Mipalloy

Mipalloy manufactures anvil contact bars in various sizes in Chromium Copper and Chromium Zirconium Copper material. Anvil contact bars are mainly used in Steel Plants and Rail Coach manufacturing Industries where ends of steel sheets are to be seam welded.

Mipalloy manufactures Flash Butt welding dies in Class 2, Class 3 as well as Class 4 alloys. Mipalloy manufactures these Anvil contact bars and Flash butt welding dies up to a length of 2000 mm. Anvil contact bars and flash butt welding dies are made out of individually forged and heat treated bars. They are proof machined to the sizes required by customers.

The constant need to keep pace with technological innovations has inspired us here at Mipalloy to produce special Copper-Alloys for solving the recurring or new problems of the engineering and electrical industries requiring:

• Good mechanical properties associated with electrical and thermal conductivity.
• Good mechanical properties at high operating temperatures.
• Good impact and fatigue properties during actual working.
• Good anti-friction properties

Beryllium Copper alloys are used for their High Strength and Good Electrical and Thermal Conductivities.

There are two groups of Beryllium Copper alloys. One is High Strength Alloys and the other High Conductivity Alloys.

Blades, Control Bearings, Housings for Magnetic Sensing Devices, Non Sparking applications, Small Springs, High Speed Plastic Molds and Resistance Welding Electrodes. Their high conductivity enables high production speed, while their good corrosion and oxidation resistance promotes long mould life.

Chromium copper alloys are high copper alloys, containing 0.5 to 1.2% Cr. The chromium copper alloys are used for their high strength, corrosion resistance and electrical conductivity. The chromium copper alloys are age hardenable, which, in this case, means that a change in properties occurs at elevated temperature due to the precipitation of chromium out of the solid solution. The strength of fully aged chromium copper is nearly twice that of pure copper and it’s conductivity remains high at 85% IACS, or 85% that of pure copper. These high strength alloys retain their strength at elevated temperatures.

The Chromium Zirconium Copper is essentially Chromium Copper alloys which has a small addition of Zirconium. The addition of Zirconium inhibits chemical reaction of Copper at elevated temperatures. It also helps to retain the physical properties at elevated temperatures. Also it marginally increases annealing temperature.

Chromium Zirconium Coppers are used widely in areas where high electrical and thermal conductivity are required combined with good mechanical properties. Uses include Resistance Welding Machine Electrodes, Seam Welding Wheels, Spot Welding Tips, Flash Butt Welding Electrodes, Anvil Contact Bars, Electrical Switch Gear Contacts & Terminals, Electrode Holders, Cable Connectors, Current Carrying Arms and Shafts, Circuit Breaker Parts, Heat Sinks, Short Circuit Rings, MIG welding contact tubes and many other applications where Copper would normally be the ideal choice for High Conductivity but is just not Strong enough.

Mipalloy manufactures bloom, slab & continuous casting moulds for steel plants & non ferrous mills. The mould material must rapidly transmit heat from the molten steel to the cooling water. The material has to meet a whole series of requirements critical to the casting process such as good thermal conductivity, sufficient hardness and resistance to wear & mechanical damage. Pure Copper or Silver Copper was the mould material until Chromium Zirconium Copper set the standard for continuous casting moulds. Only Chromium Zirconium Copper meets the demands for high quality, high casting speed economically.

The primary use for copper is the distribution and control of electricity due to copper's superior conductivity. In fact, copper's conductivity (100% IACS) is the international standard by which the conductivity of all other materials is measured. Silver is the only material which has conductivity more than copper. In terms of energy efficiency, space requirements and corrosion resistance, copper is the lowest cost, commercially available material for electrical applications.

The introduction of galvanized steels into automotive manufacturing has posed new challenges to resistance welding practices. Coated steels have gained considerable interest due to the commitment of producers to increase corrosion resistance. The zinc coating has proven to have adverse affects on the performance of the electrodes contributing to premature wear, sticking and increased maintenance and power utilization. As a result, traditional welding with chrome and/or chrome zirconium electrodes has become inefficient and costly with considerable production downtime.

Copper due to its high electrical conductivity is the preferred material in the design of switches, circuit breakers & disconnectors. Predominantly all current carrying members like terminals, conductors & contacts are manufactured out of High Conductivity Coppers.

