AMPCO® WELDING PRODUCTS

Welding Wire and Covered Electrodes

Aluminum Bronze
Nickel Aluminum Bronze
Manganese Nickel Aluminum Bronze
Copper

AMPCO METAL EXCELLENCE IN ENGINEERED ALLOYS

 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
ALLOYS

Contents
Alloys,Properties,Sizes-- page no.

AMPCO-TRODE® 7.....................................................................2
AMPCO-TRODE® 10................................................................3-4
AMPCO Copper & Copper Alloy
AMPCO-TRODE® 40...................................................................5
Welding Products
AMPCO-TRODE® 46...................................................................6
AMPCO-TRODE® 150.................................................................7 Since 1914, AMPCO METAL has pioneered in and developed
®
special bronze alloys which today have world-wide use.
AMPCO-TRODE 160.................................................................8 The development of these alloys and products has given the
AMPCO-TRODE® 940.................................................................9 AMPCO organization a vast accumulation of knowledge in the
application and use of copper alloys—all of which is reflected in the
COPR-TRODE® …………………………………..........................10 development and perfection of bronze welding products. Today,
AMPCO-TRODE® 521 & 522.....................................................12 AMPCO METAL is the leader in this specialized field.
Behind these products are exceptional plant facilities and highly
AMPCO-Core® 200....................................................................13 trained personnel. The AMPCO experienced technicians monitor
AMPCO-Core® 250....................................................................14 production and maintain quality control inspection during
manufacturing stages. Random samples of the completed products
AMPCO-Core® 250S..................................................................15 are actually weld tested as a final check of operating performance
AMPCO-Core® 300....................................................................16 and weld quality.
The latest direct reading spectrographic equipment is utilized to
Welding Formulas………………………......................................11 check and control chemical analysis. To ensure high quality and
Welding Procedures……………………….............................18-25 maximum uniformity from heat to heat, AMPCO manufactures all
weldrod products exclusively from virgin metals. This assures the
Surfacing & Overlaying………………………………………........17 user of consistent operating results and reduces defective welds
Alloys Selection Chart ………….................................................26 caused by impurities found in recycled materials. Complete
qualification tests for all specifications listed on the following pages
can be performed.
You can thus specify and use AMPCO welding products contact:
AMPCO METAL, Inc 800-844-6008, [email protected]

The information contained herein is based on data developed in the

laboratories of AMPCO METAL ("Seller"), but is presented without
guarantee or warranty, and Seller makes no recommendation for, and
disclaims any liability incurred from, any use thereof, including without
Current AMPCO METAL electrodes and wires carry warning limitation, any use in a commercial process not controlled by Seller and any
information on the package. Material safety data sheets use in violation of any existing foreign or domestic patent or applicable laws
prepared to meet the requirements of OSHA's Hazard or regulations.
Except as expressly stated in Seller's contract or sales acknowledgement
Communication Standard, 29 CFR 1910.1200, and a safety
form, all express and implied warranties, including the implied warranties of
health bulletin which provides fundamental information on merchantability and fitness for a particular purpose, are excluded by Seller.
precautions and safe practices for AMPCO METAL welding Chemical analysis and properties listed are only typical and are not to be
products and processes, are available from your welding supply construed as guaranteed values. Tests were performed in accordance with
distributor or from AMPCO METAL Inc. AWS procedures, but individual results may differ depending on conditions
of actual use.

-1-
 Bronze
Aluminum-
AMPCO-TRODE® 7
Description and Application
AMPCO-TRODE ® 7 is an iron-free, aluminum bronze alloy
available in spooled wire and 36" bare filler metal rod for use with
the gas metal-arc and gas tungsten-arc welding processes
respectively.
AMPCO-TRODE® 7 deposits are used primarily to overlay bearing
and wear-resistant surfaces requiring a hardness of approximately
125 BHN and to resist corrosion especially from salt water, metal
salts and many commonly used acids in varying concentrations
and temperatures. This alloy is not recommended for joining since
the deposit does have a tendency to be hot short.

Typical Applications
tube sheets valve scats
pickling hooks chemical plants
impellers pulp mills

Limiting Chemical Composition,

% (filler metal)
Copper* ..............................................................................balance
Aluminum .........................................................................6.0 - 8.50
Manganese ......................................................................0.50 max.
Silicon...............................................................................0.10 max.
Others ..............................................................................0.50 max.
*including silver

Mechanical Properties
(nominal all-weld metal values)
Tensile Strength, ksi...................................................68 (469 MPa)
Yield Strength, ksi......................................................28 (193 MPa)
Elongation, % in 2" (51 mm) .......................................................47
Reduction of Area, %...................................................................53
BHN (3000 kg.)
1/4" (6.4 mm) deposit.................................................................125

Standard Sizes
Aluminum bronze overlays on steel tube sheets reduce corrosive wear.

.035" .045" 1/16" 3/32" 1/8"

0.9mm 1.2mm 1.6mm 2.4mm 3.2mm

36" bare (914 mm)'

* * * Standard Sizes
AWS A5.7 Class ER CuAl-A1
30-lb spool (13.6 kg.)
* * * ASME SFA 5.7 Class ER CuAl-A1

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 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
ALLOYS
Bronze
Aluminum-
AMPCO-TRODE® 10
Description and Application Mechanical Properties
(nominal all-weld metal values)
Tensile Strength, ksi............................................77 (531 MPa)
AMPCO-TRODE® 10 aluminum bronze is the
Yield Strength, ksi ..............................................35 (241 MPa)
most versatile welding electrode in this family
Elongation, % in 2" (51 mm) .................................................27
of alloys. It is available in coated electrodes,
Reduction of Area, ％............................................................27
s poo l e d w i re a n d b a re 3 6 " ro d , and i s
BHN (3000 kg.)
intended for deposition with SMAW, GMAW,
1/4" (6.4 mm) deposit...........................................................119
GTAW welding processes.
AMPCO-TRODE ® 10 contains an additive to
inhibit inter- granular stress corrosion
cracking. This is particularly important when
welding on C61300 and C61400 base metal.
AMPCO-TRODE® 10 will weld and join many
ferrous and nonferrous metals and
combinations of dissimilar metals. These
metals include the more weld-able grades of
cast iron, high and low carbon steels, copper,
bronzes and copper-nickel alloys.
Applications for AMPCO-TRODE ® 10
include: building up bearing surfaces, joining
and fabricating copper alloys, overlaying for
resistance to corrosion and erosion and
general maintenance and repair welding.

Internal Bearing Overlay: Steel overlaid with AMPCO-TRODE® 10 Machined for

a bearing surface.

Standard Sizes
1/8" 5/32"
3.2mm 4.0mm

coated electrodes
* *
length inches/ 14 14
mm 356 356

Specifications
AWS A5.6 Class E CuAl-A2
ASME SFA 5.6 Class E CuAl-A2
AWS A5.13 Class E CuAl-A2

AMPCO-TRODE® 10 Coated

Limiting Chemical Composition

% (deposited weld metal)
Copper*..............................................................................balance
Aluminum.........................................................................8.50-11.0
Iron.....................................................................................0.50-5.0
Silicon................................................................................1.5 max.
Others................................................................0.50 max. incl. Tin
* including silver

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 Bronze
Aluminum-
AMPCO-TRODE® 10
AMPCO-TRODE® 10 Bare
Limiting Chemical Composition
% (filler metal)
Copper*................................................................................balance
Aluminum........................................................................8.50 - 11.0
Iron ...................................................................................0.75-1.50
Silicon...............................................................................0.10 max.
Others .................................................................0.50 max. incl. Tin
*including silver

Mechanical Properties
(nominal all-weld metal values)
Tensile Strength, ksi...................................................79 (545 MPa)
Yield Strength, ksi.......................................................35 (241 MPa)
Elongation, % in 2" (51 mm) ........................................................28
Reduction of Area, % ...................................................................28
BHN (3000 kg)
1/4" (6.4 mm) deposit............................................................140 Piston heads in hydraulic jacks last longer when overlaid with aluminum
bronze.
Standard Sizes
.030" .035" .045" 1/16" 3/32" 1/8" 5/32" 3/16"
0.8mm 0.9mm 1.2mm 1.6mm 2.4mm 3.2mm 4.0mm 4.8mm

GTAW 36" bare

(914mm) * * * * * * *
GMAW 30-lb. spool
(13.6kg.) * * * * *
GMAW 2lb. spool
(.68kg.) * *
Specifications
AWS A5.7 Class ER CuAl-A2
ASME SFA 5.7 Class ER CuAl-A2
Certified by ABS

Aluminum bronze marine propeller rebuilt with AMPCO-TRODE® 10 and GTAW.

