Copper C110 vs C122: Comprehensive Comparison for Intermediate Professionals

When it comes to selecting the right type of copper for your projects, understanding the nuances between different grades is crucial. Copper C110 and C122 are two commonly used types, each with unique properties that can significantly impact performance in various applications. Are you curious about which has better corrosion resistance or is easier to weld and form? This comprehensive comparison will delve into the material composition, mechanical properties, corrosion resistance, and more, providing intermediate professionals with the insights needed to make informed decisions. Ready to discover which copper variant best suits your needs? Let’s dive in.

Material Composition and Processing

Copper C110, commonly known as Electrolytic Tough Pitch (ETP) copper, is composed of approximately 99.9% copper with a maximum of 0.04% oxygen. The presence of oxygen enhances electrical conductivity, making C110 ideal for electrical applications, though it can lead to hydrogen embrittlement during welding, requiring careful control of the welding environment.

Copper C122, also called Deoxidized High Phosphorus (DHP) copper, contains about 99.9% copper and 0.015–0.040% phosphorus. Phosphorus acts as a deoxidizer, reducing porosity and improving weldability, making C122 suitable for extensive welding applications like plumbing.

Phosphorus in C122 copper deoxidizes the material, which enhances its weldability and reduces porosity. By eliminating oxygen, phosphorus prevents the formation of oxide inclusions, resulting in cleaner and stronger welds. This characteristic is particularly beneficial in plumbing applications where joint integrity is paramount.

Copper C110 is primarily processed using cold working techniques due to its high electrical conductivity and moderate ductility. Common methods include drawing, bending, and stamping. However, the oxygen content in C110 poses challenges during welding and requires specific atmospheres to prevent hydrogen embrittlement. Heat treatments can also be applied to achieve desired mechanical properties.

Copper C122 benefits from its deoxidized nature, making it more suitable for welding compared to C110. Processing methods for C122 include annealing, brazing, and welding, all of which are easier due to the phosphorus content that reduces the risk of cracking and improves weld quality. Additionally, C122 is often used in applications where bending and shaping are required due to its superior ductility.

The processing methods applied to copper alloys significantly impact their final material properties. For C110, cold working enhances its tensile strength and hardness but may introduce risks of cracking if not managed properly. On the other hand, C122’s processing benefits from phosphorus deoxidation, which maintains its ductility and weldability, resulting in fewer defects and improved joint strength. Both alloys exhibit distinct characteristics that must be considered when selecting the appropriate copper type for specific applications.

Mechanical Properties

Tensile Strength Comparison

Tensile strength is a key mechanical property for both Copper C110 and C122, affecting their suitability for various applications.

Copper C110 Tensile Strength

Copper C110 exhibits high tensile strength, particularly when cold-worked. In its soft, annealed condition, it has a typical ultimate tensile strength of around 31,900 psi, which can increase significantly to up to 50,000 psi when processed to harder tempers such as half-hard (H02) and full-hard (H04). This characteristic makes C110 an excellent choice for applications requiring both high strength and good electrical conductivity.

Copper C122 Tensile Strength

Copper C122 generally has a tensile strength similar to the annealed form of C110, about 32,000 psi. The addition of phosphorus improves its fabrication properties rather than its tensile strength. Consequently, C122 is often selected for applications where ease of welding and forming are more critical than achieving higher tensile strength.

Yield Strength Comparison

Yield strength, which indicates the stress at which a material begins to deform plastically, is another key factor to consider.

Copper C110 Yield Strength

In its soft, annealed state, C110 typically has a yield strength of around 10,000 psi, which can increase up to 45,000 psi with cold working. This range allows C110 to be tailored for different mechanical requirements, balancing strength and ductility as needed.

Copper C122 Yield Strength

Copper C122 generally displays a consistent yield strength of about 10,000 psi in its soft temper. The presence of phosphorus does not significantly alter this property compared to C110. Thus, C122’s yield strength is comparable to the annealed condition of C110, making it suitable for applications where moderate strength and enhanced fabrication properties are essential.

Other Relevant Mechanical Properties

Apart from tensile and yield strength, other mechanical properties such as hardness, machinability, and formability are important for understanding the overall performance of these copper alloys.

Hardness

Copper C110’s hardness can vary widely depending on its temper. In the half-hard condition, it typically has a Rockwell B hardness of around 40. This hardness increases with further cold working, providing a range of options for different applications. Copper C122 does not usually have its hardness specified in the same way, as its primary benefits lie in weldability and formability rather than hardness.

