Copper Welding Wire Rod (TIG, MIG)

Product Description

Copper and Copper-Alloy Welding Wire & Rods (AWS A5.7 / EN ISO 24373) cover a range of filler metals used for TIG (GTAW) and MIG (GMAW) welding of pure copper, copper-nickel, aluminum bronzes, and brasses, as well as overlaying steel for corrosion and wear resistance.

The most common primary grades fall into Pure Pure Copper (Deoxidized Copper), Silicon Bronze, and Aluminum Bronze categories depending on strength, electrical conductivity, and fluidity requirements.

Key Copper Filler Metal Grades

1. ERCu (Deoxidized Copper / Cu-DPE)

• Designation: EN ISO 24373 Cu1860 (CuSn0.6) or Cu1861 (CuSi0.5)

• Composition: ~98.0 to 99.5 percent Copper, with small additions of Silicon (Si) or Tin (Sn) and Phosphorus (P) as deoxidizers to prevent porosity.

• Primary Use: Welding deoxidized pure copper (DHP, DLP), oxygen-free copper, and electrical bus bars where maximum thermal and electrical conductivity is required.

2. ERCuSi-A (Silicon Bronze / CuSi3)

• Designation: EN ISO 24373 Cu6560 (CuSi3Mn1)

• Composition: ~3 percent Silicon, ~1 percent Manganese, Balance Copper.

• Primary Use: Welding copper-silicon alloys, galvanised steel sheet (MIG brazing), brasses, and plain carbon steel to copper. Offers lower melting temperature, excellent arc stability, and fluid weld pools.

3. ERCuAl-A2 (Aluminum Bronze)

• Designation: EN ISO 24373 Cu6100 (CuAl8)

• Composition: ~8.5 to 11.0 percent Aluminum, 1.5 percent Iron max, Balance Copper.

• Primary Use: Welding aluminum bronze alloys, high-strength joinings of copper to steel, seawater marine valves, propellers, and wear-resistant hardfacing overlays.

Typical Chemical Composition & Comparison

Mechanical & Physical Properties (Typical As-Welded)

• Tensile Strength:

  • ERCu: 200 to 220 MPa (29 to 32 ksi)

  • ERCuSi-A: 340 to 380 MPa (50 to 55 ksi)

  • ERCuAl-A2: 450 to 550 MPa (65 to 80 ksi)

• Electrical Conductivity (% IACS):

  • ERCu: 30 to 40 percent (higher if using unalloyed oxygen-free grade)

  • ERCuSi-A: ~8 percent

  • ERCuAl-A2: ~12 percent

• Melting Range: 950 to 1080 degrees Celsius (varies depending on silicon/aluminum alloy content)

Technical Considerations & Welding Process Rules

• Preheating Requirements: Pure copper has an exceptionally high thermal conductivity (roughly 10 times higher than carbon steel). For plate thicknesses exceeding 3 mm, preheating to 300 to 500 degrees Celsius is necessary to prevent severe cold-lapping and lack of fusion.

• Shielding Gas Selection:

  • 100 percent Argon (I1): Standard for thin sections up to 3 mm.

  • Argon/Helium or 100 percent Helium (I3): Required on heavier sections (>6 mm) to generate the extreme heat input required to offset copper's heat dissipation.

• Porosity Control: Oxygen-bearing coppers (ETP / Electrolytic Tough Pitch) are prone to hydrogen embrittlement and steam-porosity when welded. Use deoxidized copper base materials (DHP/DLP) and filler rods containing active deoxidizers (Si, Sn, P).

Industry Classifications & Packaging Specifications

• AWS Standards: AWS A5.7 / A5.7M (Copper and Copper-Alloy Bare Welding Rods and Electrodes)

• EN ISO Standards: EN ISO 24373

• Werkstoff-Nr. (WNr): 2.1211 (CuSn0.6), 2.1461 (CuSi3Mn), 2.0921 (CuAl8)

• Available Product Forms:

  • MIG Wire: 0.8 mm, 1.0 mm, 1.2 mm, 1.6 mm spools (D200, D300)

  • TIG Rods: 1.6 mm, 2.0 mm, 2.4 mm, 3.2 mm, 4.0 mm cut lengths (1000 mm)