Mipalloy is a leading manufacturer of high conductivity copper alloys in INDIA. Based on the service required, mipalloy offers.

Mipalloy Cap Extractors quickly removes cap electrodes and shanks without damaging the taper in the caps, shanks and electrode holders.

Mipalloy Cap Extractors enhances productivity due to its ease of handling. Its simple construction and ergonomic features encourages usage.

A spot welding shop using Mipalloy Cap Extractor can eliminate spanner slot in electrode manufacture, thus lowering the cost of electrode manufacture.

MIPALLOY Cap Extractor is 10" long and made out of hardened steel.

Electrode Dresser quickly removes the mushroomed portion of spot welding electrode and renews dome and pointed nose electrodes with the operating contour.

Electrode Dresser re-machines both upper and lower Electrodes to the correct profile "on the job" - provided both electrodes are identical - without removal of the electrodes from their holders

Electrode Dresser is 10" long, with a replaceable cutter of hardened tool steel

MIPALLOY FLEXIBLE LAMINATED SHUNTS are custom designed to customer requirements and specifications and are available in any hole pattern or size. The secondary conductor strips are of High Conductivity Copper. Terminal ends can either be deep riveted or solder dipped to allow a more positive current transfer area for improved efficiency.

Mipalloy manufactures MIG WELDING TORCHES AND ACCESSORIES to meet the urgent and ever-growing requirements of the welding industry. We can not only offer you the above torches at most competitive prices but also satisfy you with equally prompt supplies and services. Being in the welding industry for over twenty years now, we have a thorough knowledge of the requirements and the quality requisites of the industry.

We believe that you can derive the following advantages by using Mipalloy torches.

Molybdenum is a refractory metal typically used in high temperature applications. Key properties include:

• Low co-efficient of thermal expansion (5.1x10-6 m/m/°C) which is about half that of most steels
• Good thermal conductivity
• Good electrical conductivity
• Good stiffness, greater then that of steel (Young’s Modulus 317MPa)
• High melting point (2615°C)
• Good hot strength
• Good strength and ductility at room temperature
• High density (10.2 g/cm3)

Its ability to withstand high temperatures and maintain strength under these conditions are responsible for the fact that molybdenum finds most of its application at elevated temperatures. In fact, it can work at temperatures above 1100°C (in non-oxidising conditions), which is higher than steels and nickel-based super alloys.

When exposed to temperatures in excess of 760°C in air rapid oxidation can result. Under these conditions, the oxide layer sublimes and the base metal is attacked. Thus, molybdenum performs best in inert of vacuum environments.

A Nickel Silicon Chromium Copper is an alloy having a high hardness and improved electrical conductivity almost equal to that of Beryllium Copper. The alloy is composed by weight of 2.0% to 3.0% Nickel, 0.4% to 0.8% Silicon, 0.1% to 0.5% Chromium, and the balance Copper.

It replaces the Beryllium Copper in practically all applications.

Nickel Silicon Chromium Copper is used wherever a good electrical or thermal conductivity is required together with high mechanical properties

Applications include Electrode Holders and Seam Welding Shafts, Spot welding electrodes, Seam Welding Wheels, Projection and Butt welding dies, Plunger tips for cold chamber aluminium die casting machines, Parts of Moulds for Injection moulding of plastics, Injection-Nozzles and Cooling Pins etc.

When boring small diameter lengthy holes, a chatter is usually encountered by the boring tool which results in a rough surface hole.

The standard for vibration free machining & grinding has been established by our chatter free materials. It is used where rigidity & minimum vibration are critical. Heavier cuts, longer tool life and a much superior finish result when using our chatter free boring bars. Tool extensions up to 9:1 are possible depending upon the application. Tools run cooler because of the high thermal conductivity and you can braze directly to tool without affecting its physical properties.

When it comes to injection mould and blow plastic mould materials nothing speeds production like Copper alloys. Mipalloy 100's thermal conductivity is almost 10 times greater than Tool Steels, so it offers faster, more uniform heat dissipation. That means more than 20percent shorter cycle times. But speed of production is not the only factor. Current research at Western Michigan University shows Beryllium Copper cores exceed most production requirements. For extreme conditions such as long runs of 30percent Glass filled Nylon, Beryllium Copper lasts longer than P-20 Steel cores.