Machinability

Both Copper C110 and C122 have relatively low machinability compared to free-cutting brass, with a machinability rating of about 20% relative to C360 brass rod. This means they are more challenging to machine but can still be processed with appropriate techniques and tools.

Formability and Weldability

Copper C122 is excellent for formability and weldability due to phosphorus, making it ideal for plumbing and heat exchanger tubing. This makes C122 particularly advantageous for complex shaping and extensive welding applications. Copper C110, while also good in formability, does not match the weldability of C122 due to the risk of hydrogen embrittlement from its oxygen content.

By comparing these mechanical properties, it becomes clear that the choice between Copper C110 and C122 depends on the specific requirements of the application, balancing strength, formability, and weldability to achieve optimal performance.

Corrosion Resistance

Corrosion Resistance of Copper C110

Copper C110, known as Electrolytic Tough Pitch (ETP) copper, is highly valued for its excellent corrosion resistance. A small amount of oxygen in its composition is key to its corrosion resistance. When exposed to water and atmospheric conditions, the oxygen forms a stable, protective oxide layer on the surface. This oxide layer acts as a barrier, preventing further oxidation and effectively safeguarding the underlying metal from corrosive elements. This makes C110 particularly suitable for applications in water environments, such as plumbing and tubing, where long-term durability is essential.

Corrosion Resistance of Copper C122

Copper C122, known as Phosphorus-Deoxidized High Residual Phosphorus (DHP) copper, also has excellent corrosion resistance due to its deoxidation process, which reduces oxygen content, minimizing porosity and enhancing integrity. While phosphorus improves the weldability and formability of C122, it does not notably alter its corrosion resistance compared to C110. C122 performs exceptionally well in similar environments, including water and atmospheric conditions, making it a reliable choice for plumbing and industrial applications.

Comparative Analysis in Water and Plumbing Applications

Both Copper C110 and C122 show high corrosion resistance in water and plumbing applications, with some subtle differences:

• Protective Oxide Layer: Copper C110 benefits from the formation of a protective oxide layer due to its oxygen content, which slightly enhances its resistance to further oxidation. This makes C110 slightly more resistant in some specific scenarios, especially in fresh water applications.

• Phosphorus Deoxidation: While the phosphorus in C122 improves its weldability and reduces porosity, it does not significantly impact its corrosion resistance compared to C110. Both alloys are equally effective in resisting corrosion in typical water and atmospheric environments.

Factors Influencing Corrosion Performance

Several factors influence the corrosion performance of both Copper C110 and C122:

• Environmental Conditions: Both C110 and C122 perform well in water and atmospheric conditions. However, in highly corrosive environments, such as those with high chloride concentrations, additional protective measures may be necessary.

• Mechanical Properties: C110’s higher tensile and yield strengths in harder tempers can indirectly enhance its corrosion resistance by better resisting mechanical damage, which can expose the metal to corrosion.

• Fabrication and Joint Integrity: The superior formability and weldability of C122, due to phosphorus deoxidation, can lead to better joint integrity and fewer defects during fabrication. This can indirectly enhance corrosion resistance by reducing potential sites for corrosion initiation.

Practical Considerations

For practical applications, both Copper C110 and C122 are suitable for plumbing and tubing due to their excellent corrosion resistance. The choice between them often depends on factors like mechanical strength and ease of fabrication:

• Copper C110: Preferred when slightly better corrosion resistance is desired, along with higher mechanical strength.

• Copper C122: Chosen for its superior weldability and formability, making it ideal for complex fabrications and extensive welding applications.

Formability and Weldability

Formability

Copper C110 is known for its high electrical and thermal conductivity and has decent formability. However, its formability is somewhat limited by the presence of oxygen. Oxygen in C110 reduces its ductility, making it less malleable than other copper grades. Despite this, C110 can still be effectively shaped, bent, and drawn for various applications, though it may not be as ideal for complex forming operations.

Copper C122, on the other hand, excels in formability due to its deoxidized nature. Phosphorus in C122 removes oxygen, increasing its ductility and making it easier to shape and form. This increased malleability is particularly beneficial in applications that require extensive bending, shaping, and forming, such as plumbing and HVAC systems. C122’s superior formability allows for the creation of intricate pipe and tubing shapes without the risk of cracking.

