By Frank Ross

This copper repoussé of a Native American dancer is filled with intricate detail.

Kirk Sullens has a gift when it comes to seeing the hidden beauty in metal. He is the sole proprietor of Kirk Sullens Metal Arts, located in Mount Dora, Florida. His work, over the past two decades, marks the waypoints in a long and winding path that began by simply turning the pages of a book. Sullens describes himself as a bookworm, a dedicated bookworm, and relates back to the tome that started him on his journey to becoming a gifted metal artist. For him the first step toward his future was taken innocently during the 70’s, in what he described as his “back-to-the-land movement.”

“I picked up a book titled The Complete Blacksmith by Alexander Weygers and that changed my life,” he said. To him, blacksmithing looked cool and from the moment he read Weygers book he said, “I was hooked.”

He started out in his backyard and then got some instruction. Now, some 22 years later, he says he couldn’t imagine doing anything else.

Sullens was a long distance operator for AT&T when the company began cutting back its work force and offering to retrain their employees in another field. Seeing a great opportunity to further his passion for metalworking, Sullens asked if he could be trained as a blacksmith. Although he was told that he could never make a living as a blacksmith, and should choose some other line of training, he persisted and ultimately convinced them to finance his new passion for metal, heat and hammer.

Before his boss cooled on the concept, Sullens struck while the iron was hot.

This Native American themed lantern is one of a pair that graces the entry of the Bass Pro Shops/Outdoor World store in Broken Arrow, near Tulsa Oklahoma.

“I started looking for a school to train me and discovered the Blacksmith’s Gazette, published in Washington State. There was an ad in it for a school near where I lived in Missouri, but when I called about enrollment the instructor said that ad was old and he had stopped teaching,” he explained.

Either Sullens was destined to be a blacksmith and nothing was going to stand in the way, or he is one persuasive salesman because he convinced Bob Patrick, one of the country’s top blacksmiths, to teach one more student and he was soon pounding out 6 weeks of one-on-one training.

One thing led to another and Sullens found his way into a great job building custom designed metal art for Bass Pro Shops/Outdoor World many retail stores. After 15 years of creating all types of animals, countless metal railings, fireplace doors, lamps, lanterns and assorted decorative items he decided it was time to open his own studio.

Sullens uses a torch to bend a piece of steel forming a pair of antlers.

While his goals is to develop a trade catering to the horse people that are abundant in central Florida, he also creates commissioned projects for clients around the country, as well as following the many ideas that take root in his fertile imagination.

He is currently working on a sign for St. John’s Cycles a bicycle shop located in a nearby town. As fortune often smiles on Sullens, he was in the cycle shop to get a bike repaired and struck up a conversation with the owner, who was looking for a metal artist to build him a sign from an 1880’s advertising. The work features a steel shield, a bicycle and a copper repoussé of a naked woman with long flowing hair. He has completed the copper repoussé and expects to have the entire project finished before the February 14th grand opening.

This copper repoussé is part of the bike shop sign, and measures approximately 29 inches wide.

Sullens picked up his copper working style over time but he feels that his techniques became more refined after attending a workshop put on by George Dixon, whom he says is currently one of the best in the business. “I enjoy working with copper but it presents different challenges from doing repoussé in steel. Copper is very yielding to the tool and tends to show every tool mark, while steel is a much harder metal and doesn’t show the telltale lines created by tooling the metal into a raised form,” he said.

It was during the process of ordering materials to build the bike shop sign that he became involved with Storm Copper, and true to Sullens’ luck, this relationship has become one of tremendous satisfaction.

“I was ordering copper from another source but after several frustrating experiences I became very dissatisfied with their service, so I started surfing the Internet and that’s when I found Storm Copper. There was a little mix up with my order and I called their customer service department and spoke with a very nice lady who took down my information, then I got a call from another person who quickly followed up with more details. It seemed to me that everyone in that company had taken ownership of my problem and took a personal interest in resolving it and making sure I was happy with my purchase. I haven’t seen customer service like that in a very long time. I’m a Storm Copper customer for life,” he said.

This ornate metal screen features a copper repoussé of a four-foot alligator.

Although Sullens prefers to work in heavier gauges of copper, the airborne copper lady for his latest project was made from 18 gauge copper sheeting. Should you have a copper project in mind, Storm Copper has the perfect piece of copper to meet your needs and expectations. But if something should go awry between the order and the execution, one thing you can count on as sure as copper’s golden hue, the customer service can’t be beat.