Mipalloy manufactures fully machined plunger tips for die casting in Mipalloy 4 2% Beryllium Copper material. Mipalloy has vast experience & capability to machine a wide variety of plunger tips as per customer's drawing. Mipalloy 4 material has very high hardness in the range of 35 40 HRC. Its higher hardness gives higher service life for these tips. All the plunger tips are accurately machined in house in our advanced state of art CNC machine shop which gives our customers perfect repeatable quality plunger tips.

Mipalloy manufactures standard projection welding electrodes for M6, M8, M10, M12 nuts. Mipalloy's projection welding electrodes are provided with a self insulating pin made out of composite materials having high hardness for locating nuts. These pins have very high resistance to aberrations which in turn gives long life. Also the electrodes will have a Tungsten Copper facing. The Tungsten Copper facing has very high wear resistance, results in longer life of electrode. These electrodes are available off the shelf any time

Mipalloy seam welder wheels are the benchmark for quality in the industry. We manufacture forged & fully heat treated seam welder wheels in Mipalloy3, Mipalloy 3ZR. Wheels are made in varying thickness from 2” diameter to 28” diameter in proof machined condition or fully machined ready to use. Mipalloy wheels guarantee higher hardness & electrical conductivity resulting in superior performance. Most common sizes are available off the shelf.

Mipalloy is a large manufacturer of Short Circuit Rings for Traction Motors with exports to USA, Canada, Germany, UK, Spain, Italy, Switzerland Mexico, Czech Republic, etc.

Mipalloy possesses large inventory of Extruded & Cold drawn Chromium Zirconium Copper rods for rotor bars in long lengths. Mipalloy also has large inventory of Forged Chromium Zirconium Copper Rings in various sizes. Rings are often manufactured in sizes specific to customer requirements.

Silver Copper's outstanding thermal conductivity makes it the choice for mould liner plates and in the continuous casting of steel & for mould liner plate in the non-ferrous continuous casting industry and other mold plate applications. Copper plate materials are very useful in applications requiring heating/cooling cycles and rapid response to temperature variation. The addition of silver along with controlled mechanical processing provide the strength and wear resistance needed for these applications. Mipalloy is having state of the art production facilities to manufacture complicated silver copper profiles with excellent tolerance on size and with smooth surface finish. Our expertise and experience in sections and profiles makes us capable of manufacturing special shapes as per customers requirement in huge quantities. Also mipalloy is capable of handling & machining of single block up to 2 meters length & having a weight of up to 2 Tons.

Silver Copper mould plates are supplied either as bare proof machined plates or fully machined plates as per customers prints ready to use. Often plates are supplied with coating to increase the life of the mould. Coatings are mostly Hard Chrome Coating or Nickel Coating. Coated plates can increase the mould life to nearly double.

Mipalloy single bend, double bend, triple bend electrodes are cold formed from full hard straight bar stock and have properties superior to those obtained by casting or hot forging methods. Cooling tubes can be inserted into these electrodes to provide water flow near the welding face as in case of straight electrodes. These extra values assure you a more efficient, less costly electrode, superior weld quality for gun welders and special offset welding applications. These electrodes are available in Mipalloy3, Mipalloy3ZR, Mipalloy100 materials. We have shown below some standard electrodes regularly produced by Mipalloy.

Mipalloy manufactures gun arms in Mipalloy 3, Mipalloy 3ZR and Mipalloy 100. Due to our vast experience in cold working copper alloys, we manufacture gun arms out of extruded bar stock. The final shapes are achieved by cold bending extruded bar stock in closed dies in hydraulic presses. Gun arms manufactured out of extruded bar stock eliminate all the defects of casting like porosity, blow holes, inclusions, cold shuts etc.

It is an accepted norm to adopt cap & shank type of spot welding electrode for large requirements of spot welding internationally. This stems from the inherent advantages of caps which are low cost and higher productivity. Spot welder caps are commonly manufactured by cold heading which results in a double edged advantage of lower material consumption for manufacture translating into lower costs and higher mechanical properties like higher hardness, higher tensile strength etc due to intense cold working.