Typical Applications
cast iron brake drums
malleable iron tractor gear housings
cast iron to steel idler pulleys
cast iron to bronze pickling hooks
steel to bronze paper mill rolls
aluminum bronze motor bases
silicon bronze tin plate mill rolls
manganese bronze impellers
cupro-nickel valve seats
tool steel gears
copper to steel mixer arms
bearings press rams
The unique metallurgical characteristics of aluminum bronze enable it to readily join bushings ship propellers
dissimilar metals using both the GTAW and GMAW processes. AMPCO-TRODE® 10 pump housings lance heads
was selected to join the weldment shown here, consisting of aluminum bronze,
copper, brass, silicon bronze, mild steel, Copper-nickel, cast iron, galvanized steel condenser boxes turbine runners adjusting
and stainless steel plates. hydraulic pistons spindles

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 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
Aluminum Bronze
Manganese - Nickel - ALLOYS

AMPCO-TRODE® 40
Description and Application
AMPCO-TRODE® 40
manganese-nickel-aluminum bronze is available
in coated electrodes, bare filler metal rod and
wire for welding cast ship propellers conforming
to Alloy 2 for high resistance to corrosion,
erosion and cavitation.
AMPCO-TRODE® 40 also exhibits good ability to
join dissimilar metals.

Typical Applications
ship propellers
marine components
welding cast iron
joining dissimilar metals

Superston ship propeller repair welded with AMPCO-TRODE® 40.

AMPCO-TRODE® 40 Coated AMPCO-TRODE® 40 Bare

Limiting Chemical Composition, Limiting Chemical Composition,
% (deposited weld metal)
Copper * ..............................................................................balance
% (deposited weld metal)
Aluminum...........................................................................7.0 -8.50 Copper * ..............................................................................balance
Iron......................................................................................2.0 - 4.0 Aluminum.............................................................................7.0-8.50
Nickel....................................................................................1.5-3.0 Iron.........................................................................................2.0-4.0
Manganese........................................................................11.0-14.0 Nickel.....................................................................................1.5-3.0
Silicon.................................................................................1.5 max. Manganese........................................................................11.0-14.0
Others...............................................................................0.50 max. Others...............................................................................0.50 max.
*including silver *including silver

Mechanical Properties Mechanical Properties

(nominal all-weld metal values)
Tensile Strength, ksi....................................................95 (655MPa) Tensile Strength, ksi................................................. 110 (759 MPa)
Yield Strength, ksi.......................................................56 (386 MPa) Yield Strength, ksi...................................................... 67 (462 MPa)
Elongation, % in 2" (51 mm) ........................................................27 Elongation, % in 2" (51 mm) ....................................................... 27
Reduction of Area, %....................................................................38 Reduction of Area, %................................................................... 37
BHN (3000 kg.) BHN (3000 kg.)
1/4" (6.4 mm) deposit..................................................................185 1/4" (6.4 mm) deposit................................................................ 217

Standard Sizes Standard Sizes

1/8" 5/32" .045" 1/16" 3/32" 1/8" 5/32" 3/16"

1.2mm 1.6mm 2.4mm 3.2mm 4.0mm 4.8mm
3.2mm 4.0mm

coated electrodes
* *
36” bare (1000 mm)
* * * * *
Length inches
mm
14
356
14
356
30-lb spool (13.6 kg.)
* *

Specifications Specifications
AWS A5.6 Class E CuMnNiAl AWS A5.7 Class ER CuMnNiAl
ASME SFA 5.6 Class E CuMnNiAl ASME SFA 5.7 Class ER CuMnNiAl
Certified by ABS

-5-
 Bronze
Nickel - Aluminum -
AMPCO-TRODE® 46
Description and Application
AMPCO-TRODE® 46 nickel-aluminum bronze spooled wire, bare
rod and coated electrodes were developed for the welding of cast
and wrought nickel-aluminum bronze.
AMPCO-TRODE ® 46 is also recommended for weld repairing
NiBral boat propellers.

Typical Applications
ship fittings welding AMPCO® 45
ship propellers marine propulsion systems
power plant valves propeller gear housings
piping systems oil recovery pumps
intake screens Submarine propulsion unit fabricated with
welding AMPCO® 483 AMPCO-TRODE® 46.

AMPCO-TRODE® 46 Coated

Limiting Chemical Composition, AMPCO-TRODE® 46 Bare

% (deposited weld metal)
Copper*...............................................................................balance Limiting Chemical Composition,
Aluminum.......................................................................8.50 - 9.50
Iron.....................................................................................3.0 - 6.0 % (filler metal)
Nickel.................................................................................4.0 - 6.0 Copper*...............................................................................balance
Manganese....................................................................0.50 - 3.50 Aluminum.........................................................................8.50 -9.50
Silicon................................................................................1.5 max. Iron......................................................................................3.0 - 5.0
Others..............................................................................0.50 max. Nickel..................................................................................4.0 - 5.5
*including silver Manganese.....................................................................0.60 - 3.50
Silicon...............................................................................0.10 max.
Mechanical Properties Others...............................................................................0.50 max.
(nominal all-weld metal values) *including silver
Tensile Strength, ksi..................................................99 (683 MPa)
Yield Strength, ksi.....................................................58 (400 MPa)
Elongation, % in 2" (51 mm) ......................................................25
Mechanical Properties
Reduction of Area, %..................................................................22 (nominal all-weld metal values)
BHN (3000 kg.) 1/4" (6.4 mm) deposit......................................187 Tensile Strength, ksi.................................................104 (718 MPa)
Yield Strength, ksi......................................................59 (407 MPa)
Elongation, % in 2"(51 mm) ........................................................23
Standard Sizes Reduction of Area, %...................................................................22
BHN (3000 kg.) 1/4" (6.4 mm) deposit.......................................196
1/8" 5/32"
3.2mm 4.0mm
Standard Sizes
coated electrodes
* *
SMAW length inches 14 14 .035" .045" 1/16" 3/32" 1/8" 5/32"
mm 356 356 0.9mm 1.2mm 1.6mm 2.4mm 3.2mm 4.0mm

GTAW
Specifications 36" bare (914 mm) * * * *
GMAW
AWS A5.6 Class E CuNiAl
ASME SFA 5.6 Class E CuNiAl
30-lb. spool (13.6kg.) * * *
Specifications
AWS A5.7 Class ER CuNiAl
ASME SFA 5.7 Class ER CuNiAl
Certified by ABS

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 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
Bronze
Aluminum- ALLOYS

AMPCO-TRODE® 150
Description and Application
AMPCO-TRODE ® 150 aluminum bronze
spooled wire and bare filler rod produce a
deposit of high strength and good ductility
with a nominal hardness of 166 Brinell as
applied with the inert-gas processes.
AMPCO-TRODE® 150 is recommended for
welding AMPCO ® 18 alloy. It is ideal for
piston overlay applications and bearing
surfaces requiring high strength and good
ductility.