Weldability

Weldability is the ease of welding a material without defects. Copper C110’s weldability is affected by its oxygen content, which can cause porosity and hydrogen embrittlement during welding. These issues necessitate careful control of the welding environment, often requiring a protective atmosphere or specialized welding techniques to prevent defects. As a result, C110 is generally less preferred for applications that involve extensive welding.

Copper C122 offers significantly better weldability due to its deoxidized composition. The phosphorus content in C122 minimizes the presence of oxygen, reducing the risk of porosity and cracking during welding. This leads to cleaner, stronger welds, even with standard methods. The improved weldability of C122 makes it a preferred choice for plumbing, HVAC systems, and other applications where reliable and high-quality welding is essential.

Advantages of C122 in Welding and Forming

Copper C122’s enhanced formability and weldability provide several advantages:

• Improved Ductility: The absence of oxygen and the presence of phosphorus in C122 increase its ductility, making it easier to shape and form without cracking.
• Cleaner Welds: The deoxidized nature of C122 reduces the likelihood of porosity and hydrogen embrittlement, resulting in stronger and more reliable welds.
• Versatility: These properties make C122 highly versatile, suitable for a wide range of applications that require both intricate forming and high-quality welding, such as plumbing and heat exchanger tubing.

Common Applications

Applications of Copper C110

Copper C110 is ideal for electrical wiring, bus bars, and connectors because of its high electrical conductivity, ensuring efficient transmission of electrical current. Its superior electrical conductivity makes it indispensable in the manufacturing of electrical components, including precision parts where reliability and performance are critical.

In plumbing and heat transfer applications, C110 is valued for its thermal conductivity and cost-effectiveness, making it commonly used in general plumbing systems, heating systems, and heat exchangers. While it provides good corrosion resistance, it is particularly favored in applications where extreme ductility and corrosion resistance are not the primary requirements.

C110 is also used in industrial applications where moderate mechanical strength is sufficient. It is suitable for manufacturing various copper parts and components that do not require extensive forming or bending. Its balance of strength and conductivity makes it a versatile choice for many industrial uses.

Applications of Copper C122

Copper C122, also known as Deoxidized High Phosphorus (DHP) copper, is preferred for applications requiring superior weldability and formability.

C122’s excellent corrosion resistance and high ductility make it ideal for plumbing applications, especially those involving potable water. Its deoxidized nature prevents embrittlement, ensuring long-lasting water supply systems. This makes C122 a popular choice for high-quality plumbing installations where ease of installation and bending are critical.

The composition of C122 enhances its ability to be formed and welded, making it suitable for creating complex shapes, fittings, and components that require brazing or welding. The reduced risk of embrittlement associated with oxygen content makes C122 an excellent material for operations involving extensive welding and forming.

C122’s higher tensile and yield strengths make it preferable for applications where mechanical robustness is necessary. It is commonly used in the production of fasteners, connectors, and other components that demand both mechanical strength and corrosion resistance.

Comparative Analysis of Applications

Copper C110 is mainly used in electrical applications because it conducts electricity very well and has good mechanical properties. In contrast, Copper C122 excels in plumbing applications where weldability and formability are paramount. The choice between C110 and C122 depends on the specific requirements of the application, balancing conductivity, strength, and ease of fabrication.

Both C110 and C122 are used in heat transfer applications, but C122’s superior corrosion resistance makes it more suitable for environments where long-term durability is critical. For general plumbing and heat exchangers where cost is a consideration, C110 is often the preferred choice.

In industrial settings, C110 is favored for its moderate strength and conductivity, making it suitable for various general applications. On the other hand, C122’s higher mechanical strength and ease of welding make it ideal for more demanding mechanical applications, such as high-strength connectors and fasteners.

When selecting between Copper C110 and C122, it is essential to consider the specific needs of the application. For electrical components and general plumbing, C110 provides a cost-effective solution with good performance. For high-quality plumbing, drinking water systems, and applications requiring extensive welding and forming, C122 offers superior properties despite its higher cost. The decision should be based on factors such as mechanical strength, corrosion resistance, ease of fabrication, and budget constraints.

Cost Considerations and Availability

Cost Considerations

When comparing Copper C110 and Copper C122, it’s essential to consider the cost implications of each material.

