CALCIUM COPPER MASTER ALLOY (5% Ca)

1. PRODUCT IDENTIFICATION AND CHEMICAL IDENTITY

Parameter	Information
Product Name	Calcium Copper Master Alloy (5% Ca)
Alloy Designation	CuCa5%
Composition	5% Calcium by weight, balance Copper
Form	Master alloy ingot (typical weight: 1-5 kg / ingot)
CAS Number (Calcium)	7440-70-2
CAS Number (Copper)	7440-50-8
Alloy CAS	Not applicable (alloy mixture)
HS Code (Turkey)	7403.29 – Copper alloys, unwrought (other copper alloys)
EINECS / ELINCS	Not applicable (alloy)

2. CHEMICAL STRUCTURE AND PHASE DIAGRAM

2.1. Molecular Structure

Calcium Copper Master Alloy (CuCa5%) consists of a copper-rich matrix with finely distributed intermetallic CaCu₅ phases. The alloy is designed to provide controlled calcium addition to copper melts. The intermetallic phases are finely dispersed within the copper matrix, ensuring homogeneous distribution during melting.

Crystal Structure:

                    CALCIUM COPPER MASTER ALLOY (CuCa5%)
                               |
                 Cu Matrix + CaCu₅ Intermetallic Phases
                               |
             +----------------+----------------+
             |                |                |
         Cu-rich Matrix    CaCu₅ Intermetallic  Fine
         (FCC)             (Intermetallic)      Distribution

2.2. Phase Structure and Crystallographic Properties

Phase	Chemical Formula	Crystal System	Description
Cu-rich Matrix	Cu (Ca)	Face-Centered Cubic (FCC)	Copper solid solution with dissolved calcium
CaCu₅ Phase	CaCu₅	Hexagonal	Primary intermetallic phase; provides calcium delivery
CaCu₂ Phase	CaCu₂	Orthorhombic	Secondary intermetallic phase (minor)

2.3. Crystal Structure Details

Parameter	Cu-rich Matrix	CaCu₅ Phase
Crystal System	Cubic (FCC)	Hexagonal
Space Group	Fm3̄m	P6/mmm
Lattice Parameter (a)	3.61 Å	5.02 Å
Coordination Number	12	10
Hardness	Low (ductile)	High (brittle)

3. PHYSICAL AND THERMAL PROPERTIES

Property	Value	Unit / Note
Calcium Content	5.0 ± 0.5	% by weight
Copper Content	Balance (~95%)	% by weight
Liquidus Temperature	1203 K	930 °C
Solidus Temperature	1190 K	917 °C
Phase	Intermetallic (I)	Alloy solidification behavior
Density (20°C)	~8.2	g/cm³
Electrical Conductivity	~45-55	% IACS (process dependent)
Thermal Conductivity	~180-200	W/(m·K)
Appearance	Metallic, copper-colored	Solid ingot form
Microstructure	Fine CaCu₅ intermetallic phases dispersed in copper matrix	-

4. METALLURGICAL PROPERTIES

4.1. Microstructure

The microstructure consists of a copper matrix with finely distributed intermetallic CaCu₅ phases. The intermetallic phases are formed during solidification and are uniformly dispersed throughout the matrix. This structure ensures rapid dissolution when the master alloy is added to copper melts.

4.2. Metallurgical Mechanisms

Mechanism	Description
Grain Refinement	Calcium acts as a grain refiner, reducing cast grain size and improving mechanical properties
Deoxidation	Calcium forms stable CaO, removing dissolved oxygen from molten copper
Degassing	Calcium binds with hydrogen, reducing hydrogen-induced porosity
Intermetallic Formation	CaCu₅ phases provide controlled calcium release during melting
Segregation Reduction	Homogeneous distribution minimizes micro-segregation

4.3. Deoxidation Mechanism

Ca + O → CaO (slag)

Calcium reacts with dissolved oxygen in the melt to form calcium oxide, which floats to the surface as slag. This is more stable than phosphorus or lithium deoxidation for certain high-conductivity applications.