Limiting Chemical Composition,

% (filler metal)
Copper*............................................balance
Aluminum...................................10.0 - 11.50
Iron..................................................2.0-4.50
Silicon...........................................0.10 max.
Others...........................................0.50 inax.
* including silver

Mechanical Properties
(nominal all-weld metal values)
Tensile Strength, ksi.....................................................90 (621 MPa)
Yield Strength, ksi........................................................40 (276 MPa) Propulsion Gear: Aluminum Bronze cast & wrought components fabricated into a
4000 lb. propulsion gear for a minesweeper.
Elongation, % in 2" (51 mm) .........................................................20
Reduction of Area, %.....................................................................22
BHN (3000 kg.)
1/4" (6.4 mm) deposit..................................................................166

Standard Sizes
.045" 1/16" 3/32" 1/8"
1.2mm 1.6mm 2.4mm 3.2mm

GTAW
36"bare (914mm) * * *
GMAW
30-lb. spool (13.6kg.) * * *
Specifications
AWS A5.7 Class ER CuAl-A3
ASME SFA 5.7 Class ER CuAl-A3

Typical Applications Main support shaft of steel mill coiling machine AMPCO-faced to resist abrasion
and wear.
hydraulic pistons cable sheaves
bearing overlays mill slippers
impellers valve seats and
turbine runners parts
press rams breaker blocks
ceiling machine
mandrels
steel mill rolls
welding AMPCO® 18

-7-
 Bronze
Aluminum-
AMPCO-TRODE® 160
Description and Application
AMPCO-TRODE ® 160 aluminum bronze coated electrodes
produce a deposit of high strength and good ductility with a
nominal hardness of 160 Brinell as applied by the shielded
metal-arc process.
AMPCO-TRODE ® 160 is recommended for joining aluminum
bronzes (AMPCO® 18), ferrous and dissimilar metals requiring
higher strength than produced by AMPCO-TRODE ® 10 filler
metal.
The deposit has excellent bearing characteristics and is suitable
for overlaying bearing surfaces subject to normal wear and
shock. The deposit has properties which make it resistant to
"squashing out" in bearing service.

Limiting Chemical Composition

% (deposited weld metal)
Copper * ..........................................................................balance
Aluminum.......................................................................11.0-12.0
Iron..................................................................................2.50-5.0
Silicon.............................................................................1.5 max.
Others...........................................................................0.50 max.
*including silver

Mechanical Properties
(nominal all-weld metal values)
Tensile Strength, ksi...............................................89 (614 MPa)
Yield Strength, ksi..................................................47 (324 MPa)
Elongation, % in 2" (51 mm) ...................................................15
Reduction of Area, % ...............................................................17
BHN (3000 kg.)
1/4" (6.4 mm) deposit ...........................................................177

Standard Sizes
1/8" 5/32"
3.2mm 4.0mm

coated electrodes
* *
SMAW 14 14
Length inches mm 356 356

Specifications
AWS A5.6 Class E CuAl-B
ASME SFA 5.6 Class E CuAl-B

Typical Applications
bronze castings gate valves
strip mill guides sheaves
bearing overlays pistons
crane contact shoes mill slippers
driving sprockets turbine runners packing
drop hammers glands valve seat
manipulator slides overlays

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 EXCELLENCE
Copper AMPCO-TRODE ® IN ENGINEERED
ALLOYS

AMPCO-TRODE® 940
Description and Application

AMPCO-TRODE® 940 is an alloy

developed to provide an effective
alternative to beryllium copper. One of its
principle applications is for molds and
mold components in the plastics industry.
Because of its excellent thermal
conductivity, thermal diffusivity, wear
resistance and corrosion resistance,
AMPCO-TRODE ® 940 filler metal is
specified for the repair of complex
AMPCO ® 940 molds used in forming
plastic parts.
AMPCO-TRODE ® 940 is applied with
both the gas tungsten-arc and gas
metal-arc welding processes.

Typical Applications
mold cores and pins
repair of blow molds and injection molds

Limiting Chemical Composition,

Copper*........................................................................... balance
Nickel................................................................................2.0-3.0
Silicon................................................................................0.4-0.8
Chromium......................................................................0.10-0.60
Others...........................................................................0.50 max.
*including silver

Standard Sizes
.045" 1/16" 1/8"
1.2mm 1.6mm 3.2mm
GTAW
36” bare (914 mm) * *
GMAW
30-lb spool (13.6 kg.) *
Note: AMPCO-TRODE® 940 filler metal should only
be used for minor weld repair of AMPCOLOY® 940
base material.

-9-
 Copper
COPR-TRODE®
Description and Application
COPR-TRODE ® is a deoxidized copper alloy developed to
provide dense, high quality deposits with relatively high
electrical conductivity for use in joining and overlay with the
inert-gas processes.
COPR-TRODE ® spooled wire and filler metal rod are used
primarily to fabricate deoxidized copper and repair weld copper
castings with the gas metal-arc and gas tungsten-arc
processes. It may also be used to weld galvanized steel and
deoxidized copper to mild steel where high strength joints are
not required.
COPR-TRODE® spooled wire and filler metal rod are used to
overlay surfaces to resist corrosion.
Unlike competitive sources of deoxidized copper wire,
COPR-TRODE ® is produced completely from virgin copper.
This eliminates the undesirable residual impurities which are
found in recycled copper and which drastically reduce
conductivity and overall weld deposit quality. In addition, a final
scalping operation removes any trace of scale from the wire
surface. These "extra measure" efforts assure trouble-free wire
feeding efficiency and highest quality weld deposits.

Limiting Chemical Composition,

% (deposited weld metal)
% (filler metal)
Copper*.........................................................................98.0 min.
Tin...................................................................................1.0 max.
Manganese...................................................................0.50 max.
Silicon...........................................................................0.50 max.
Phosphorus..................................................................0.15 max.
Others...........................................................................0.50 max.
*including silver

Mechanical Properties
(nominal all-weld metal values)
Tensile Strength, ksi...............................................29 (200 MPa)
Yield Strength, ksi.......................................................8 (55 MPa)
Elongation, % in 2" (51 mm) ....................................................29
Reduction of Area, %................................................................45
BHN(500 kg.)
1/4"(6.4 mm)deposit..............................................................54
Electrical Conductivity, %LACS................................................40

Specifications
Standard Sizes AWS A5.7 Class ER Cu

.035" .045" 1/16" 3/32" 1/8"

0.9mm 1.2mm 1.6mm 2.4mm 3.2mm
Typical Applications
GTAW billet molds steel mill electrode holders
36” bare (914 mm) * * * conductor rolls bus bars
GMAW heater elements copper connectors
30-lb spool (13.6 kg.) * * * copper sculptures

- 10 -
 EXCELLENCE
Welding Formulas AMPCO-TRODE ® IN ENGINEERED
ALLOYS

Welding Formulas
Method of Calculating Pounds Metric Conversion Chart
Required for Welding Groove or
Overlay (Approximate Conversion Factors)

Pounds Deposit Density

= X
Required (CU. IN.) (LBS/CU. IN.)
Density of AMPCO-TRODES® = 0.27 LBS./CU. IN.

To Convert From To Multiply By

in…………………………….....m…………………………….….....0254
Deposition of
in…………………………….....mm…………………………….........25.4
AMPCO-TRODE®
in2……………………………....mm2…………………………........645.2
Aluminum Bronze Spooled mm2………………………........in2 ……………………………......00155
Wire lb………………………….........kg (kilo)………………………….....454
kg (kilo)…………………..........lb…………………………….............2.2
Formula:
Diameter2 x .7854 x Density x IPM x 60 = LBS/HR ton (2,000 lbs.)……………......kg (kilo)………………..........…......908
kg (kilo)…………………….......ton (2,000 lbs.)………………......0011
AMPCO-TRODE® Electrode Melting metric ton (2,200 lbs.)…….....kg (kilo) …………………….........998.8
Rates and Efficiencies (SMAW) kg (kilo)…………………….......metric ton……………................0010
Ib./hr………………………........kg/hr……………………................454
Dia. AMPS Melt Rate Melt Rate Efficiency kg/hr……………………….......Ib./hr……………………………...... 2.2
(inches) (IPM) (LBS/HR) (%)
litres/min…………………........cu. ft./hr. ………………………....2.119
1/8 125 20 5.7 75.6 cu. ft./hr……………………......litres/min……………………….....4719
5/32 150 17 4.6 73.7
psi………………………….......KPa……………………………....6.895
3/16 185 16 8.7 68.5
1/4 235 13 12.1 75.9 K Pa………………………......psi……………………………….......145
M Pa……………………….......psi………………………………......145
psi………………………….......M Pa ………………………….......0069
Approximate Feet Per Pound Bare ipm…………………………......mm./sec………………………........423
Rod or Wire ft. lbs……………………….......Joule (J)………………………....1.356
Joule (J)…………………….....ft. lbs……………………………......737
Dia. FT/LB IN/LB
(inches)

