Copper Alloys Ltd

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QUALITY IS CRITICAL

Manufacturing to Lloyd's Register Quality Assurance ISO 9001:2008 AS 9100, quality is critical to Copper Alloy's success.

Metallurgical engineering for critical and extreme environments


Working with engineers across the world creating non-ferrous solutions for highly technical applications, Copper Alloys Limited is a custom producer of specific Wrought, Continuous Cast, Chill Cast, and Sand Cast non-ferrous materials.

Typical materials include:

  • Aluminium [Large forgings only]
  • Aluminium Bronze
  • Copper-Chrome
  • Copper-Nickel
  • Copper-Nickel-Silicon
  • Gun Metal
  • Leaded Bronze
  • Alloy 400
  • Alloy K-500
  • Phosphor Bronze


Typical formats include:


Copper Alloys manufactures to order over 140 different copper-based and nickel-based metals and also produces finished machined components to drawing with its dedicated machine shop.

  • Extensive Petrochemical Industry Experience

Requirement  not listed? Call the Copper Alloys Technical Team on 0044 (0) 1782 816 888.

Alloy Development

       
Save money, time and effort: Outsource your R&D

Have you ever had this urge for an all singing, all dancing Copper-based alloy?   We have devised and created Copper-based alloys with any number of the following requirements:  
  • High thermal conductivity
  • High strength
  • High electrical conductivity
  • High-speed bearing properties
  • Easy machinability
  • Self-lubrication
  • Anti-corrosion
  • Anti-bacterial
  • High Young's Modulus
  • Wear-resistant alloys
Alloy Development

Cast Products


Rounds, Flats, Square, Triangle, Big Hex, D-shape, L-shape

Copper Alloys manufactures concast copper-based metals in every copper-based alloy (except copper-beryllium). Our regular copper-based alloys include:     We can also offer you a forging billet that is perfectly suitable for your own forging process if required.
 
Cast Products

Copper Chrome

      
Forged Rings

We can offer you Copper Chrome with:  
  • Zirconium (Zr)
  • Magnesium (Mg)
Specifications include ASTM (UNS) C18150, C18200... or manufactured to your own spec!   We can offer lead times shorter than six weeks for forged products!!   Our wrought division also manufactures bar, rings, blocks, shafts and discs to your specific requirements.   All these exciting developments are in addition to our continuous casting facilities that currently produce over 80 different copper-based alloys.
Copper Chrome

Integrated Engineering Supply

Copper Alloys operates a fully integrated supply programme from which it's customers can pick and choose the support level they need.
  
Support Level 1 - Raw Materials

Manufactured to order, Copper Alloys is a leading producers of high integrity exotic materials, which can be supplied in a form ready for further processing. Materials produced to any specification:  
Processes:
  • Hot/Cold Forging - GFM, Press Forging and Hand Forging
  • Heat Treatment
  • Drawing and Extruding
  • Cold Forming
  • Pressing
  • Rolling
  • Continuous casting
  • Sand casting

Formats:
  • Bar
  • Shafts
  • Flanges
  • Pipe
  • Plate
  • Blocks
  • Rings

Custom sections
Support Level 2 - Proof and finished machined components   The key to a high integrity component is the material from which it is manufactured, so it is important that the same level of integrity is continued throughout the production process.   Copper Alloys has a number of automated CNCs and manufactures components to print, in any of the materials from Level 1, the more complex and critical, the better.   Remove the risk of a loss in integrity and let Copper Alloys supply components, packed and fully certified.     Support Level 3 - Project Management Copper Alloys has the technical competencies and quality management systems to manage the production and supply of whole engineering projects.
Supporting engineering on a global scale, working with Copper Alloys to Support level 3 will yield the following benefits:  
  • Effective risk management by delivering on time and in full
  • Guaranteed integrity of components and systems
  • Continuous metallurgical improvement
  • Reduced costs through outsourcing the supply of complex projects
  Testing & Certification   Underpinning all levels is Copper Alloys competitive advantage, which is the ability to supply detailed certification packs and supporting documentation to ensure the integrity of all products supplied, from raw material to whole projects. Copper Alloys holds the ISO AS9100 quality approval, which is the highest level achievable by a manufacturer. This has been scrutinised by defence organisations around the world and is continuously updated, revised and improved to ensure full compliance with the latest requirements in quality.   Testing methods include:
  • Mechanical Testing
  • Fracture Toughness & Fatigue Testing
  • Chemical Testing
  • Ultrasonic Testing
  • Dye Penetrant Testing
  • Metallographic & Hardness testing
  • X-Ray Testing
  • Corrosion Testing
Integrated Engineering Supply

Machining


Making products to drawings and much more

Copper Alloys can offer any level of machining that you require.  This includes:  
Drawings: we are happy to manufacture specifically to drawings, providing you with the completed finished product.
Machining

Quality and Approvals


Quality Assurance is the number one priority at Copper Alloys

Copper Alloys has worked hard over the last decade to achieve some of the most stringent Supplier Approvals on Earth from some of the most recognized blue-chip companies.   Copper Alloys holds key supplier approvals in the following industries:     Please call us if you would like to know the specifics on 01782 816 888.

