Copper Forging, Copper Forged Parts Manufacturer & Exporter from India
We are one of the leading manufacturers and exporters of Copper Forging and Copper Forged Parts from India. We have been supplying Copper Forged Components to the world market for 3 decades. As an ISO 9001:2015, ISO 14001:2015, ISO 45001:2018 certified manufacturer, we specialize in high conductivity Copper forgings, precision Copper forged and machined parts, and custom Copper hot forged components for demanding global industries. With advanced forging presses, precision CNC machining centers, metallurgical testing laboratories, and strict quality control protocols, we manufacture Copper components that meet ASTM, DIN, BS, IS, and JIS international standards.
Our Copper forging facility supports custom design development, tool design, die making, forging simulation, post-forging heat treatment, CNC machining, and advanced surface finishing under one roof. With a typical turnaround time of 4–6 weeks, we offer reliable supply to OEMs, electrical utilities, power transmission companies, railways, renewable energy manufacturers, switchgear producers, automotive OEMs, and heavy engineering sectors worldwide.
Overview of Copper Forging & Copper Forged Parts
Copper Forging is a metal forming process in which Copper billets or rods are plastically deformed under compressive forces to achieve superior mechanical strength, refined grain structure, and improved conductivity performance. Compared to casting or fabrication, forged Copper parts offer higher density, lower porosity, improved fatigue strength, and enhanced structural integrity.
Copper Forged Parts are widely used in high-current electrical connectors, transformer connectors, grounding clamps, busbar terminals, automotive terminals, marine hardware, heat exchanger fittings, and heavy-duty industrial components. The forging process aligns grain flow with component geometry, improving tensile strength, impact resistance, and electrical efficiency.
Our forging operations include open-die forging, closed-die forging, hot forging, warm forging, precision forging, and Copper stamping. All components undergo strict metallurgical inspection including chemical composition analysis via spectrometer, mechanical property testing, dimensional inspection, and surface finish validation.
We manufacture forged Copper components in electrolytic tough pitch (ETP), oxygen-free Copper (OFHC), deoxidized high phosphorus Copper (DHP), and high conductivity Copper alloys depending on application needs.
Types of Copper Forging & Copper Forged Components
Copper Forging
Copper Forging involves controlled deformation of heated Copper billets between dies to produce near-net shape components. The process enhances structural continuity, eliminates casting defects, and ensures uniform mechanical properties. We utilize hydraulic forging presses ranging from 160 to 1000 tons with automated billet heating furnaces ensuring uniform temperature control. Copper forging is ideal for high current terminals, grounding connectors, transformer lugs, spade terminals, and heavy-duty mechanical fittings.
Copper Forged Components
Copper Forged Components are engineered parts designed for electrical, mechanical, and thermal conductivity applications. These include busbar terminals, cable lugs, battery connectors, grounding clamps, Copper forks, Copper spade connectors, and custom industrial connectors. Forged components offer high conductivity with superior tensile strength compared to fabricated or cast alternatives.
Copper Hot Forged Parts
Copper Hot Forged Parts are manufactured at temperatures typically between 700°C – 900°C to enhance malleability and reduce forging loads. Hot forging improves grain refinement and reduces internal stresses. These parts are commonly used in transformer connectors, railway earthing systems, marine connectors, heavy current terminals, and renewable energy systems.
Copper Stamped Parts and Components
Copper Stamped Parts are produced using high-tonnage mechanical presses where sheet or strip Copper is blanked, pierced, and formed into precision shapes. These parts are widely used in switchgear, panel boards, electrical connectors, battery terminals, and automotive electrical systems. Copper stamping ensures repeatability, high production rates, and tight dimensional control.
Copper Precision Forging
Copper Precision Forging produces near-net shape components requiring minimal machining. This process reduces material waste and ensures dimensional accuracy within ±0.05 mm depending on geometry. Precision forged Copper components are used in aerospace connectors, EV battery terminals, and high-voltage switchgear systems.
Copper Forged and Machined Parts
Copper Forged and Machined Parts combine forging strength with CNC precision machining. After forging, parts undergo turning, milling, drilling, tapping, slotting, and surface finishing operations. This process ensures tight tolerances, surface finish up to Ra 1.6 µm, and dimensional repeatability for critical applications.
Material Grades (International Standards)
| Region | Grade | Standard |
|---|---|---|
| USA | C11000 (ETP), C10100 (OFHC), C10200, C12200 (DHP) | ASTM B152, ASTM B187 |
| Europe | CW004A, CW008A, CW009A | EN 13600 |
| UK | C101, C103 | BS 2870 |
| India | IS 191, IS 613 | IS Standards |
| Germany | Cu-ETP, Cu-DHP | DIN 1787 |
| Japan | C1100, C1020 | JIS H3100 |
| China | T2, TU1, TP2 | GB Standards |
Typical Manufacturing Process
Billet Cutting → Induction Heating → Forging (Open/Closed Die) → Trimming → Shot Blasting → Heat Treatment → CNC Machining → Surface Finishing → Inspection → Packaging
Machinery Used:
Hydraulic forging presses, mechanical power presses, CNC turning centers, VMC machining centers, induction heating furnaces, trimming presses, shot blasting machines, CMM, spectrometer, hardness tester.