.035 316 3,792

.045 191 2,292
1/16 101 1,212
3/32 46 552

Electrode Approximate Equivalents in mm for standard

Diameters AWS Electrode Diameters

in .030 .035 .045 .052 1/16 5/64 3/32 7/64 1/8 5/32 3/16 7/32 1/4

mm .8 .9 1.2 1.3 1.6 2.0 2.4 2.8 3.2 4.0 4.8 5.6 6.4

- 11 -
 Copper - Nickel
AMPCO-TRODE® 521 AMPCO-TRODE®
SG- CuNi30Fe
522
Rod/wire electrode for copper ML CuNi10Fe
Rod/wire electrode for copper
Classification
Classification
ISO 24373 S Cu 7158
(CuNi30Mn1FeTi) ISO 24373 S Cu 7061 (CuNi10)
DIN 1733 SG-CuNi30Fe DIN 1733 SG-CuNi10Fe
Material No. 2.0837 Material No. 2.0873
AWS A 5.7 ER CuNi BS 2901 part 3 C 16
BS 2901 part 3 C 18

Base materials Base materials

Particularly suitable for high stressed corrosion resistant weld Particularly suitable for highly stressed
surfacing on cast iron and on unalloyed and low- alloyed steel as corrosion resistant weld surfacing on cast iron
well as seawater resistant CuZn alloys. Suitable for welding on and on unalloyed and low-alloyed steel, seawater
CuNi resistant CuZn alloys. Appropriate to joining/surfacing
on Cu-Ni material. Especially recommended for plant
engineering.
Physical properties (Approx. values)
Electrical conductivity [S*m/mm²] 2 Physical properties (Approx. values)
Therm. conductivity [W/m K] 30
Density [kg/dm³] 8,9 Electrical conductivity [S*m/mm²] 5
Melting temperature [° C] 1.210 Therm. conductivity [W/m K] 45
Tensile strength Rm [MPa] 400 Density [kg/dm³] 8,9
Elongation A5 (Lo=5d0) [%] 35 Melting temperature [° C] 1.150
Tensile strength Rm [MPa] 350
Elongation A5 (Lo=5d0) [%] 40
Typical composition in % Modulus of elasticity [MPa] 126.000

Ni 29,0 - 32,0
Fe 0,4 - 1,0
C < 0,05
Typical composition in %
Mn 0,5 - 1,5
Si < 0,2 Ni……………………………….…………………………..........9,0 - 11,0
Ti 0,2 - 0,5 Fe…………………………………………………………............0,5 - 2,0
S < 0,015 C.....…………………………………………………………...........< 0,03
P < 0,02
Mn…………………………………………………………...........0,5 - 1,5
Pb< 0,02
Others total < 0,5 Si…………………………………………………………..................< 0,2
Ti.…………………………………………………………............0,2 - 0,5
Shielding gas Al....…………………………………………………………............< 0,03
S.....…………………………………………………………............< 0,02
Argon, Helium or Argon/Helium-mixtures
P…………………………………………………………...............< 0,007

Shielding gas
(Argon, Helium or Argon/Helium-mixtures)

- 12 -
 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
Bronze
Aluminum- ALLOYS

AMPCO-CORE® 200
Description and Application
Operating conditions
AMPCO-CORE ® 200 is an aluminum
bronze flux core wire for use with the Gas Current type
Metal Arc Welding process. DC+ (DCEP)
Gas flow rate
AMPCO-CORE® 200 is primarily an overlay 25 - 46 cfh (12-22 L/min)
filler metal. The high strength values of the Intensity [A]
deposit combined with excellent 0.045" (1.2 mm) 200-300
wear-resisting characteristics make this 0.062" (1.6 mm) 360-400
alloy unsurpassed for bearing overlays Voltage [V]
where extreme wear and high pressures All diameters 28-30
are encountered in service. Stick-out [inch (mm)]
All diameters 5/8-1" (15-25)

Typical Applications
Gear teeth, pump shafts, stripper columns,
wear plates. Also, friction plates, bearings,
sliders, high speed bearings, etc.

Limiting Chemical Composition

% (filler metal)
Copper………………………………………...........................balance AMPCO®® 8/18
Aluminum…………………………………………...........................9.0 AMPCO-CORE
®®
200
Iron………………………………………………..............................4.0

Mechanical Properties*

BHN (3000kg.) AMPCO® 200 overlaid for a wear friction plate in the steel industry.
Three layer deposit on mild steel………………..........................183

Product availability and packaging

AMPCO-CORE ® 200 is available from stock in two diameters:
0.045” (1.2mm) and 0,062” (1.6mm). Both sizes are available in
12" (300mm) spools weighing 33lb (15kg) each. Other diameters
are available upon request.
*Hardness will vary depending on quality of the weld and
experience and knowhow of the welder.

Welding position and deposits

The flat welding position is recommended. Backhand (trailing)
welding is preferred rather than forehand (pushing) to make either
stringer or weaved beads.

Shielding gas Wire

100% Argon

- 13 -
 Bronze
Aluminum-
AMPCO-CORE® 250
Description and Application
Shielding gas
AMPCO-CORE 250 is an aluminum bronze flux core wire for use
®
100% Argon
with the Gas Metal Arc Welding process.

AMPCO-CORE ® 250 is primarily an overlay filler metal. The

Operating conditions
characteristics of this filler metal make the deposit adaptable for
Current type
use in those extreme bearing applications where very high
DC+ (DCEP)
pressures are encountered operating against hardened steel
Gas flow rate
surfaces.
25 - 46 cfh (12-22 L/min)
Intensity [A]
AMPCO-CORE ® 250 often use for overlaying in applications
0.045" (1.2 mm) 200-300
where it unusual wear-resistant qualities increase service life of
0.062" (1.6 mm) 360-400
wearing parts.
Voltage [V]
All diameters 28-30
Typical Applications Stick-out [inch (mm)]
All diameters 5/8-1" (15-25)
Friction plates, bearings, sliders, high speed bearings, etc.

Limiting Chemical Composition

% (filler metal)
Copper………………………………………...........................balance
Aluminum…………………………………………..........................11.5
Iron………………………………………………..............................4.0

Mechanical Properties*
(Nominal all-weld metal value)
AMPCO® 22 AMPCO-CORE
® ®
250
BHN (3000kg.)
Three layer deposit on mild steel……………….........................250
*Hardness will vary depending on quality of the weld and
experience and knowhow of the welder.

Product availability and packaging

AMPCO-CORE ® 250 is available from stock in two diameters:
0.045” (1.2mm) and 0,062” (1.6mm). Both sizes are available in
12" (300mm) spools weighing 33lb (15 kg) each. Other diameters
are available upon request. Deflecting Roll: AMPCO® 250 overlaid for a wear surface on a deflecting roll for
the steel industry.

Welding position and deposits

The flat welding position is recommended. Backhand (trailing)
welding is preferred rather than forehand (pushing) to make
either stringer or weaved beads.

- 14 -
 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
Bronze
Nickel - Aluminum - ALLOYS

AMPCO-CORE® 250S
Description and Application
Shielding gas
AMPCO-CORE® 250S is a nickel aluminum
bronze metal core wire for use with the Gas 100% Argon
Metal Arc Welding process producing
sound, pore free deposits.

AMPCO-CORE® 250S is primarily an

overlay filler metal for aluminum bronzes
and ferrous materials. The characteristics of
this filler metal make a good choice for
overlaying components used in bearing
applications where very high pressures are
encountered operating against hardened
steel surfaces.

