Which copper alloys provide the best conductivity for automotive cooling systems?
Which Copper Alloys Provide the Best Conductivity for Automotive Cooling Systems?
Importance of Conductivity in Automotive Cooling Components
In automotive cooling systems—such as radiators, heat exchangers, and electric motor cooling channels—copper is favored for its exceptional thermal conductivity, corrosion resistance, and manufacturability. The right copper alloy ensures fast and efficient heat transfer, system stability under thermal cycling, and compatibility with glycol-based coolants. Neway Die Casting recommends high-conductivity alloys like C11000, C12200, and C18200 for these demanding environments.
Best Copper Alloys for Thermal Conductivity
C11000 – Electrolytic Tough Pitch (ETP) Copper
Thermal conductivity: 390–400 W/m·K
Electrical conductivity: ≥100% IACS
Ideal for heat exchanger plates, electric vehicle cooling plates, and battery cooling modules
Excellent for parts requiring high purity and brazing compatibility
C12200 – Phosphorous Deoxidized Copper
Thermal conductivity: ~330 W/m·K
Resistant to hydrogen embrittlement, suitable for brazed joints
Preferred for tubes, manifolds, and sealed cooling enclosures
Complies with ASTM B75 and B88 for plumbing and HVAC applications
C18200 – Chromium Copper
Thermal conductivity: ~320 W/m·K
Enhanced mechanical strength with good thermal performance
Suitable for thermally and mechanically loaded parts like connectors or pump housings
Stable under pressure and thermal fatigue conditions
Comparison of Copper Alloys for Automotive Cooling
Alloy | Thermal Conductivity | Key Strength | Common Applications |
|---|---|---|---|
C11000 | 390–400 W/m·K | Maximum conductivity | Heat exchanger fins, EV battery plates |
C12200 | ~330 W/m·K | Excellent brazing & ductility | Radiator tubes, coolant manifolds |
C18200 | ~320 W/m·K | High strength & wear resistance | Pump components, high-load fittings |
Standards and Validation
Neway ensures all copper components meet or exceed:
ASTM B124 / B75 / B88 – Standards for copper rod, tube, and die castings
ISO 16348 – Copper alloy casting tolerances
SAE J461 / J463 – Copper alloy composition and mechanical property specifications
Thermal performance is validated through thermal conductivity tests and accelerated coolant exposure to ensure resistance to corrosion and erosion.
Customer-Oriented Copper Casting Solutions
Neway Die Casting offers complete support for automotive cooling component production:
Copper Die Casting Services: High-conductivity alloy solutions for thermal applications
Post-Machining Services: CNC finishing of mating surfaces, flanges, and sealing paths
Engineering Support: Material and design consultation for thermally optimized cooling components
