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Copper Metal Forming for High-Voltage Electrical Components
Engineered for high-voltage electrical systems, this T2 Copper Tail Pipe utilizes low-pressure die casting to achieve dense, thick-walled structures. Verified by 20kN tension tests, it ensures perfect conductivity and thermal performance for 110kV applications, free from shrinkage pores or bubbles.
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High-Voltage Copper Forming Component (T2 Copper Tail Pipe for Power Systems)
Application – 110kV High-Voltage Electrical Equipment
Engineered for high-voltage transmission and substation systems, this T2 copper tail pipe is designed for applications requiring maximum electrical conductivity, thermal stability, and structural integrity under continuous current load.
Advanced Process – Precision Low-Pressure Die Casting
Manufactured using low-pressure die casting technology for thick-walled copper components, ensuring dense, void-free internal structure.
Key engineering controls:
- Strict minimum wall thickness control (≥ 1.8 mm)
- Optimized mold temperature for T2 high-purity copper flow behavior
- Eliminates shrinkage porosity, gas bubbles, and internal voids
- Produces uniform wall thickness and high-density metal structure
Structural Result:
A fully zero-porosity copper component optimized for electrical conductivity systems.
Material Performance – High-Purity T2 Copper (≥99.9%)
Specialized in high-conductivity copper forming, delivering:
- Ultra-low electrical resistivity
- Excellent thermal conductivity for heat dissipation
- Stable performance under high-current load conditions
- Ideal for power transmission and HV connection systems
Precision Control for High-Voltage Fitment
- General tolerance: GB/T 1804-m
- Hole inspection: 100% plug gauge testing (12-Φ14 interfaces)
- Concentricity control: Φ200 flange OD vs Φ150 ID within 0.05 mm (CMM verified)
Ensures precise assembly with high-voltage bushings and conductive interfaces.
Surface Engineering – Conductive Interface Preparation
- Smooth surface finishing with no burrs or sharp edges
- Edge chamfering (R0.5) for stress reduction and assembly safety
- Chemical polishing + manual finishing for defect-free surface
- Suitable base for silver plating or conductive coating processes
Engineering Value (Electrical Performance Focus)
Compared with conventional casting or welded copper parts, this solution delivers:
- Improved current carrying stability under 110kV systems
- Elimination of internal porosity-related conductivity loss
- Enhanced thermal dissipation performance
- Higher long-term reliability in substation environments
Optimized Solution
A high-performance copper forming solution for high-voltage electrical systems, ensuring:
- Maximum conductivity efficiency
- Structural density with zero internal defects
- Stable operation under continuous electrical load