When sourcing components for induction heating coils or large motor windings, procurement managers are often tempted by the lower upfront cost of Cast Copper. However, choosing a casting over a wrought C10100 Oxygen-Free Electronic copper profile is a gamble with your equipment's efficiency.
The primary issue is not just the chemistry, but the structural integrity. While 99.99% pure C10100 is extruded or forged into a dense, void-free structure, cast copper inherently contains microscopic gas pockets (porosity) that act as thermal and electrical insulators.
Why cast copper cannot match the 101% IACS of C10100?
Conductivity is a direct reflection of metallurgical density. In a C10100 Round, Square & Flat Bar, the grains are tightly packed and aligned. In contrast, cast copper (often categorized as C81100) suffers from random grain orientation and dendritic structures that scatter electrons.
Cast Copper: Typically offers only 80% to 92% IACS conductivity.
C10100 (OFE): Guaranteed 101% IACS conductivity.
In high-power induction heating, a 10% drop in conductivity means 10% more energy is wasted as heat within the coil itself. This I-squared R loss leads to "hot spots" that can melt the coil or cause cooling water to boil, leading to catastrophic system failure.
Wrought C10100 vs. Cast Copper (C81100) Comparison
| Feature | C10100 (Extruded/Forged) | Cast Copper (Sand/Die Cast) | Impact on ROI |
| Density | 8.94 g/cm3 (Zero Voids) | 8.3 - 8.7 g/cm3 (Porous) | Castings fail under vacuum |
| Conductivity | 101% IACS | 85% - 92% IACS | C10100 saves electricity |
| Thermal Cond. | 391 W/m-K | ~300 - 340 W/m-K | C10100 cools 20% faster |
| Oxygen Content | < 5 ppm | High (uncontrolled) | Castings crack during brazing |
| Machinability | Consistent / Predictable | Pockets cause tool breakage | C10100 is better for CNC |
Consult GNEE Engineers: Should I Switch from Castings to C10100?
The Risk of "Virtual Leaks" in Vacuum-Brazed Assemblies
If your component requires vacuum brazing-common in C10100 Seamless Tube & Pipe assemblies-cast copper is a disaster. The internal gas pockets (porosity) in a casting act as "virtual leaks." During the bake-out process, these pockets slowly release trapped gases, preventing your system from reaching the required vacuum level.
Because C10100 is vacuum-melted and extruded, it is 100% dense. When you order Custom CNC Machined Parts made from C10100, you are guaranteed a material that is hermetically stable. This is why C10100 is the only choice for ultra-high vacuum (UHV) components where cast copper would fail instantly.
For a procurement manager, the "savings" from cast copper disappear the moment a machine goes offline. The superior thermal and electrical performance of 99.99% pure C10100 ensures that your induction coils run cooler and your motors run more efficiently. GNEE METAL provides certified C10100 in bars, tubes, and plates, offering the density and 101% IACS performance that cast copper simply cannot provide.
Request a Quote for Certified C10100 Bars and Tubes
GNEE METAL Product Range
| Product Type | Shapes Available | Common Grades | Diameter/Thickness Range | Length/Width Range | Applications |
|---|---|---|---|---|---|
| Copper Tubes | Round, Square, Rectangular, Coiled | C10100, C10200, C11000, C12200, C12000 | OD: 0.5mm - 300mm Wall: 0.1mm - 20mm | Up to 6000mm or custom | HVAC, Plumbing, Heat Exchangers, Refrigeration, Hydraulic Lines |
| Copper Plates & Sheets | Flat Sheets, Perforated, Embossed, Tread Plate | C10100, C11000, C12200, C23000, C26000 | Thickness: 0.1mm - 200mm | Width: Up to 2500mm Length: Up to 6000mm | Electrical Busbars, Roofing, Cladding, Gaskets, Transformers |
| Copper Bars & Rods | Round Bar, Square Bar, Hexagonal Bar, Flat Bar | C10100, C11000, C14500, C17200, C18200 | Diameter: 1mm - 300mm | Length: 1000mm - 4000mm | Machined Components, Electrical Contacts, Busbars, Fasteners |
| Copper Wires | Round Wire, Flat Wire, Square Wire, Stranded, Braided | C11000, C11600, C17200, C17510 | Diameter: 0.05mm - 12mm | Coil weights: 1kg - 500kg | Electrical Wiring, Cables, Springs, Mesh, Welding Wire |
| Copper Strips & Coils | Thin Strip, Foil, Slit Coil, Profile Strip | C11000, C12200, C19400, C26000, C26800 | Thickness: 0.03mm - 5mm | Width: 2mm - 1000mm Coil ID: 300mm - 600mm | Transformers, Radiators, Shielding, Terminals, Connectors |
About Our Factory
We operate a full range of production lines including extrusion presses, cold drawing benches, high-speed rolling mills, slitting lines, and precision CNC machining centers, enabling us to produce copper tubes, plates, bars, wires, and strips entirely in-house. For quality assurance, we maintain a dedicated inspection laboratory equipped with spectral analyzers, universal testing machines, hardness testers, surface roughness testers, and optical measuring instruments. Every batch is tested for chemical composition, mechanical properties, and dimensional accuracy before shipment. Our production capacity reaches 500+ tons per month, and we hold ISO 9001:2015 certification with full traceability from raw material to finished product. Whether you need standard mill stock or custom-processed components, we deliver precision copper products with short lead times and complete material certification.
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