You can see more photos of Sullens’ artistry at his page on FaceBook.

Order on line, or call our friendly customer service department toll free at 888-334-2177.

Once again the heat radiating properties of copper provides a solution to a high-tech overheating issue with computer components. With computers and especially video cards, fast isn’t often fast enough, and the ever present quest for more speed usually leads to an upgrade of existing components, which sometimes creates compatibility and heat issues, especially in the confined spaces of a laptop.

When Dell owners upgraded the video card in an Inspiron 8500 with the Mobility Radeon 9600 Pro Turbo, over heating became a serious issue. Although the Inspiron BIOS recognizes the Radeon 9600 correctly and it does work in the 8500, there is no BIOS support for the overheating issue.

During operation, users discovered the BIOS shut-off temperature is set low enough that the heat generated by the upgraded video card will cause the notebook to shut down. Thanks to Dell Community Member MadMax for supplying the pictures and the instructions that solves this problem. They key to the solution is using a small piece of copper plate that measures 3cm x 3cm x 1.5mm thick. Other items required include a heat sink compound such as Arctic Silver 5, rapid glue such as cyanacrylat from Loctite, soldering paste to clean the copper, Acetone and a small Philips head screwdriver.

It appears that the main issue that needs to be addressed is with the thermal pads that Dell uses for contact between the chip and heat sink on both GPU and CPU. These pads are quite thick and only marginally effective so you need to replace them with the 1.5 mm thick copper plate so the heat sink and GPU chip makes contact.
First, disassemble the video card until it looks like this photo. Then remove the pad that covers the die of the GPU. Clean the die with Acetone or Isopropyl alcohol that is over 99% pure. Apply the thermal compound to the copper plate, and then apply the rapid glue to each corner of the copper plate. Next, fix the copper plate to the metal making sure the side with the heat sink compound and glue is facing the metal. Apply some thermal compound on the die and screw the parts together making sure that you do not tighten the screws too much, which can crack if too much pressure is applied to the die. Remember, copper expands when it gets warm so you need to make sure there is enough room for expansion.

Install the card back into your notebook and you will note that the CPU operates at about 50°C while the GPU heats up to 75-80°C in 3D games, compared to the original 100°C.

For more detailed photos and instructions, use this link and note the English instructions are on the photos. MadMax instructions.
Copper, so many solutions for such a simple metal! Call 1-888-334-2177 for your copper solution.

When a customer contacted Quick Ship Metals customer service staff looking for a solution, he thought it was a “strange request”, but it turns out he is only one of many with this same problem.

Custom cut copper sheet is available in any thickness.

Custom cut copper sheet is available in any thickness.

His email stated, “This may be a strange request but I’m having trouble finding what I need and you seem pretty versatile. Basically, all I need is a square-inch of 12-gauge copper sheet with both surfaces polished (smooth edges would be a nice touch).”

It turns out this individual repairs computers and the HP Laptop Models dv2xxx, dv6xxx, and dv9xxx all have a common design flaw involving the GPU (graphics processing unit), which causes it to overheat and become detached – making the laptop fail completely. These laptops come with a small thermal pad which wears out and doesn’t transfer heat very well. He stated, “It is possible to reflow the solder under the chip, which gets the laptop working again, but it is just a matter of time until it happens again. Replacing the thermal pad with a copper shim as described above greatly improves heat transfer and firmly secures the chip to the logic board which effectively makes the repair permanent.”

Fortunately, a solution was readily available because QSM has been getting numerous requests for this item every day. Copper transfers heat or cold readily, so it didn’t take long for technicians to start calling. Quick Ship Metals can custom fabricate any metal order, large or small, and usually it’s out the door in 24 hours. That’s where the name comes from: Quick Ship Metals!

Log on to the web site for a live chat session to solve your metal needs: quickshipMetals.com

By Dan Kitts

Coil Sheeting is very flexible and is used in countless ways including flashing, crafts and decorative applications.

Selecting the right type of copper for any application requires an understanding of some rather technical terms like: alloy, temper, hardness, gauge and finish. Don’t be put off by the number of terms. When taken one at a time they’re not that difficult to understand. So please, stick with me through this brief article and you will have a greater understanding of copper and have the confidence to purchase for any application.

Alloy

Copper Sheet, foil, bar, rod and tube is available in many different alloys. These different alloys give certain physical properties to copper it doesn’t usually have, but those new properties often bring new limitations as well. What makes the alloy discussion a little easier is that 99% of the copper sold in the United States is represented by the three alloys listed below.