Mipalloy manufactures a large variety of Spot / Projection and Butt welding electrodes to meet diverse needs of the welder. Mipalloy manufactures fully machined electrodes in Chromium Copper, Chromium Zirconium Copper, Beryllium Copper, Tungsten Copper, Tungsten and Molybdenum. We also manufacture composite spot welding electrodes with refractory tips of Tungsten or Molybdenum Silver brazed on to Chromium Copper shanks.

Mipalloy manufactures a large variety of Screwed Adaptors to suit Spot weder Gun Arms in various lengths. A screwed adaptor is generally manufactured from a hexagonal rod with one side a taper thread to suit gun arm & to ensure leak proof joint & other side is machined to suit either a bent holder, or shank and some times it is made to directly fit a cap tip. Generally Screwed Adaptors are manufactured in Mipalloy100 material to ensure a longer life. Screwed adaptors are also manufactured in Mipalloy3 or Mipalloy3ZR material.

Mipalloy manufactures Mipalloy 4 2percent Beryllium Copper material. This material has a very high hardness in the range of 35 40 HRC. This material is used for manufacture of stud welder collets, plunger tips etc. Stud Welder Collets when made out of Mipalloy 4 material has a very high hardness, moderate electrical conductivity and excellent spring properties. These properties contribute to very long service life.

Mipalloy manufactures wide range of collets for various stud welding application.

The following list illustrates some of the tungsten applications:

Thoriated or Zirconated or rare earth oxide alloyed rod electrodes for inert gas welding (TIG welding electrodes).

Sintered pure tungsten electrical contacts3

High temperature furnace parts such as tungsten heating coils, reflectors and structural material etc.

Tungsten Copper alloy is an alloy composite of Tungsten and Copper which has the combination s of the excellent properties of Tungsten and Copper, such as heat resistance, aberration resistance, high density, excellent thermal and electrical conductivity. It is easy to be machine.

Mipalloy manufactures Tungsten Copper by Press, Sinter and Infiltration method with the tungsten content ranging from 50percent to 90percent by weight. The balance is copper.

Mipalloy manufactures

• TUNGSTEN COPPER
• TUNGSTEN
• MOLYBDENUM
• HIGH DENSITY TUNGSTEN BASED HEAVY METAL

Refractory metal composites used for:

• ELECTRICAL CONTACTS
• EDM & ECM ELECTRODES
• RESISTANCE WELDING ELECTRODES, INSERTS & FACINGS
• WEAR SURFACES REQUIRING HIGH ELECTRICAL & THERMAL CONDUCTIVITY
• NO CHAT BORING BARS & GRINDING QUILLS
• HIGH TEMPERATURE DIE CASTING TOOLING
• EXTRUSION & COLD DRAWING DIES
• HOT UPSETTING & ELECTRO-FORGING ANVILS
• RADIATION SHIELDS
• WEIGHTS & COUNTER BALANCES

MIPALLOY

A name synonymous with the production & supply of High Conductivity Coppers in India & abroad, now offers powder metallurgy products manufactured in its ultra modern state of art factory. Manufacture of Tungsten Copper & other sintered materials is a natural augmentation to its primary business of Chromium Copper & Beryllium Copper. Synergy in application of these materials has now made Mipalloy an undisputed leader in several fields of engineering including electrical, automobile, nuclear, metallurgy & fabrication.

COPPER TUNGSTENS

This family of unique composite materials consists of tungsten combined with copper. The refractory metals are insoluble in copper. They do not form alloys & cannot be made by conventional melting & casting methods. Instead they are made by powder metallurgy techniques. Certain complex geometries such as multiple angles, steps, radii & combination of these shapes can be incorporated into the die tooling & pressed into the part.

Mipalloy engineers stand ready to assist in the design & selection of your materials. Modern metallurgical, chemical, electrical & destructive test facilities provide any additional design or problem solving assistance that you may require.

Pure copper is an excellent electrical conductor but it is not particularly hard and it softens easily at elevated temperatures. Adding a small amount of zirconium into copper raises the softening temperature substantially and also the strength of copper is improved. Zirconium content of 0.15 per cent increases the softening temperature as much as 300°C while the effect on the electrical conductivity is not significant. Precipitation hardening metals require a good experience and knowledge to obtain optimized properties in the final product.