AMPCO-CORE ® 250S is especially suited

for marine environments due to its Ni
content which increases corrosion
resistance in brackish seawater. It also
exhibits resistance to cavitation and stress
corrosion.
Operating conditions
Typical Applications
Current type
Shafts, guide grooves, marine applications, overlaying steel parts DC+ (DCEP), continuous or pulsed
without a buffer layer Gas flow rate
25 - 42 cfh (12-20 L/min)
Intensity [A]
Limiting Chemical Composition 0.045" (1.2 mm) 150-320
0.062" (1.6 mm) 200-350
Voltage [V] (all diameters)
% (filler metal) Continuous 27-31
Copper..................................................................................Balance Pulsed 22-25
Aluminum....................................................................................11.5 Stick-out [inch (mm)]
Nickel............................................................................................4.8 All diameters 5/8"- 3/4" (10-20)
Iron................................................................................................2.0
Manganese...................................................................................1.0
NB. Higher intensities and voltages can be used but will result in increased
element burn-off (particularly Al) and dilution, leading to lower hardness
Mechanical Properties* levels. Preheating and working temperatures of up to 300 ° C are
recommended to avoid cracking.
(Nominal all-weld metal value)
BHN (3000kg.)
Three layer deposit on mild steel………………...........................320
*Hardness will vary depending on quality of the weld and experience
and knowhow of the welder.

Product availability and packaging

AMPCO-CORE ® 250S is available in two diameters: 0.045”
(1.2mm) and 0,062” (1.6mm). Both sizes are available in 12"
(300mm) spools weighing 33lb (15 kg) each. Other diameters are
available upon request.

Welding position and deposits

Flat position welding is recommended. Backhand (trailing) welding
is preferred rather than forehand (pushing) to make either stringer
or weaved beads.

- 15 -
 Bronze
Aluminum-
AMPCO-CORE® 300
Description and Application
Shielding gas
AMPCO-CORE 300 is an aluminum bronze flux core wire for use
®
100% Argon
with the Gas Metal Arc Welding process.

AMPCO-CORE® 300 is primarily an overlay filler metal. In addition

to high hardness, the deposit also has excellent bearing and
wear-resistant qualities.

These characteristics – hardness, bearing properties and wear

resistance all combine to make AMPCO-CORE ® 300 ideal for
surfacing iron and copper-base materials. Dies overlaid with
AMPCO-CORE® 300 have surprising freedom from scratching and
galling; die marks are almost completely eliminated.

Typical Applications
Fabrication of new, or rebuilding of worn, ferrous dies, used for
forming or drawing titanium, stainless steel and low to medium
carbon steel.

Limiting Chemical Composition ®

AMPCO® 22/25
®
AMPCO® 18/22
% (filler metal) AMPCO-CORE® 300
Copper………………………………………..............................balance
Aluminum…………………………………………............................13.5
®
AMPCO® 22/25
Iron………………………………………………................................4.0

Mechanical Properties*
(Nominal all-weld metal value)

*Hardness will vary depending on quality of the weld and experience Deep drawing Tool: AMPCO-TRODE® 300 for repair or build-up of deep draw
and knowhow of the welder. dies for the manufacture of stainless sinks.

BHN (3000kg.)
Three layer deposit on mild steel……………….............................364 Operating conditions
Current type
DC+ (DCEP)
Product availability and packaging Gas flow rate
25 - 46 cfh (12-22 L/min)
AMPCO-CORE ® 300 is available from stock in two diameters: Intensity [A]
0.045” (1.2mm) and 0,062” (1.6mm). Both sizes are available in 12" 0.045" (1.2 mm) 200-300
(300mm) spools weighing 33lb (15 kg) each. Other diameters are 0.062" (1.6 mm) 360-400
available upon request. Voltage [V]
All diameters 28-30
Stick-out [inch (mm)]
All diameters 5/8-1" (15-25)
Welding position and deposits

The flat welding position is recommended. Backhand (trailing)

welding is preferred rather than forehand (pushing) to make either
stringer or weaved beads.

- 16 -
 EXCELLENCE
AMPCO-TRODE ® IN ENGINEERED
Overlaying
Surfacing and ALLOYS

Surfacing & Overlaying

Surfacing or overlaying with aluminum bronze or copper is extensively practiced to obtain corrosion resistance or to build
up a bearing surface. Also known as weld cladding, this technique offers benefits in reducing materials costs and, in
salvage applications, enables an expensive or difficult-to-replace part to be reclaimed and restored to operation with
minimum of downtime.

Selection of a welding process is determined largely by the equipment available and the desired deposition rate. Gas
metal-arc welding is the most widely selected process for surfacing with AMPCO-TRODE ®. When the job dictates, gas
tungsten-arc or shielded metal-arc welding may be used satisfactorily. The higher current densities associated with the
inert-gas processes give deep penetration into the base metal. To reduce base metal pickup when overlaying iron or
steel, apply the first layer with low amperage and use a weave technique. Excessive base metal dilution would result in
difficult machinability and reduced service performance.

Experience has demonstrated that four weld layers to obtain a finish machined deposit of 1/4"(6.4 mm) provide the best
performance and mechanical properties of the weldrod with the GMAW process. A finish thickness of 3/16" (4.8mm)
would be considered a minimum satisfactory buildup. In cases where the dimensional geometry does not allow a 1/4" (6.4
mm) deposit to be added on, undercut the area to be overlaid and proceed to build up with weld metal.

Machine or grind base metal prior to first pass and wire brush or grind weld deposit between passes. Oil, cutting fluids, etc. must be removed
before welding.

Apply first pass at low side of amperage range to minimize dilution.

Bearing surface overlays are often designed with preferential wear requirements. To do this with AMPCO-TRODE ® alloys, select a filler metal
and associated welding process that will result in a weld deposit of 50 to 75 points Brinell softer than the mating surface. This will assure a
preferential wear system.

Careful application of the first layer is important to obtain a smooth, uniform contour without crevices. A weave bead or oscillated torch head
produces the best results with consistent deposit thickness. Subsequent passes may be applied practicing the same technique. Welding in the
flat position is recommended.

- 17 -
 Welding Procedures
Repair of AMPCO
Die Alloys Welding Composite Dies

AMPCO® 21, 22 and 25 aluminum bronze die alloy castings are AMPCO-TRODE ® 200, 250 and 300 filler
used in many industries for the precision forming and deep metal rod are used extensively to fabricate
drawing of stainless and mild steel, aluminum, magnesium, new forming and drawing dies by overlaying
titanium and prefinished metals where the finished product S.A.E. 1030 or 1040 steel and for the
requires a highly polished surface. Such dies have less tendency resurfacing of used cast iron and alloy steel
to scratch, seize and gall than ferrous dies, therefore, product dies where the superior qualities of
finishing time and scrap are reduced. AMPCO-TRODE ® deposits are required to
And, although these dies do have longer life expectancy, they do eliminate seizing, galling and scratching of
become worn and occasionally broken in service, requiring the blanks in forming stainless steel, mild
repair. steel, aluminum, magnesium and titanium. In
addition to providing lower finishing costs
and scrap losses, such dies require less
Recommended Filler Metal redressing and last longer.

AMPCO-TRODE® 300 / AMPCO-TRODE® 250 with gas

tungsten-arc welding. Recommended Filler Metal
AMPCO-TRODE® 300 or AMPCO-CORE® 300
AMPCO-TRODE® 200 or AMPCO-CORE® 200 AMPCO-TRODE® 300 AMPCO-TRODE® 250 with gas
AMPCO-TRODE® 250 or AMPCO-CORE® 250 tungsten-arc welding; AMPCO-TRODE® 200 with gas
tungsten-arc and gas metal-arc welding.
Preheat AMPCO-TRODE® 300 or AMPCO-CORE® 300 / AMPCO-TRODE®
200 or AMPCO-CORE® 200 / AMPCO-TRODE® 250 or
Preheat and interpass temperature of 1150°F (621°C). AMPCO-CORE® 250

Welding Procedure Preheat

For a complete fracture, crack should be ground from both sides For the initial layer on mild steel, none required. For cast iron and
to form a double U-groove having a 70-90 ° included angle with alloy steels, use a 400 ° F (204 ° C) preheat. With all subsequent
3/16" (4.8 mm)radius at bottom with 1/8" to 3/16" (3.2 to 4.8mm) layers, a 600-700 ° F (315-371 ° C) interpass temperature is
lip to maintain dimension. Apply AMPCO-TRODE ® 10 deposit required.
with either shielded metal-arc or gas tungsten-arc, alternating
from side to side to control distortion to within two layers of the
finished draw surface. Finish by applying either AMPCO-TRODE®
Welding Procedure
250 with the gas tungsten-arc process or AMPCO-TRODE® 300. Surfaces must be clean. Undercut for a minimum finished deposit
thickness of 3/16" (4.8mm)... 1/4" (6.4mm) preferred.
For complete build-up of a worn die, grind the surface to remove Edges or shoulders should have no less than a 1/4" (6.4 mm)
all oxides. If the depth of overlay exceeds 1/4" (6.4 mm), apply a radius to avoid excessive base metal pickup. Deposits must be
buffer layer of AMPCO-TRODE® 10 deposit. Subsequent layers applied with a minimum of three layers. Weld using the gas
can be applied with AMPCO-TRODE® 300 or AMPCO-TRODE® metal-arc processes, apply the initial layer at lowest amperage to
250 and the gas tungsten- arc process. If the build-up is less than reduce base metal dilution. Wire brush or grind between passes.
1/4" (6.4mm), the buffer layer of AMPCO-TRODE® 10 deposit is Subsequent layers can be applied at higher amperage. No special
not required. technique is required with the gas tungsten-arc process.

