by Kat Griffin Kat Griffin

Why Should I Use Copper Impregnated Graphite: EC-15C and HK-6C?

copper impregnated graphite

Copper impregnation provides increased resistance to erosion and corrosion, making Copper Impregnated Graphite suitable for harsh operating conditions and chemically aggressive environments. Copper Impregnated Graphite, specifically EC-15C and HK6-C grades, offer several advantages that make them a preferred choice in various applications like electrodes. 

top 3 benefits of using copper impregnated graphiteSome reasons you should consider using EC-15C and HK-6C grades include:

  1. Higher Electrical Conductivity:

    Copper impregnation significantly improves the electrical conductivity of the graphite material. This makes it ideal for applications where high electrical conductivity is essential, such as in electrical discharge machining (EDM), electrical contacts, and other electrical applications.

  2. Flexural Strength:

    Flexural strength is a crucial aspect to consider when evaluating electrodes. Unlike other materials, copper graphite is suitable for wire EDM to cut at higher speeds and provide finer finishes. EC-15C and HK-6C is an excellent choice for EDMing carbide and exotic alloys, as well as work pieces with limited flushing conditions. 

  3. Improved Thermal Conductivity:

    Copper impregnation also enhances the thermal conductivity of the graphite material. This property enables efficient heat dissipation, making it suitable for applications that require effective thermal management, such as heat sinks, thermal interfaces, and electronic cooling systems.

  4. Increased Mechanical Strength:

    Copper impregnation strengthens the graphite matrix, resulting in improved mechanical strength and stability. This makes Copper Impregnated Graphite more resistant to chipping when machining thin ribs and sharper detail, ensuring better durability and resistance to wear or deformation in demanding applications.

  5. Electrode Wear:

    Copper impregnation provides increased resistance to erosion, making copper graphite suitable for harsh operating conditions and chemically aggressive environments. Utilizing this metal is less prone to DC arcing in poor flush conditions. 

  6. Metal Removal Rates (MRR):

    Copper graphite used on common metal substrates have higher metal removal rates in roughing applications than standard graphite. Properties of copper graphite offer lower resistivity, higher flexural strength, high conductivity, and better finish with lower amperage settings which improves electrode wear.

  7. Versatile Applications:

    Copper Impregnated Graphite finds applications across various industries, including automotive, aerospace, electronics, power generation, and more. It can be used in EDM electrodes, current-carrying components, thermal management solutions, seals, gaskets, and other high-performance applications.

It is important to note that when selecting the appropriate electrode material for an EDM job, several factors come into play. Copper impregnated graphite has proven to be a suitable choice for EDM electrodes in various applications. However, the decision to opt for this material depends on specific application requirements and the desired outcomes. It is crucial to evaluate these variables carefully in order to make an informed choice regarding the use of copper impregnated graphite as the electrode material.

by Kat Griffin Kat Griffin

Applications of Graphite Electrodes

Operator uses graphite EDM electrode to make precision mold and die.

Graphite electrodes have a wide range of applications due to their high electrical conductivity, high thermal resistance, and ability to withstand high temperatures. They are extensively used in the steel and aluminum industries for electric arc furnaces, specialty metals and alloys, and electrical discharge machining (EDM) for shaping metal parts. In addition, they are used as anode material in lithium-ion batteries.

EDM Applications

Synthetic graphite electrodes are commonly used in electrical discharge machining (EDM), which is a thermal energy-based manufacturing process that involves removing material from an object by using electrical sparks. The sparks are generated between a graphite or metal electrode and the workpiece, which is submerged in a dielectric fluid. The thermal energy generated by the sparks vaporizes the material, leaving behind a precise and accurate shape.

EDM is often used for small-volume production, as well as for making complex shapes and intricate details that are difficult to achieve with conventional machining methods. It’s also regularly used in the production of dies, molds, and other metal parts for industries such as aerospace, automotive, medical, and electronics.

EDM Applications Using Graphite Electrodes

EDM applications require specific electrode materials and shapes to achieve the desired results, and the choice of electrode will depend on factors such as the type of metal being machined, the desired accuracy and precision, and the production volume.

Regular uses for graphite electrodes in EDM include:

  • Die-sinking EDM: Graphite electrodes are used to make metal molds and dies for various industries, such as automotive and aerospace.
  • Wire EDM: Graphite electrodes can be cut using the wire electrical discharge machining (wire EDM) process to produce complex shapes and intricate details in metal parts.
  • Profile EDM: Graphite electrodes are used to make metal parts with specific shapes, such as gears and camshafts.
  • Micro EDM: Graphite electrodes are used to make micro-scale metal parts, such as medical implants and electronic components.

It’s important to note that the choice of graphite electrode material and its properties, such as electrical conductivity, thermal conductivity, and hardness, will depend on the specific EDM application and the requirements of the metal parts being machined.

by Kat Griffin Kat Griffin

Why is graphite used for electrodes?

electrode made out of graphite
Electrodes can be made from any conductive material. Depending on the nature of the application, electrodes are typically from graphite. Noble metals like gold, silver or platinum can be used but are very expensive. Copper, titanium and brass are other options, but they are also costly.

Graphite is used as an electrode material because it is a good conductor of electricity, is chemically stable, and can withstand high temperatures. It also has a low reactivity and thermal expansion coefficient, making it suitable for electrode use in electrochemical cells.

Graphite is a Good Conductor of Electricity

Graphite’s unique structure, with layers of carbon atoms arranged in hexagonal, allows the electrons to move freely, making it a good conductor of electricity and useful as an electrode material.

In graphite, the carbon atoms are arranged in layers, retaining their structure through covalent bonds. A significant feature of graphite’s structure is the number of delocalized electrons present. Graphite requires only three of its outer energy electrons to bond, leaving the fourth free to act in a delocalized manner. Delocalized electrons are not readily associated with a particular atom and move freely. These electrons enable graphite to exhibit a high level of conductivity, explaining why the material is frequently used for electrodes.

Graphite Electrode Materials

Check out MWI’s graphite product guide that contains information for our Electro-Carb “EC” family of graphite electrode materials. Graphite grades include EC-4, EC-12, EC-14, EC-15, EC-15C. EC-16, EC-17, HK-6, and HK-6C.

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