Copper Nickel Tube

Copper-nickel Tube: The Complete FAQ Guide

If you want to learn about alloy grades, uses, standard specifications or fabrication of copper, nickel tubes, then read this guide.

Explores all the vital aspects about copper nickel tubes.

Here’s all you should know:

What is a Copper Nickel Tube?

Copper nickel tubes are hollow sections that are round, square, oval or rectangular.

Of course, this unlike copper nickel pipes which are available in round cross-section.

Copper-nickel tube

Where can you use a Copper Nickel Tube?

The use of copper-nickel tubes is common in the following applications

• Desalination plants
• Underwater tubing
• Exchanger system
• Marine hardware

What is the Difference between a Seamless Copper Nickel Tube and Welded Copper Nickel Tube?

The main difference between seamless and welded copper-nickel tubes is their structure.

Seamless copper-nickel tubes have a smooth surface characterized by lack of joints.

Welded copper-nickel tubes have joints as a result of the welding process.

The manufacturing process of these tubes also differ.

What are the Types of Copper Nickel Tubes?

The main types of copper-nickel tubes are:

• Seamless copper-nickel tubes
• Welded copper-nickel tubes

Of course, other classification may be based on the copper nickel alloy grade where we have – CuNi 90/10 tubes and CuNi 70/30 tubes.

What Standard Specifications are Applicable for Copper Nickel Tubes?

The standard specifications applicable to copper-nickel tubes are, ASTM B111, ASME, DIN, and EEMUA.

Do Copper Nickel Tubes have a Standard Pressure Rating?

The pressure rating of copper-nickel tubes differs depending on their thickness and operating temperature.

Of course, this will also depend on the standard specification.

Can you Differentiate between Copper Nickel Tube and Copper Nickel Pipe?

The main difference between a copper-nickel tube and a copper-nickel pipe is in their design.

A Cupronickel pipe has a round cross-section.

On the other hand, the cross-section of copper nickel tube varies from round, square, rectangular to oval.

A Copper Nickel Tube has which Characteristics?

Copper-nickel tubes have the following characteristics:

 Round copper nickel tube

• Perfect welding properties. This allows for welding methods such as gas shielding arc welding, spot, coated metal arc and seam welding.
• Excellent soldering properties
• Perfect cold working and hot formation properties. This enhances the individual features of these pipes, such as strength properties.
• They have a machining rating of 20, which allows for perfect fitting in your application.
• They have a high anti-corrosive and anti-erosion property which allows for use in a saline environment.
• They are highly flexible, which makes it easy to modify to different requirements.
• They prevent the growth of microbial and macrofouling, which enhances their usage in human sensitive applications.

How do you Join Copper Nickel Tubes?

There are two main ways you can connect copper-nickel tubes to your piping system depending on their end configuration.

Connecting a threaded copper-nickel tube involves selecting the correct size of the tube that corresponds to that of your application.

“Configuration” is critical for proper connection.

A male threaded end connects to a female threaded end.

The difference is in the direction of the tapered grooves.

When connecting, ensure the copper-nickel tube fits into your application and screw it in a clockwise manner until it is secure and tight.

Copper-nickel tubes with beveled and plain ends require welding.

However, you have to insert a plain end copper-nickel tube into your application before you weld.

Proper welding should give water and airtight connection.

You, therefore, have to check for any leakages before you start operating these connections.

Copper Nickel Tubes have which Chemical Elements?

The available grades dictate the volume of the chemical elements in a specific copper nickel tube.

In copper-nickel 90/10 tube, the copper has a significant volume of between 88-90% of the total volume.

Nickel has a volume of between 8-9% while iron and magnesium occupies the rest.

In copper-nickel 70/30, the percentage of copper ranges between 66-68% while that of nickel ranges between 26-28.5 %.

Other elements such as iron, magnesium, zinc, and lead have a volume range of between 0.5-1%.

What are the Copper Nickel Tube End Types?

You have three main end designs for copper-nickel tubes.

That is beveled, threaded, and plain end designs.

Threaded end designs feature tapered grooves that can either be cylindrical or conical.

The difference between these two is the angle of the tapered threads.

Threaded end designs can either be male or female.

Connecting involves the use of the opposite gender.

The connection process entails fixing the tube on your system and screwing it.

Always ensure there is a tight connection.

A beveled copper-nickel tube has its ends not running perpendicular to its surface.

Ideally, the standard angle for a beveled end is 37.5 degree.

However, it is possible to have different beveled degree depending on various needs.

Its connection involves welding.

Several welding options are available that one can use when connecting these tubes.

