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Soldering to sheet metal problems
#11
Concerning the machinability of copper, pure soft copper is absolutely difficult, and its softness means cutting edges "dig in" and gall. I agree with korishan, press the copper sheet between two other substances, and "punch" the holes in the sheet. The top plate can be aluminum, but the punch and bottom plate should be steel with sharp edges on the holes...

In any application where copper is highly desired, minor machining operations can work acceptably when you spec the C14500 alloy. It has a very small amount of tellurium, which makes the copper chips break off more easily. I used to have a problem breaking 1/4-inch drill bits when boring holes in copper (one inch deep) until I switched to C14500. It still has IACS 93/100 conductivity of pure copper. Much better conductivity than 25/100 IACS for nickel.
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