5. DETAILED APPLICATION AREAS

5.1. Grain Refinement and Microstructure Control

Application	Function
Cast Grain Refinement	Reduces cast grain size, improves mechanical properties, reduces segregation
Continuous Casting	Provides homogeneous, equiaxed grain structure in continuously cast copper products
Wrought Products	Improves formability and surface quality

5.2. Deoxidation and Degassing

Application	Function
Oxygen Removal	Forms stable CaO, removing dissolved oxygen from molten copper
Hydrogen Binding	Reduces hydrogen-induced porosity, minimizing gas defects in final castings
Stable Deoxidizer	More stable than phosphorus or lithium for certain high-conductivity applications

5.3. Mechanical Property Enhancement

Application	Function
Strength Increase	Increases tensile strength and hardness of copper alloys without significant loss of ductility
Creep Resistance	Improves creep resistance and high-temperature stability
Wear Resistance	Enhances wear resistance in bearing and sliding applications

5.4. High-Performance Electrical Components

Application	Function
Electrical Contacts	Improves arc resistance and reduces contact welding
Vacuum Interrupters	Used in circuit breakers and switchgear
Conductivity Retention	Maintains good electrical conductivity (up to 55% IACS) while providing superior mechanical wear resistance

5.5. Specialty Copper Casting

Application	Function
Continuous Casting	Improves surface quality and reduces casting cracks in copper rods, wires, and tubes
Oxygen-Free Copper	Ideal for oxygen-free copper grades (e.g., Cu-OF + Ca) requiring trace calcium additions

5.6. Lead-Free Copper Alloys

Application	Function
Lead Substitution	Used as a substitute for lead in some copper alloys to improve machinability
RoHS Compliance	Ensures compliance with RoHS, WEEE, and other environmental regulations
Chip Breaking	Improves chip breaking in machining operations similar to leaded brasses and bronzes

5.7. Bearing and Wear-Resistant Alloys

Application	Function
Anti-Friction Alloys	Added to copper-tin and copper-aluminum bearing alloys
Solid Lubricant	Forms hard intermetallic particles that act as solid lubricants under limited lubrication conditions

5.8. Corrosion-Resistant Copper Alloys

Application	Function
Dezincification Resistance	Improves dezincification resistance in brasses
Pitting Corrosion	Enhances pitting corrosion resistance in copper-nickel alloys used in marine environments

6. ADVANTAGES

Advantage	Description
Precise Calcium Addition	Master alloy form prevents oxidation losses that occur when adding pure calcium directly to molten copper
Improved Strength-Conductivity Balance	Enables precise tuning of mechanical and electrical properties in final products
Homogeneous Microstructure	Ensures uniform distribution of calcium throughout the melt, eliminating local segregation
Reduced Slag Formation	Lower oxidation tendency compared to pure calcium, resulting in cleaner melting operations
Cost-Effective Alloying	Lower melting temperature (~930°C) compared to pure calcium (839°C boiling point), providing safer and more efficient addition
Compatibility	Suitable for use in induction furnaces, crucible furnaces, and continuous casting lines
Beryllium-Free	Non-toxic alternative to beryllium-containing alloys

7. ADVANTAGES OVER PURE CALCIUM

Feature	CuCa5% Master Alloy	Pure Calcium
Melting Point	~930°C	839°C (boils)
Handling	Safe, easy to handle	Pyrophoric, reacts with moisture
Oxidation Loss	Minimal	High
Recovery Rate	>95%	50-80%
Storage	Standard dry storage	Requires inert atmosphere or oil
Addition Method	Direct addition	Requires special equipment

8. STORAGE AND HANDLING

8.1. Storage Conditions

Parameter	Recommendation
Environment	Dry, well-ventilated area with relative humidity below 60%
Containers	Store in original packaging or closed containers to prevent surface oxidation
Avoid	Direct contact with water, steam, or acidic vapors
Shelf Life	Minimum 12 months when properly stored (surface darkening does not affect performance)

8.2. Usage Precautions

Parameter	Recommendation
Equipment	Use clean, dry tools and crucibles to prevent contamination
Preheating	Preheat master alloy to 150-200°C before adding to molten metal to prevent moisture-related splashing
Addition Temperature	Add to melt at 950-1050°C with gentle stirring
Avoid	Do not add directly to superheated melt above 1150°C (may cause calcium vaporization)

8.3. Personal Protective Equipment (PPE)

Equipment	Standard
Protective Gloves	Leather or heat-resistant (EN 407)
Safety Goggles / Face Shield	EN 166
Heat-Resistant Apron	-
Safety Shoes	-
Respiratory Protection	N95 or P2 filter for operations generating dust/fumes (grinding, cutting, machining)

9. SAFETY INFORMATION

Hazard Type	Information
Solid Form	Not hazardous. No acute toxicity
Dust / Fumes	May cause respiratory irritation. Calcium oxide fumes are mildly alkaline
Reaction with Water	Slow reaction: may form calcium hydroxide and hydrogen gas on moist surfaces (negligible in solid ingot form). Do not immerse in water
Fire Hazard	Not flammable. However, fine powder may be combustible under extreme conditions
First Aid (Inhalation)	Move to fresh air. Seek medical attention if irritation persists
First Aid (Skin)	Wash with plenty of soap and water. Molten metal contact requires immediate medical attention
Disposal	Recycle as copper scrap. Do not dispose with household waste. Follow local regulations for metal recycling

Always comply with local occupational health and safety regulations (OSHA, EU-OSHA, or Turkish ISG legislation).

