When To Choose Copper for Die Casting

When applications demand excellent thermal conductivity, corrosion resistance, and mechanical strength, copper die casting offers a superior solution. At Neway, we provide precision copper die casting services for industries that require parts capable of withstanding aggressive environments and mechanical stress—particularly in marine, electrical, and industrial applications.

This article outlines the key advantages of copper alloys in die casting and guidelines on when to choose copper over aluminum or zinc for your project.

Advantages of Copper Alloys in Die Casting

Copper and copper-based alloys such as brass and bronze exhibit a unique combination of physical and mechanical properties that make them ideal for specialized casting applications.

Exceptional Thermal and Electrical Conductivity

Copper is second only to silver in electrical and thermal conductivity. Pure copper (C101) has a thermal conductivity of approximately 390 W/m·K and an electrical conductivity of 100% IACS. Even copper alloys like Brass 360 and CuZn40 maintain excellent conductive properties, making them ideal for:

• Electrical terminals and bus bars

• Heat exchangers and radiator components

• High-power switchgear parts

Outstanding Corrosion Resistance

Copper alloys resist environmental degradation, oxidation, and many corrosive chemicals. Alloys like CuNi10Fe1 are commonly used in marine systems due to their resistance to saltwater and biofouling. For plumbing and fluid-handling systems, copper alloys prevent bacterial growth and degradation.

Typical corrosion performance includes:

• Salt spray resistance exceeding 1,000 hours (with proper surface finish)

• Resistance to acidic and alkaline environments

• Stable performance in high-humidity and coastal atmospheres

High Mechanical Strength and Wear Resistance

Copper-based die casting alloys can achieve tensile strength levels ranging from 310 to 450 MPa and Brinell hardness values up to 150 HB. This makes them suitable for components that must withstand continuous mechanical stress, friction, or impact.

Applications include:

• Valve bodies and impellers

• Mechanical bushings and wear rings

• High-pressure fittings and couplings

When to Choose Copper for Die Casting Projects

Copper die casting is typically recommended for parts requiring the following performance characteristics:

1. High Thermal or Electrical Conductivity

Copper’s unmatched conductivity makes it the first choice for:

• Electrical contact points and bus bars

• Grounding clamps and terminals

• Heat sinks and high-efficiency heat spreaders

While aluminum is a common alternative, copper offers approximately 60% higher electrical conductivity and significantly better thermal inertia, especially under high-load conditions.

2. Resistance to Corrosive Environments

For marine and industrial fluid systems, copper and brass components provide:

• Long-term stability in saline, chlorinated, or chemically aggressive environments

• Resistance to dezincification and stress corrosion cracking in alloys such as Brass 464

• Reliable performance in HVAC, potable water, and fire suppression systems

This makes copper alloys ideal for:

• Water pump housings and manifolds

• Naval hardware and offshore structures

• Industrial process valves and fittings

3. High Mechanical Load and Friction Applications

Copper alloys have exceptional fatigue and impact resistance. Alloys such as C18200 and C17500 are frequently used in:

• High-speed rotating components

• Resistance welding electrodes

• Structural support brackets and couplings

These materials provide superior performance in applications with repeated load cycles, vibration, or surface contact.

4. Antimicrobial or Bio-Safe Requirements

Copper and its alloys possess inherent antimicrobial properties, making them ideal for:

• Medical equipment and touch surfaces

• Sanitary fittings in hospitals and laboratories

• Drinking water and food-grade plumbing systems

Studies show that copper surfaces can kill 99.9% of bacteria such as E. coli and MRSA within 2 hours of exposure.

5. Decorative and Architectural Components

Copper-based alloys are often selected for components requiring both aesthetic appeal and durability. When combined with Neway’s post-processing treatments—such as polishing, painting, or plating—copper parts can achieve both high functionality and luxury-grade finishes.

Common Copper Die Casting Alloys

Brass 360

• Tensile strength: ~345 MPa

• Hardness: ~80 HB

• Machinability rating: 100 (industry benchmark)

• Used in connectors, plumbing parts, decorative fittings

CuZn40

• Higher strength and corrosion resistance

• Cold-workable and pressure tight

• Used in industrial fluid and gas systems

CuNi10Fe1

• Exceptional seawater corrosion resistance

• Tensile strength: ~390 MPa

• Used in naval, offshore, and marine components

C18200 (Chromium Copper)

• Tensile strength: up to 450 MPa

• Electrical conductivity: ~80% IACS

• Used in welding, switchgear, and thermal dissipation systems

View our complete selection of copper/brass alloys for more technical data.

When Copper May Not Be Ideal

Despite its advantages, copper die casting may not be suitable for every scenario:

• Copper’s melting point (1085 °C) results in increased tool wear and energy usage

• Die life is shorter compared to zinc or aluminum, especially for high-complexity molds

• Higher material cost and processing difficulty may affect the feasibility for non-critical applications

• Extremely thin walls (<1.0 mm) are more difficult to cast compared to zinc

Consider zinc die casting or aluminum die casting for less demanding environments or lower-cost applications.

Full-Service Copper Casting Support from Neway

At Neway, we offer a complete end-to-end solution for copper die cast parts:

• Design for Manufacturability for mold-friendly geometries and thermal control

• Tool and die making using hardened steel with thermal regulation

• Rapid prototyping for early validation

• Post-machining, finishing, and assembly in-house

• Low-volume manufacturing to mass production with ISO 9001:2015-certified quality

We guide customers through material selection, process optimization, and lifecycle management to maximize value and performance.

Conclusion

Copper die casting is a powerful choice for components that must excel in conductivity, corrosion resistance, durability, and wear resistance. It is ideal for demanding marine, electrical, medical, and mechanical applications where performance and reliability are non-negotiable.

If you’re considering copper alloys for your next project, contact Neway for a quote or technical consultation.

Frequently Asked Questions

1. What are the most common copper alloys used in die casting?

2. Can copper die cast parts be used in saltwater or marine environments?

3. How does copper compare to aluminum and zinc in conductivity and strength?

4. What are typical applications for copper die casting?

5. What are the challenges of casting copper-based alloys?