These end designs are common in copper-nickel tubes with a small diameter.

Copper-nickel tubes have their ends perpendicular to its surface.

Their connecting procedure is mainly welding.

However, before welding, you have to insert the tubes onto your system and then weld around it.

You can also have grooved end copper-nickel tubes.

These tubes have a groove on the ends, and their connection procedure is relatively simple than the other end designs.

The only limitation with this end configuration is that it is not ideal for use in high-pressure applications.

This is because the connection is not that tight to guarantee no leakages.

What are the Available Grades for Copper Nickel Tubes?

Rectangular copper nickel tube

There are two main grades of copper-nickel tubes.

Each of these grades has specific properties, and their area of use differ.

Coper nickel 90/10 tubes are strong and ideal for use in high water velocity application.

This is due to the high amount of copper.

The electrical resistivity of copper-nickel 90/10 is high and are cheaper compared to copper-nickel 70/30 tubes.

Copper nickel/70/30 tubes have a high resistance to corrosion due to the high nickel content.

Do Copper Nickel Tubes have Standard Length?

Copper nickel tubes are available in a specified length of 6meter.

However, a credible producer can produce these tubes in lengths that meets your specifications.

Is it Possible to Cut Copper Nickel Tubes?

Yes. It is possible to cut copper-nickel tubes using a variety of methods.

Common methods for cutting copper-nickel tubes include laser-cutting, oxyfuel cutting, waterjet cutting and plasma cutting arc.

Plasma cutting arc method is preferred due to its simplicity in terms of use and readily available.

It entails superheating ionized gas and letting this gas flow to the cutting point using a plasma torch.

As the gas flows, it causes this region to melt, resulting in a cut.

In general, we can sum up the plasma cutting arc method in these steps:

• Initiating the pilot arcing process
• Main arc generating process
• Heating and melting localization
• Ejection of material
• Arc movement

What should you Consider when Selecting Copper Nickel Tubes?

Proper selection of copper-nickel tubes puts into consideration the following factors:

· Grade of Copper Nickel Tube

Copper-nickel 90/10 tubes have unique properties which differ to those of copper-nickel 70/30 tube.

These properties facilitate their functions in different environments.

You have to consider the environment that you are going to use your tube before selecting one.

For instance, the salinity level or electrical condition.

· Type of Copper Nickel Tube

The main types of coper nickel tubes that you have to specify are seamless and welded.

Each of these types has unique properties that you have to consider before selecting one for your use.

· Quality Standards

Proper copper-nickel tubes should meet specific quality standards.

Such tubes function correctly and are durable.

In addition to internationally recognized quality standards, these tubes should adhere to the standard that governs a given jurisdiction.

Purchasing from a reliable manufacturer ensures you have quality copper-nickel tubes.

· Dimensions of Copper Nickel Tube

The dimensions of a given copper-nickel tube is an essential aspect when making the purchase.

Besides, the critical dimensions you need to check into include the thickness and the length of the copper-nickel tube.

· Copper Nickel Tube End Type

The tube end type is critical when considering the connection method of a particular copper nickel tube.

Besides, the primary end type includes threaded, plain, and beveled.

The end type you select should be compatible with your application, and it should offer a tight and secure connection.

· Operating Temperature and Pressure

An ideal copper-nickel tube should handle the optimum operating pressure and temperature of an application.

This prevents bursting of the tubes due to high pressure.

Checking on the pressure and temperature markings on the individual tubes can assist you in selecting the best one for your use.

Is it Possible to Weld Copper Nickel tubes?

Several welding methods for copper-nickel tubes exist.

The choice of which method depends on, among other factors the grade of the copper-nickel tube.

Standard welding methods are:

Welding copper nickel tube

· Gas Tungsten Arc Welding/ Tungsten Inert Gas Welding

There is a formation of an arc between the welding point on your copper nickel tube and an electrode which is non-consumable.

The inert tungsten gas covers the welding region shielding it against the atmosphere.

Again, the advantage of this method is that you can use it even on thinner copper-nickel tubes.

If you are welding thicker copper-nickel tubes, you have to apply filters.

The filter should have an ideal chemical composition for compatibility purposes.

You can also automate this method or use it manually.

· Shield Metal Arc Welding/ Manual Metal Arc Welding

This method uses a weld pool and a consumable electrode which has a flux covering.

Feeding of the electrode into the weld pool takes place resulting in its decomposition of the flux into gases.

It is this gas that is responsible for shielding the pool.

This process has a lower cost compared to other welding methods.