10. QUALITY CONTROL

Test	Method	Acceptance Criteria
Chemical Analysis	ICP-OES	Ca: 5.0 ± 0.5%; Cu: Balance
Impurity Analysis	ICP-OES	Total impurities < 0.3%
Weight and Dimensions	Checked against tolerances	Within specified limits
Visual Inspection	Metallographic	No cracks, large shrinkage cavities, or surface contamination
Microstructure	Optical Microscope / SEM	Fine CaCu₅ intermetallic phases in copper matrix
Certificate of Analysis (COA)	Provided with each shipment	Heat number, batch number, and chemical composition

11. PACKAGING

Parameter	Information
Standard Packaging	Ingots stacked on painted steel pallets (~1000 kg per pallet)
Ingot Weight	2 kg, 5 kg, or custom upon request
Pallet Dimensions	1200 x 800 mm (Euro pallet) or custom
Packaging Material	Stretch-wrapped or steel-banded
Labeling	Product name, heat number, net weight
Special Packaging	Available upon request (e.g., small quantity boxes, anti-tarnish foil packaging)

12. REGULATORY COMPLIANCE

Regulation	Status
RoHS (2011/65/EU)	Compliant (lead-free, cadmium-free)
REACH (EC 1907/2006)	Registered for copper and calcium substances; alloy is exempt from registration as a mixture
Conflict Minerals	Copper sourced from conflict-free smelters (RMI certification available upon request)
Turkey Customs	HS Code 7403.29 – Correct classification for unwrought copper alloys with alloy element content below 15%

13. QUICK REFERENCE TABLE

Property	Value
Product Name	Calcium Copper Master Alloy
Alloy Designation	CuCa5%
Ca Content	5.0 ± 0.5%
Cu Content	Balance (~95%)
Liquidus Temperature	930 °C
Solidus Temperature	917 °C
Melting Range	917 – 930 °C
Density (20°C)	~8.2 g/cm³
Electrical Conductivity	~45-55 % IACS
Thermal Conductivity	~180-200 W/(m·K)
Form	Ingot (1-5 kg)
Primary Phase	Cu-rich matrix + CaCu₅ intermetallic
HS Code	7403.29
RoHS Compliant	Yes
Beryllium-Free	Yes

14. CRITICAL NOTICES AND BEST PRACTICES

CRITICAL NOTICES:

Calcium Content: Nominal composition is 5% Ca. Final alloy calcium content typically 0.05-0.5% depending on application.
Melting Range: 917-930°C. Do not exceed 1150°C to prevent calcium vaporization.
Preheating Required: Preheat to 150-200°C before addition to prevent moisture-related splashing.
Deoxidation Effect: Calcium acts as a stable deoxidizer. Consider this when calculating oxygen levels in the melt.
Lead-Free Alternative: Provides RoHS-compliant, lead-free alternative for machinability enhancement.
Beryllium-Free: Non-toxic alternative to beryllium-containing alloys.
Moisture Sensitivity: Store in dry conditions; reacts slowly with moisture.

BEST PRACTICE RECOMMENDATIONS:

Storage:

Store in dry, well-ventilated area (RH < 60%)
Keep in original packaging or closed containers
No direct contact with water or steam
Shelf life: minimum 12 months

Handling:

Use protective gloves, safety goggles, and heat-resistant apron
Use clean, dry tools and crucibles
Preheat to 150-200°C before addition

Melting:

Add at 950-1050°C
Apply gentle stirring for homogeneity
Do not exceed 1150°C
Expected calcium recovery >95%

Waste Management:

Recycle as copper scrap
Do not dispose with household waste
Follow local regulations

LEGAL DISCLAIMER

This Technical Data Sheet (TDS) is for informational purposes only and is prepared based on available technical data. The user is solely responsible for determining the suitability of the product for their specific application and for complying with all local, national, and international regulations. For complete safety, storage, handling, transport, waste, and regulatory compliance information, the official Safety Data Sheet (SDS/MSDS) provided by the manufacturer/supplier must be consulted. This document does not substitute professional advice. Calcium is a reactive metal; appropriate precautions must be taken during handling.

Calcium Copper Master Alloy, Calcium Copper ingot, 7440-70-2, 7440-50-8