Postheat Postheat
To remove stresses and avoid deposit cracking, hold die in None required-air cool.
furnace at 1150° F (621° C) for one hour per inch of thickness and
cool rapidly in air blast.

- 18 -
 EXCELLENCE
Welding Procedures AMPCO-TRODE ® IN ENGINEERED
ALLOYS

Welding
AMPCO® 8 Alloy
Proper preparation of the base metal is essential to obtain
satisfactory welding results. The base metal in the weld area must
be free of any surface oxide. To remove this oxide layer, a
mechanical grinding operation is recommended and can be easily
AMPCO ® 8 aluminum bronze sheet and performed. Welding should only be attempted on bright gold base
plate conforming to C61300 are used metal.
extensively in welded fabrications to resist
various corrosive media. This alloy is readily Wide grooves are essential. Tack with 3/4" (19.1 mm) welds at
weldable with the inert-gas and shielded intervals of 4" to 8"(102 to 203 mm) on reverse side of plate when
metal-arc welding processes. possible and remove when back chipping for root pass. String and
small-to-moder- ate weave beads are preferred when using the gas
metal-arc and shielded metal-arc processes.

Although flat position welding is preferred to obtain highest quality

Recommended Filler Metal deposits, AMPCO ® 8 plate can be welded in the vertical and
overhead positions by skilled operators with the gas tungsten-arc
AMPCO-TRODE® 10 process and with the pulsed-arc methods using .035" (.9 mm)
and .045"(1.2mm) diameter AMPCO-TRODE® 10 spooled wire.

Preheat
Postheat
Preheating is not essential when using the inert-gas processes.
With the shielded metal-arc process, use 300° F (149° C). Interpass Generally, none required. For complicated weldments, consult
temperature should not exceed 600°F (315°C). AMPCO METAL.

Welding Procedure

AMPCO® 8 is a single-phase alloy and is not subject to undesirable

microstructure changes caused by welding.

AMPCO® 8 Fabrication, power plant water component. AMPCO® 8 Fabrication, Potash industry.

- 19 -
 Welding Procedures
Welding AMPCO® 18
Welding Cast Iron
Alloy Cast iron is a generic term describing a
variety of iron- base alloys containing 1.7%
AMPCO ® 18 is a popular aluminum bronze which offers good to 4.5% carbon. The high carbon content of
bearing qualities with resistance to wear, abrasion and fatigue. c a s t i r o n i n c r e a s e s w e l d i n g d i ff i c u l t y
Highly resistant to deformation under load, this alloy is available as compared to welding steels which possess a
sand, centrifugal and shell mold castings, extruded rod and bar, and lower carbon content.
continuous cast shapes.
The most common cast irons are the gray
irons although malleable and nodular types
are often encountered. Malleable and
nodular cast iron offer more ductility than
Recommended Filler Metal gray iron since they include a round graphite
AMPCO-TRODE ® 150 with gas tungsten-arc or gas metal- arc structure whereas gray iron contains graphite
welding; AMPCO-TRODE® 160 with shielded metal-arc welding. in flake form which results in brittleness.

Because welding on these cast irons does

Preheat create undesirable metallurgical changes in
the heat-affected zone, every procedure
Generally, no preheat is necessary. However, when joining AMPCO® imaginable has been written for cast iron welding. The procedure
18 to a ferrous metal with the shielded metal-arc process, it may be listed here is successful in most cases. However, it should be
necessary to slightly preheat the ferrous metal. pointed out that some cast irons are virtually unweldable.

Recommended Filler Metal

Welding Procedure AMPCO-TRODE® 10 and AMPCO-TRODE® 40

For joining AMPCO® 18 to itself, apply either AMPCO- TRODE®

150 or AMPCO-TRODE® 160, using a wide groove appropriate to Preheat
the thickness. Proper restraint will help minimize warpage and
300° to 600°F (149° to 315°C) depending on type and mass.
distortion when joining pieces end to end.

Welding Procedure
Postheat Small size electrodes are used with the shielded metal- arc process
None required except for corrosion service; then a temper anneal is since they prevent localized overheating which may cause cracking.
recommended. The weld metal should be deposited in stringer beads by the skip
welding technique, depositing welds three to five inches long to
prevent localized overheating. If the part being welded is of such a
construction that its ends are not free to expand or contract, it is
advisable to peen the weld immediately after depositing to remove
the stresses.
In the case of objects that do not permit preheating, smaller sized
electrodes should be used with the lowest possible amperage in
order to obtain a good bond. In some cases, welds of only one inch
long can be deposited without overheating the part. On some
grades of cast iron, AMPCO-TRODE® 10 will do a better job while
on others, AMPCO-TRODE® 40 will perform better.

Postheat
A postheat equal to or slightly higher than the preheat temperature
is recommended followed by slow cooling, often using a welding
blanket.

- 20 -
 EXCELLENCE
Welding Procedures AMPCO-TRODE ® IN ENGINEERED
ALLOYS

Welding Welding Copper

Galvanized
and Aluminized Most commercially available copper falls into three basic

Steel categories: (1) oxygen-bearing copper, (2) deoxidized copper, (3)

oxygen-free copper. The most w i del y used gr ade is the
oxygen-bearing copper, commonly referred to as ETP or
electrolytic tough pitch copper (C11000). Welding on ETP copper
Galvanized and aluminized steel can be reduces the strength and ductility of the material because of
successfully welded using AMPCO-TRODE ® cuprous oxides in the grain boundaries. Deoxidized copper
10 and the shielded metal-arc or gas metal-arc (COPR-TRODE®) is the most desirable and successfully welded
welding processes. AMPCO-TRODE® 10 offers copper since it does not have the detrimental presence of cuprous
advantages in welding these coated materials oxide.
because it provides high strength with
corrosion resistance. No post weld painting or
c oati n g i s n e c e s s a ry a n d th e c orrosi on
resistance of the base metal is retained
because coating burn-off is minimized. Recommended Filler Metal
COPR-TRODE® (for higher electrical conductivity).

Recommended Filler Metal

AMPCO-TRODE® 10
Preheat
Depends upon material thickness, the welding process and heat
Preheat input. In many cases, preheat could range from 700 ° to 1000 ° F
(360° to 540°C).
None required.
Welding Procedure
Welding Procedure Deposit weld metal by means of stringer beads or narrow weave
beads, using spray transfer. Wide weave beads may result in
All welding should be done in the flat position, using the low side oxidation at the edges of the bead. With the gas metal-arc welding
of the recommended amperage ranges (see page 18). Stringer process, the forehand welding technique should be used.
beads should be used at a rapid rate of travel since bronze
electrode melting points are much lower than those for steel
electrodes.
Postheat
Postheat None required.

None required.

- 21 -
 Welding Procedures
Welding
Recommendations
AMPCO-CORE® Cored Wires
AMPCO METAL is now offering new hardfacing cored MIG wire
with various degrees of hardness for the welding of AMPCO ®
alloys or for overlay welding on steel.