Material Cost

Copper C110, known as Electrolytic Tough Pitch (ETP) copper, is generally more affordable due to its simpler processing and widespread production. This makes it an attractive option for large-scale projects with budget constraints.

In contrast, Copper C122, or Deoxidized High Phosphorus (DHP) copper, tends to be slightly more expensive. The higher cost is attributed to its deoxidized, higher purity form and the inclusion of phosphorus, which enhances its weldability and formability.

Manufacturing and Processing

The manufacturing and processing costs of Copper C110 are lower. Its production involves standard annealing and tempering processes, making it easier and cheaper to produce in bulk. This contributes to its economical nature for large-scale projects.

Copper C122 incurs higher processing costs. The deoxidation process and the incorporation of phosphorus for improved weldability and formability add to the overall expense. Despite the higher initial cost, these properties can lead to cost savings in specific applications by reducing installation and maintenance expenses.

Cost Efficiency in Application

Copper C110 is cost-effective for general plumbing and electrical uses where high formability or corrosion resistance isn’t crucial. Its lower material and processing costs make it suitable for standard uses without the need for enhanced properties.

On the other hand, Copper C122, while more expensive upfront, can offer better lifecycle cost efficiency. Its superior corrosion resistance and ease of shaping can reduce overall installation and maintenance costs, particularly in complex plumbing systems and applications that require high weldability.

Availability

Understanding the availability of Copper C110 and Copper C122 is critical for project planning and procurement.

Market Availability

Copper C110 is widely available due to its extensive use in electrical wiring, plumbing, and various industrial applications. Its wide range of uses makes it a standard copper grade in many areas, ensuring easy accessibility.

Copper C122 is also readily available but is slightly less common than C110. It is often stocked by suppliers specializing in plumbing and HVAC materials, catering to its niche applications. This focused availability means that while it can be procured, it may require sourcing from specialized suppliers.

Supply Chain

The supply chain for Copper C110 is robust, with strong networks ensuring quick procurement in various forms such as bars, sheets, and pipes. This widespread availability in multiple forms makes it a versatile choice for many industries.

Copper C122, while generally available, may have longer lead times or higher minimum order quantities. This is due to its more specialized production requirements and focused market. Planning ahead is essential when large volumes or non-standard forms are needed.

Stocking in Various Forms

Copper C110 is available in diverse forms, including bars, rods, sheets, and pipes with a range of thicknesses suitable for multiple industries. This extensive range ensures that it can meet various application needs without significant delays.

Copper C122 is primarily stocked in plumbing-specific forms such as pipes and tubes. Its availability in other product forms may be limited, which can affect its suitability for applications outside its primary use cases.

Impact of Cost and Availability on Choice

• General Plumbing and Electrical Applications: Copper C110’s lower cost and wide availability make it the default choice for standard plumbing pipes, electrical conductors, and heat exchangers where corrosion resistance and formability are adequate.
• Specialized Plumbing: Copper C122’s superior corrosion resistance and enhanced formability justify its higher cost. Its phosphorus content improves weldability, simplifying installation and reducing labor costs in complex pipe networks.
• Mechanical and Structural Components: While the strength differences are marginal, Copper C110’s higher mechanical strength in harder tempers can be advantageous and more cost-effective in applications requiring durability without complex shaping.

Balancing upfront costs with long-term performance and availability helps in choosing between Copper C110 and C122 for specific applications.

Frequently Asked Questions

Below are answers to some frequently asked questions:

What are the main differences between copper C110 and C122?

Copper C110 (Electrolytic Tough Pitch) and Copper C122 (Deoxidized Phosphorus Copper) are both high-purity copper grades with key differences in their composition, mechanical properties, and applications.

Copper C110 contains a small amount of oxygen introduced during the electrolytic refining process, which gives it excellent electrical conductivity but can affect its weldability and ductility. In contrast, Copper C122 is deoxidized with phosphorus, which removes oxygen, enhancing its weldability and formability.

Mechanically, C110 generally exhibits higher tensile and yield strengths, especially in hardened tempers, while C122’s strength is comparable to C110 in its soft temper. Both grades have excellent corrosion resistance, making them suitable for water-related applications.

C110 is typically used in electrical applications and general plumbing due to its superior conductivity and strength. C122 is preferred in applications requiring extensive welding and forming, such as plumbing systems with complex shapes.

Which copper type has better corrosion resistance?