The decomposition of the electrode is faster than that of a gas tungsten arc welding.

It also does not use other gases since the shielding gas emanates from the flux covering.

The main shortcoming of this method is the constant removal of slag.

· Resistance Welding

The advantage of resistance welding is it uses fewer materials compared to the other types of welding.

Moreover, the only materials here are flowing current and pressure.

The welding process involves sustaining a pressurized current flow on the welding point to obtain an excellent joint.

There are different types of resistance welding, including projection, upset, spot, seamless, and flash welding.

The design of the weld is what differentiates the resistance welding types.

· Gas Metal Arc Welding/ Metal Inert Gas Welding

This process involves heating of an uninterrupted solid electrode and feeding it in a weld pool using a welding gun.

As feeding takes place, there is melting of the copper-nickel tubes making them join.

An inert gas protects the welding region against environmental contaminants.

The advantage of this method is it allows for use in a variety of copper-nickel tubes regardless of the thickness.

How do you produce Copper Nickel Tube?

There are two types of copper-nickel tubes that have a different manufacturing process.

There are four main methods of manufacturing welded copper-nickel tubes.

That is:

• Electric fusion welding (EFW)
• Electric resistance welding (ERW)
• Submerged arc welding (SAW)
• High-frequency welding (HFW)

The different methods available for fabrication of seamless copper-nickel tubes are:

Mandrel Mill Method

mandrel mill method of producing seamless copper-nickel tubes has the following steps:

• Heating of a solid ingot using a rotary hearth heater until it is in a semi-solid state.
• Passing the semi-solid billet through a piercer. This creates a hollow shell on the billet.
• Reducing the outer diameter of the hollow shell and its thickness using a mandrel mill.
• Reheating the mother copper-nickel tube before passing it through a stretch reducer. The stretch reducer is responsible for reducing the mother tube further as per specific dimensions.
• Passing these tubes through a cooling panel where there is rapid cooling of the tubes under specific controls. Rapid cooling enhances the strength of the copper-nickel tubes.
• Finishing of the tubes takes place before final packaging in recognized packaging standards

Extrusion Method

Extrusion method entails the following:

• Material heating. This involves heating the solid billets in a tunnel heater until they are in a semi-solid state. This allows for alteration of the billet without losing its chemical properties.
• Extrusion of the semi-solid billet.

Proper extrusion involves lubricating the billets first to allow for smooth extrusion without the billet sticking.

The extrusion takes place in a die that has the dimensions you need of your tubes.

• Cooling of the copper-nickel tubes. This is by rapidly passing the copper-nickel tubes through a cooling panel. Rapid cooling enhances the strength of these tubes.
• Stretching and cutting as per the specifications available.
• Final processing takes place, including aging and surface application to enhance its anti-corrosion properties.
• Packaging in packages that meet internationally recognized standards.

Plug Rolling Mill Method

Plug rolling mill production process  goes through the following:

• Heating of solid ingots uniformly inside a rotary hearth heater until they are in a semi-solid state.
• The semi-solid ingots pass through a Mannesmann piercer where piercing occurs. This results in the creation of a hollow shell.
• There is a reduction in the thickness and outer diameter of the hollow shell through rolling using a reeling machine. The reeling machine burnishes the inside and outside of the tubes.
• A sizing mill sizes the copper-nickel tube according to necessary dimensions.
• The tube goes through final finishing where a straightener straightens the tubes also, other surface finishing takes place here.
• The final step is the packaging of these tubes in specific packaging materials.

Forging Method

Using the forging method to produce copper-nickel tubes entails the following:

• Heating of a pre-forged copper-nickel solid ingot until they attain a molten state. This state allows for easy alteration while maintaining the shape.
• Pre-forming of the molten ingots by pressing it between dies takes place. The pressing allows for edging of the castings to specific shapes.
• Forging facilitates shape formation as per the necessary dimensions. Such dimensions include the thickness and length of the copper-nickel tubes.
• The copper-nickel tubes go through a cooling bed to reduce their temperature under the given controls.

This allows for proper cooling while maintaining the shapes of these tubes.

• Finishing – The copper-nickel tubes go through final finishing processes to improve their appearance and their anti-corrosion properties.

Such processes include trimming and surface operations.

• The final step is the packaging of these tubes in specific packaging materials that meet internationally recognized standards.

With all the information here, you can now choose the best copper nickel tube for your applications.

At Shihang, we supply a range of copper nickel tubes for various applications.

We follow strict quality control to give you the best copper nickel tubes at competitive prices.

Talk to us now for the best prices on Cupronickel tubes.