We h a v e m a d e e x t e n s i v e t e s t s a n d t r i a l s w i t h o u r n e w
AMPCO-CORE® alloys. We would like to share our experiences
with you, which are in some aspects significantly different to
welding with our well known AMPCO-TRODE® solid wires.

Welding Parameters
MIG process
Wire diameter: 1.2 /1.6 mm
Shielding gas: 100 % Argon
Flow rate: 17 - 22 L/min
Welding current: DCEP (DC+)
Welding voltage: 28-30 Volts
Welding amperage: 360 - 400 A
Wire feed speed: 6-7 m/min.

Welding Procedure

Preheat: Steel - 300°C may be recommended, depending on

size and chemical composition
Preheat: Bronze - 300°C is required
On steel – a buffer layer of AMPCO-TRODE® 10 is required
before applying the AMPCO-CORE® material.
Wire stick-out: approx. 15 mm
Direction of gun travel: Dragging (trailing) the gun is better than
pushing the gun even if the surface after pushing looks nicer,
more glossy
Grinding away the oxidized surface after each layer is necessary.
Brushing with a stainless steel brush isn't enough!

Interpass temperature: maintain an interpass temperature

between 280 and 350 ° C during the entire welding process. If the
part gets too hot, wait until the work piece temperature comes
down before continuing to deposit weld metal.

Post weld treatment: cool part slowly with a welding blanket or

other similar method
Always use sufficient exhaust to extract the welding smoke and
fumes. Use enough ventilation, exhaust at the arc, or both, to
keep fumes and gases from your breathing zone and the general
area. Always follow your employer’s safety practices.

- 22 -
 EXCELLENCE
Welding Procedures AMPCO-TRODE ® IN ENGINEERED
ALLOYS

Shielded Metal-Arc Gas Tungsten-Arc Welding

Welding
The shielded metal-arc welding process The gas tungsten-arc welding process (GTAW) is recommended
(SMAW) is a long-standing favorite in the when the operator requires the utmost in deposit quality and
industry. Probably one of the most familiar of precision control of the weld metal. The GTAW process is often
the processes, SMAW is a first choice for employed to repair castings, construct or repair forming dies,
many welders involved with maintenance fabricate copper alloy piping systems and for code work weldments.
and repair applications. The process is Direct current electrode negative (dcen) is preferred with this
portable and the equipment necessary is process although alternating current high frequency (achf) can be
commonly available. Preheating is often used. For most applications, 100% helium is recommended. Refer
recommended with this welding process, to page 19 for additional gas information. A sharp pointed tungsten
especially on heavy section thicknesses, or electrode is the preferred style. Tungsten electrodes with 2%
when welding on cast iron. The presence of thorium are preferred to deposit copper and copper alloys since 2%
moisture may introduce porosity. Use deep thoriated tungsten electrodes have higher electron emmissivity,
and maintain a short arc length. Joint longer life and are easier to start than pure tungsten electrodes. To
design information is described on page 20. d e p o s i t A M P C O - T R O D E ® w i t h G TAW, a d i p t e c h n i q u e i s
Good preparation of the base metal to clean recommended similar to the technique used to deposit aluminum
and remove surface oxidation and rod. Care must be exercised to avoid melting off the end of the filler
contamination is necessary to obtain best rod with the arc, as this will result in an oxidized ball on the end of
weld results. Do not weld on a scaly or the filler rod and impair "wetability" of the filler rod. The tungsten
greasy surface. Either stringer or weave beads may be used in should extend from 1/4" to 3/8" (6.4 to 9.5 mm)beyond the cup of
joining with equal success. However, weave beads are preferred the welding torch. Maintain an arc length of 1/16" to 3/16" (1.6 to 4.8
because slag entrapment is minimized. To deposit a weave bead, mm).
oscillate the electrode approximately three times the electrode
diameter, hesitating at the sidewalls to fill undercutting. Upon
completion of depositing a weld, thoroughly remove all slag before
applying successive layers. For overlays, apply the first layer using
a low amperage to minimize base metal dilution. Best results are
obtained when three layers are deposited. As with any welding
process, optimum results are obtained when good welding
practices are observed.

RECOMMENDED WELDING
AMPERAGE

Shieded Electrode Diameter Amperes* Gas Filler Diameter Amperes* Amperes*

3/32” 50-110 （dcen) （achf)
Metal-arc Tungsten-
1/8” 90-160
(dcep)-Positive 130-180 arc 1/16” 70-120 70-150
5/32”
3/16” 150-225 3/32” 120-160 140-230
1/8” 170-230 225-320
5/32” 220-280 175-300
Wire Diameter Voltage Amperes* 3/16” 280-330 200-320
Gas
.035” 20-26 100-200
Metal-arc
.045” 22-28 100-250
(dcep)-Positive 1/16” 29-32 250-400
3/32” 32-34 350-500 *Use low side of range for iron- or nickel-base alloys;
middle of range for bronze alloys; high side for copper.

- 23 -
 Welding Procedures
Gas Metal-Arc Welding PREHEATING

The gas metal-arc welding process (GMAW) is the most popular Preheating copper-base alloys is
process for depositing AMPCO-TRODE ® and COPR-TRODE ® frequently unnecessary when using the
alloys. GMAW affords high deposition rates, increased efficiency, gas tungsten-arc or gas metal-arc welding
high quality and reduced operator fatigue. In many cases, it processes provided section thicknesses
eliminates the necessity to preheat the work. are not unusually heavy. When welding on
copper,preheating and maintenance of
To insure a bright clean weld deposit, the gas flow rate should be interpass temperature to 1000° F (538° C)
set on 45-50 cfh (21.2-23.6 L/min.). The direction of travel and is often required, regardless of welding
angle of the gun are very important in obtaining a smooth bright process. Preheating is suggested when
deposit (see photo). The presence of a black oxide on the surface using the shielded metal-arc process. The
of the weld indicates an unsatisfactory gas coverage situation. For following recommendations are only
most applications, 100% argon gas is suggested. When sustained suggestions and will often vary depending
use of the equipment is anticipated, a water-cooled torch performs on section thicknesses, selected welding
best due to cooler operation. This is especially true with 1/16" and process and other variables.
3/32" diameter wire. Most of the current efficient air-cooled torches
will perform satisfactorily with .035" and .045" diameter wire. Arc
length within normal limits does not seem to affect deposit quality.

The power source should be set on dcep. Best results are obtained
PREHEATING
with the machine settings operating in the spray transfer range. As
w i t h a l l w e l d i n g , t h e f l a t p o s i t i o n i s p r e f e r r e d . H o w e v e r,
RECOMMENDATIONS
out-of-position welding may be performed with a pulsed-type of
power source. Suggested joint designs may be found on page 20.
1. Low carbon and mild steels up to 0.29 C - none required.
2. Medium carbon steels 0.30 C to 0.59 C - 300°F to 600°F (149°C
to 315°C), depending on carbon content.
3. Low alloy steels - same as low carbon and mild steel.
GAS SELECTION 4. Gray cast iron 400°F to 600°F (204°C to 315°C), slow cool.
5. Nodular and malleable cast iron - 300°F to 400°F (149°C to 204°
Proper shielding gas selection is one of the most important single C), post weld annealing is advisable.
factors to consider when welding with copper-base alloys. In most 6. Cupro-nickel and silicon bronze - no preheat, interpass
cases, 100% argon or 100% helium will provide best results. If temperature - 200°F (93°C) maximum.
desired, a mixture of 75% argon, 25% helium may be used with the
gas metal-arc welding process when welding on high-conductivity 7. Aluminum bronze - alloys up to 10% aluminum - no preheat,
base metal. The accompanying table shows recommended gas type 300°F (149°C) maximum interpass.
and flow rates. Alloys exceeding 10% aluminum - 300°F and 600°F (149°C and
315°C) maximum interpass.
Argon provides a soft arc and is good for welding on thin section 8. Manganese bronze - 300°F (149°C) for inert gas and 500°F
thickness. Helium has more current-carrying ability and provides a (260°C) for shielded metal-arc.
hot arc with greater speed and more penetration.
9. Copper - 1000°F (538°C).
GTAW 100% helium 40-55 cfh (19.0-26.0 L/min.)
100% argon 40-55 cfh (19.0-26.0 L/min.)