Both Copper C110 and C122 offer excellent corrosion resistance, particularly in plumbing and water-related applications. Copper C110, known as Electrolytic Tough Pitch (ETP), contains trace amounts of oxygen, which helps form a stable oxide film that enhances its corrosion resistance in fresh water and atmospheric conditions. On the other hand, Copper C122, which includes up to 0.02% phosphorus, is deoxidized to minimize hydrogen embrittlement and improve ductility and weldability, without significantly altering its corrosion resistance.

In practical terms, the corrosion resistance of C110 and C122 is largely equivalent under normal conditions. However, C110 may exhibit slightly better performance in certain aqueous environments due to its oxygen content. The choice between the two should primarily consider mechanical and fabrication requirements rather than corrosion resistance alone.

Is copper C122 easier to weld and form compared to C110?

Copper C122 is indeed easier to weld and form compared to Copper C110. The primary reason is the presence of phosphorus in Copper C122, which acts as a deoxidizing agent. This addition reduces the oxygen content, minimizing porosity and improving the quality of welded joints. As a result, Copper C122 is particularly well-suited for brazing and welding applications, such as in pipes and tubing.

In terms of formability, Copper C122’s reduced oxygen content and the phosphorus addition make it more malleable and ductile. This allows it to perform better in forming processes like bending and drawing. On the other hand, Copper C110, while stronger with higher tensile and yield strengths, is less malleable and can be more challenging to shape, particularly in hard tempers.

Therefore, for applications requiring extensive welding and forming, Copper C122 is generally the superior choice due to its enhanced weldability and formability.

Which copper type is better for plumbing applications?

For plumbing applications, Copper C122 is generally the better choice compared to Copper C110. Copper C122, also known as deoxidized copper, offers superior corrosion resistance, which is crucial for potable water systems and environments where the pipes are exposed to aggressive conditions. Its higher ductility makes it easier to bend and shape, facilitating installation in complex plumbing layouts. Additionally, Copper C122 has excellent weldability and brazing characteristics, ensuring strong, leak-resistant joints.

In contrast, Copper C110, while offering excellent thermal conductivity and being more cost-effective, is less ductile and more challenging to weld due to its oxygen content. This can lead to potential issues such as porosity or embrittlement in welds. Therefore, for critical plumbing applications where reliability, ease of installation, and long-term performance are essential, Copper C122 is the preferred material despite its higher cost.

How do the mechanical strengths of C110 and C122 compare?

Copper C110 and C122 differ significantly in their mechanical strengths. Copper C110, also known as Electrolytic Tough Pitch copper, exhibits a broad range of tensile strength, especially when cold-worked. In its annealed state, C110 has an ultimate tensile strength of approximately 31,900 psi, which can increase up to 42,100 psi in harder tempers like half-hard and full-hard. Similarly, its yield strength ranges from 10,000 psi in the annealed condition to 45,000 psi in full-hard temper.

In contrast, Copper C122, known as Phosphorus Deoxidized copper, typically maintains a more consistent mechanical profile. It generally features an ultimate tensile strength around 32,000 psi and a yield strength of about 10,000 psi, mostly supplied in a soft annealed state to facilitate forming and welding.

Therefore, Copper C110 is mechanically stronger than C122, especially in its hardened states, making it suitable for applications requiring higher strength. Conversely, Copper C122, with its stable mechanical properties and enhanced weldability and formability, is preferred for applications like plumbing and tubing where ease of fabrication is critical.

What processing methods are used for C110 and C122?

Copper C110 and Copper C122 have distinct processing methods that influence their applications and manufacturing efficiency.

Copper C110, known as Electrolytic Tough Pitch (ETP) copper, typically undergoes electrolytic refining, resulting in a small oxygen content (~0.02-0.04%). This oxygen presence requires controlled machining with carbide or high-speed steel tools and water-soluble cutting fluids to prevent oxidation and embrittlement. Cold working is excellent, but annealing must be done in reducing atmospheres to avoid grain growth and oxidation. Welding and brazing are possible but need inert gas shielding to minimize oxidation.

Copper C122, a phosphorus-deoxidized copper, includes about 0.02% phosphorus, which significantly reduces oxidation during processing. This improves its versatility in both hot and cold forming operations, making it ideal for heavy-forming applications like pipes and tubing. It has similar machinability to C110 but offers superior weldability and brazing due to reduced oxidation risks. Annealing is more straightforward, resulting in consistent mechanical properties.