Typical Parts Produced
Transformer connectors
Copper cable lugs
Copper grounding clamps
Busbar terminals
Battery connectors
Railway bonding connectors
Marine electrical connectors
Renewable energy connectors
Dimensional Reference (Sample Forged Copper Lug)
| |
| Hole |
|_______|
| |
| |
|___|
| Size (mm²) | Hole Dia (mm) | Length (mm) | Thickness (mm) |
|---|---|---|---|
| 16 | 6 | 40 | 4 |
| 25 | 8 | 50 | 5 |
| 50 | 10 | 70 | 6 |
| 95 | 12 | 90 | 8 |
| 185 | 16 | 120 | 10 |
(Custom sizes available)
Surface Finish & Plating
Electro Tin Plating (ASTM B545)
Silver Plating
Nickel Plating
Electrolytic Polishing
Bare Copper with anti-oxidation coating
Mechanical & Electrical Properties (C11000)
| Property | Value |
|---|---|
| Electrical Conductivity | 100% IACS |
| Tensile Strength | 220 MPa |
| Yield Strength | 70 MPa |
| Elongation | 35% |
| Density | 8.89 g/cm³ |
Tolerances
Forging tolerance: ±0.3 mm to ±1.0 mm
Machining tolerance: ±0.01 mm to ±0.05 mm
Surface roughness: Ra 1.6 – 3.2 µm
Performance Metrics
High current carrying capacity
Low contact resistance
Improved fatigue strength
Superior corrosion resistance
Enhanced grain flow alignment
Industries Served
Power Transmission & Distribution
Renewable Energy (Solar & Wind)
Railways & Metro
Automotive & EV
Marine & Shipbuilding
Switchgear & Panel Boards
Heavy Engineering
Packaging & Shipping
Custom export packaging in corrugated cartons, wooden crates, vacuum packing, VCI packaging. Customer-specific labeling with barcode and logo. Bulk or palletized shipment. Worldwide shipping via sea and air freight.
Why Choose Us
With 30+ years of global export experience, we understand technical drawings, ASTM and DIN compliance, and OEM expectations. Our flexibility in production planning ensures urgent deliveries within 4–6 weeks. We provide customized die development, flexible MOQ, responsive communication, technical support, and global logistics handling. Our integrated forging and machining facility ensures cost efficiency and quality consistency.
Customer Testimonials
Michael Anderson (USA)
“The quality of Copper Forged Parts supplied consistently meets ASTM standards. Excellent communication and reliable delivery timelines.”
James Whitmore (UK)
“Highly professional manufacturer with deep technical knowledge of Copper forging. Precision machining and plating quality are exceptional.”
Frequently Asked Questions (Q&A)
-
What is the difference between Copper forging and casting?
Forging improves grain structure and strength compared to casting. -
What Copper grades do you supply?
C11000, C10100, C12200, CW004A, T2, and more. -
What is your typical lead time?
4–6 weeks depending on quantity and tooling. -
Do you provide custom forging dies?
Yes, in-house tool design and development. -
Can you meet ASTM and DIN standards?
Yes, we comply with ASTM, DIN, BS, IS, JIS. -
What surface finishes are available?
Tin, Silver, Nickel plating and bare finish. -
Do you export globally?
Yes, USA, UK, Europe, Australia, Middle East. -
What is your minimum order quantity?
Depends on part complexity; flexible MOQ. -
Do you provide PPAP documentation?
Yes, on request. -
What inspection equipment do you use?
CMM, spectrometer, hardness tester. -
Can you machine forged parts?
Yes, complete CNC machining facility. -
Do you offer anti-oxidation treatment?
Yes. -
Are your products RoHS compliant?
Yes. -
Can you handle bulk production?
Yes, high capacity forging presses. -
Do you provide customized packaging?
Yes, logo and barcode labeling available.
Glossary of Terms
Forging: Metal shaping by compressive force.
Grain Flow: Directional alignment of metal microstructure.
ETP Copper: Electrolytic Tough Pitch Copper.
OFHC Copper: Oxygen-Free High Conductivity Copper.
IACS: International Annealed Copper Standard.
Closed Die Forging: Forging within shaped dies.
Shot Blasting: Surface cleaning using abrasive media.
Related parts: Copper cable lugs, Copper grounding clamps, Copper busbars, Copper transformer connectors, Copper electrical terminals, Copper battery connectors, Copper earthing connectors.
Related Parts
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Request a Quote
Email: sales@cableglandsindia.com
Phone / WhatsApp: +91-22-43449300
Website: www.cableglandsindia.com