Graphite or copper electrodes is the mainstay of the electrode market. Both materials have different physical properties. For example, the amorphous form of carbon results in lower conductivity when compared with copper. Copper, on the other hand, is a natural choice for applications like arc-welding. In addition, their manufacturing process also affects the properties.
Both types electrodes require the use of high-quality materials, impregnation or baking, and finishing. The end result is electrodes that have unique properties and are tailored to meet specific industrial needs.
Graphite and copper both exhibit an impressive electrical conductivity. Their conductivity varies primarily based on how tightly their atoms or molecules are packed. The density of the material determines its conductivity. Graphite's density is lower than that of copper. Copper is highly crystalline.
Carbon electrodes do not only have electrical conductivity but also chemical inertness. This makes them the ideal choice for arc welded. This property allows them to resist corrosion and chemical reaction when exposed to reactive materials. Their oxidation resistance also allows them to last for longer in environments that are exposed to high temperatures.
The primary raw materials used to manufacture graphite electrodes are petroleum-based needle coke and coal-based needle coke, which are byproducts of the oil refining and coal tar industries, respectively. Addition of nitric is used to transform these raw materials into spheroidal coal. The spheroidal carbon is then crushed and used to make pencil graphite.
The graphite is then transformed into electrodes. The graphite can then be reformed and shaped into electrodes. It is then sanded and buffed to create the desired surface finish. The electrodes are then baked and impregnated in pitch to increase their conductivity. The electrodes are then coated with a coating to increase their oxidation resistance.
Graphite electrodes are subjected to strict testing and inspections during the manufacturing process in order to guarantee the highest possible quality. During this phase of inspection, an expert graphite checks the density and dimensions to make sure the product is up to standard. A graphite expert will also check the density and dimensional accuracy of the product to ensure it meets the required standards.
Graphite is generally more durable than Copper. They have a lower tensile and fracture strength. Copper, however, is more resilient to stress because of its exceptional ductility. The fabrication of copper electrodes is also much easier than the fabrication of graphite. This is because, unlike graphite and other metals, copper doesn't have layers that make it difficult to machine. Due to this, it can be adapted better to machining. It also boasts superior abrasion resistant. This translates to smoother machining that leads to high-quality electrodes.
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