C11000
Most of the copper sold today in the United States is alloy C11000, also known as Electrolytic-Tough-Pitch. Plain and simply, C11000 is 99.9% pure copper. It makes an excellent electrical conductor, an equipment ground bar, a fine looking kick plate on your front door, does a great job as a back splash in your kitchen, makes a very classy looking rain gutter and adorns some of the finest looking roofs in the world.

C12200
Copper used for tube and pipe is usually alloy C12200. You get this alloy by adding a very small amount of phosphorus to pure copper. This makes the copper easier to weld and braze. Unfortunately, it also makes the copper considerably less conductive. Generally speaking, you rarely see this alloy being used for electrical applications, but if you need to weld or braze, this alloy is your best option.

Because Storm Grounding maintains a million-pounds of copper inventory, barstock orders usually ship the next business day. Copper Barstock is also available custom cut to specific lengths.

C14500
If you’re going to turn or machine copper, C14500 is your alloy. When copper is alloyed with a small amount of tellurium it greatly improves the ability of copper to “make chips”. Pure copper (alloy C11000) tends to be “gummy” (I apologize for using such a technical term) when machining. This gumminess means you have to slow the machining process down quite a bit. Pure copper is also hard on machine tools, which adds to the expense of machining. C14500 is not quite as conductive as pure copper, but it is relatively close.

An interesting fact about copper alloys; if you add a little zinc to the metal – you get brass.

Temper

Basically, the Temper of a metal refers to its hardness. The two extremes of Temper are denoted as “hard” and “soft”. While the Copper Development Association has installed a numbering convention H01(soft) to H04(hard), most people in the industry simply refer to the degree of hardness. “Hey, I’ll take some ‘quarter-hard’ copper sheet,” is really all you have to say to your local copper mill* to call out the Temper.

So, why does anybody even worry about Temper? To a large degree, the hardness of the metal determines the application. If you were to make a beautiful pot rack out of soft Temper copper bars and chose to hang your grandmother’s favorite cast iron frying pan on your new creation, the weight of the frying pan could well deform the rack. Bottom line, if your copper project involves supporting any kind of weight, stick to harder Tempers.

On the other hand, if you are interested in making a copper etching or simply forming the copper by hand, you would be much better off with a softer Temper. Softer Tempers are also easier to cut as well. For decorative and craft applications that do not require supporting much weight, soft Temper should be your choice.

One final point about Temper, because of the end use of the product, copper bar is generally available only in the harder Tempers and copper sheet in softer Tempers. This has to do with how the two different forms of the metal are most commonly used.

Gauge, Oz. and Inches

copper_chartCalling out the gauge of the metal is another way of saying the thickness. It is important to keep in mind that with gauge, the larger the number the thinner the material. 30 gauge copper sheet is much thinner than 16 gauge. To make matters even more confusing, the roofing industry measures copper thickness in ounces per square foot! 16 oz copper sheet is a very common size of roofing copper. Use this cross reference table to help you convert gauge to inches to ounces.

Finish

If you have ever walked in the lower level of a fancy department store and happened to see the gorgeous copper pots hanging in the kitchen department, you have seen an unnatural copper finish. Unless copper is treated with a synthetic lacquer, it will not have that deep mirror-like finish. Also, if that lacquer finish should ever crack (even a very small one) and air reaches the copper, it will discolor fairly rapidly.

Generally, the finish of copper bar and sheet will provide a dull reflection. Occasionally, the metal will also have a slight waviness to it, although it will be very smooth. Over time the metal will darken with exposure to air. The oxygen in the air is actually corroding the metal. Over a number of years a greenish patina will form on the metal. Most people find the character gained by copper through this corrosion process to be quite attractive. As a matter of fact, you can actually purchase copper that has been treated with chemicals which greatly accelerates the corrosion process. If you want that greenish finish on that copper bay window roof right away, not a problem, chemical engineering has provided the product for you. If you would prefer more of a grayish patina, that’s available as well.

Congratulations, you now know the important factors in specifying copper sheet, foil, bar, rod and tubing. Good luck with your project!

*I am being sarcastic about your local copper mill. There are only two full line copper mills in the US. If you want to go direct to the source, bring your check book. The minimum order is at least 5,000 lbs.

© 2011 Quick Ship Metals News-Blog Suffusion theme by Sayontan Sinha