GMAW 100% argon 45-55 cfh (21.2-26.0 L/min.)

75% argon-
25% helium 45-55 cfh (21.2-26.0 L/min.)

- 24 -
 EXCELLENCE
Welding Procedures AMPCO-TRODE ® IN ENGINEERED
ALLOYS

Welding Copper-Tin Welding Copper-Silicon

Alloys Alloys
(Phosphor Bronze) (Silicon Bronze)
Copper-tin alloys, commonly called The copper-silicon alloys, commonly referred to as silicon bronzes,
phosphor bronze, have tin contents in the contain small additions of iron, manganese and tin. The silicon
range of 1 to 10%. The two commonly-used content in bare ER CuSi-A filler metal is between 2.8 to 4.0% and
welding filler metals are ER CuSn-A which is the primary hardening element in the composition. Silicon
contains about 5% tin and ER CuSn-C bronze filler metal is used for welding silicon bronzes and brasses
w h i c h c o n t a i n s a b o u t 8 % t i n . Ti n and to weld galvanized steel.
strengthens the alloy and phosphorus is
added as a deoxidizer. These bronzes are extremely hot short and care must be
exercised to avoid overheating the joint which tends to cause
Copper-tin alloys have rather wide freezing cracking.
ranges. They solidify with coarse, dendritic
grain structures. In weld metal, these grain
structures have a tendency to crack unless
the welding procedure is designed to prevent it. Hot peening of
Recommended Filler Metal
each layer of multiple - pass welds will reduce welding stresses, Silicon bronze or AMPCO-TRODE® 10
resulting in a fine grained structure possessing increased tensile
strength and ductility.
Preheat
Preheat slightly to remove moisture. Interpass temperature should
Recommended Filler Metal not exceed 150°F (66°C).
Phosphor bronze grade A or C; AMPCO-TRODE ® 10
Welding Procedure
Preheat With gas metal-arc welding, the weld metal should be deposited in
On light sections, none required. However, preheat and interpass stringer beads, maintaining a small molten pool to avoid
temperatures up to 300°F (149°C) are recommended for heavy overheating the hot short base metal. Use argon shielding gas and
sections if the shielded metal-arc welding process is used. Preheat relatively high welding travel speed.
is not essential when gas metal-arc welding with spray transfer.
With the gas tungsten-arc process, welding is accomplished with
dcen (dcsp) and argon or helium gas shielding. ACHF with argon
Welding Procedure gas shielding may be used to take advantage of the arc cleaning
action.
Gas metal-arc process is suggested for welding on large and thick
phosphor bronze fabrications. Direct current electrode positive In applications where steel is joined to silicon bronze, use
(deep) and argon shielding gas are normally used. The molten AMPCO-TRODE ® 10 and the gas metal-arc or gas tungsten-arc
weld pool should be kept small and the travel speed rather high. welding processes. Position the work so that the steel is in the
Stringer beads should be used in order to obtain a dense, fine vertical plane and the bronze is in the horizontal plane to avoid
grain deposit. Hot peening of each layer will reduce welding undercutting.
stresses. In gas tungsten-arc welding, use alternating current
high frequency (achf) or direct current electrode negative (dcen) Postheat
and helium or argon gas shielding. Hot peening of each layer of
weld metal is beneficial. The base metal should be preheated to None required.
the 300° F to 400° F (149° C to 204° C) range and the travel speed
should be as fast as practical.

Postheat
Ordinarily, for most service requirements, postheating is not
essential. However, if maximum ductility in the deposit is required,
a postheat treatment of 900 ° F (482 ° C) with fast cooling is
recommended.

- 25 -
 Selection Chart
Bronze Filler Metal
C861
C102

EL
NZE

STE

EL
ZE EL

EL
ZE
C122

UM

STE
RON ICK

EEL
STE
R ON

BRO

B ON
ZE

U IN
M. B SE N
L
R ON

Y ST
ALU ANE 58

B ON
CKE

B ON
C110

MAN ZE. C9M

OR B

CAR
ESE

N
18

BRO EL AL
ON B

ALLO
I

CAR
8

T IRO
CAR
RO-N
GA N
PER
SPH
CO ®

CO ®

IUM
G
N
SILIC

NICK

HIGH
L OW
L OW
MAN

MED
AMP

AMP
C OP
PHO

CUP

CAS
AMPCO® 8 1,B 1,B 1,G 1,7,C 1,A 1,B 1,B 1,5,B 1,4,B 1,B 1,B 1,B 1,B 1,C

AMPCO® 18 1,B 2,3,B 1,G 1,7,C 1,A 1,A 1,A 1,5,B 1,B 1,B 1,A 1,C 1,D 1,C

COPPER C110 C122 C102 1,G 1,G 8,G 7,8,G 1,8,G 1,8,G 1,8,G 1,5,8,G 1,4,8,G 1,G 1,G 1,G 1,G 1,G

PHOSPHOR BRONZE 1,7,C 1,7,C 7,8,G 7,8,C 7,A 1,7,C 7,1,C 7,C 7,C 7,1,C 7,1,C 7,1,C 7,1,D 7,1,C

SILICON BRONZE 1,A 1,A 1,8,A 7,A 6,A 1,6,A 1,A 1,A 1,A 1,C 1,A 1,A 1,C 1,6,B

MANGANESE BRONZE C861 1,A 1,A 1,8,G 1,7,C 1,6,A 1,B 1,B 1,B 1,B 1,C 1,A 1,C 1,D 1,C

CUPRO-NICKEL 1,B 1,A 1,8,G 7,1,C 1,A 1,B 9,10,B 1,A 1,4,A 1,C 1,A 1,C 1,D 1,C

NICKEL ALUMINUM BRONZE. C958 1,5,B 1,5,B 1,5,8,G 7,C 1,A 1,B 1,A 5,B 4,B 1,C 1,B 1,C 1,D 1,C

MANGANESE NICKEL ALUM. BRONZE 1,4,B 1,B 1,4,8,G 7,C 1,A 1,B 1,4,A 4,B 4,B 1,C 4,B 4,C 4,D 4,C

LOW ALLOY STEEL 1,B 1,B 1,G 7,1,C 1,A 1,C 1,C 1,B 1,C ... ... ... ... ...

LOW CARBON STEEL 1,B 1,A 1,G 7,1,C 1,A 1,B 1,A 1,B 4,B ... ... ... ... ...

MEDIUM CARBON STEEL 1,B 1,C 1,G 7,1,C 1,A 1,B 1,A 1,C 1,C ... ... ... ... ...

HIGH CARBON STEEL 1,B 1,D 1,G 7,1,D 1,C 1,D 1,D 1,D 1,D ... ... ... ... ...

CAST IRON 1,C 1,C 1,G 7,1,C 1,6,B 1,C 1,C 1,C 4,C ... ... ... ... ...

How to Use the Chart Fill Metal Designation Preheat &

Suggested AMPCO® filler metal for welding like and dissimilar 1. AMPCO-TRODE 10 Interpass ®

metals are coded by numbers. The selected filler metals are based 2. AMPCO-TRODE 150 Temperature ®

on using the inert-gas welding processes. Covered electrodes are 3. AMPCO-TRODE ® 160
selected according to weldability except in those cases where A.150°F Max.(66°C)
mechanical properties are considered of more importance. 4. AMPCO-TRODE ® 40
5. AMPCO-TRODE ® 46 B.300°F (149°C)
Preheat and interpass temperatures are coded by letters. Preheat 6. SILICON BROZE C.400°F (204°C)
and interpass temperature shown for joining dissimilar metals is D.500°F (260°C)
that suggested for the metal or alloy requiring the highest 7. PHOSPHOR BROZE
temperature of the two. Temperatures also vary with the mass and 8. COPR-TRODE ® E.600°F (315°C)
shape of the weldment. See page 19 for additional preheating 9. AMPCO-TRODE ® 521 F.1000°F (538°C)
information.
-70/30 Copper/Nickel
10. AMPCO-TRODE ® 522
-90/10 Copper/Nickel

- 26 -
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