Wrought Products


From our casting of billets and slabs, we can offer semi-manufactured wrought products and fully finished components in non-ferrous alloys, particularly to aluminium bronze and cupro nickel specifications.

All of our forging's are made from the highest quality virgin materials that are cast into a billet and then forged to your specific requirements.   We can also machine them!
We can convert the cast structure of our billets and slabs through thermo-mechanical working operations, to produce wrought products. There are a huge number of different processing operations, such as forging, rolling and extruding. We can after hot working an alloy, manipulate the final microstructure and mechanical properties through heat treatment, optimising the alloy for a particular application. Our wrought products are superior to cast products. They are characterised as having:
We manufacture an entire range of wrought copper alloy products, in all the major alloys, using a variety of mechanical working operations as follows:  
  • Forging (press / hammer / GFM) - bars, stepped shafts, discs, boss forging's, flanges, blocks, rings, precision rotary forged bars.
  • Extrusion - rods and bars, round, square, flat, profiles.
  • Hand rolling - rods and bars, round, square, flat, profiles.
  • Hot Rolling - Plates and sheets

We can complement these operations with down-steam cold drawing, heat treatment, grinding, peeling and machining operations (conventional and CNC). We are able therefore to offer semi-finished wrought products, or supply finished components.
Our capacity in terms of maximum component weight continues to grow as we invest in our casting facility in Stoke.
Wrought Products

Nickel-Copper Alloys - Ni400 & NiK500

 
Ideal for aggressive environments, such as sea water, oilfield environments and industrial chemical applications

Nickel Alloy Standards that are offered to order by Copper Alloys Limited:
 
Trade Name UNS British Yield Strength (0.2% offset) Tensile Strength Elongation (%)
      Psi MPa Psi
 MPa  
Ni400 N04400 BS 3076 NA13 35,000 240 80,000 550 40
Ni401 N04401            
Ni404 N04404            
NiR405 N04405            
NiK500 N05500 BS 3076 NA18 100,000   130,000   45-20

 

 All of these alloys present significant advantages in terms of marine corrosion resistance and are created by Copper Alloys Limited, further benefits are as follows:

  • Stronger than steel
  • Malleable
  • Resistant to corrosion
  • Low coefficient of thermal expansion
  • Highly resistant to alkalis
  • Inexpensive compared to similar alloys
  • Can be welded, brazed and soldered

Specifically to their customer’s bespoke requirements, Copper Alloys works in partnership with members of the industry to tailor Nickel Alloys according to the distinct applications in all types of marine industries, such as:  
  • Naval Marine
  • Oil and Gas
  • Petrochemicals
  • General Sub-sea
  Copper Alloys works with engineers to meet new and progressive technical requirements.
 
 
Nickel-Copper Alloys - Ni400 & NiK500

Nickel Alloy Forgings and Castings

       
Now available from Copper Alloys Ltd...

Manufactured to order on short lead times for competitive prices  
Nickel Alloy Forgings and Castings

Specialist Steel Forgings

Copper Alloys now have an extensive range of Forged materials available for the Engineer from our traditional suits of Copper-based Alloys and Nickel-Copper Alloys (Alloy K-500 & Alloy 400) to high-spec Nickel Based Alloys (such as Alloy 718, Alloy 625 and Alloy 825), Titanium, Duplex Steels and specialist Engineering Steels. These alloys are available as a variety of forged shapes including Bars, Rings and Complex shapes.

Our experienced and dedicated team have a vast experience and working knowledge within the specialist metals industry to meet your requirements.

Specialist Steel Forgings

Project Management

Copper Alloys has the technical competencies and quality systems to manage the production and supply of complete engineering projects.

The material selection and development team at Copper Alloys is always searching for the next opportunity to apply its unique knowledge to meet new metallurgical challenges. Some recent work includes projects involving:

  • Lead-free bearing development
  • Highly abrasive environments
  • Heat transfer applications
  • Defence engineering
  • Petrochemical extraction and process engineering

Contact Us

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