336-5152, ext. 6 OR 440-338-5151, ext. 6 (Outside U.S.) For more information: Ken Geremia, Copper Devel- Fax: 440-338-4634 opment Association, New York, NY 10016; tel: 212/251- www.asminternational.org/Volume14A 7209; e-mail: [email protected]; Web site: E-mail: [email protected] www.copper.org. ADVANCED MATERIALS & PROCESSES/JANUARY 2006 51