UNIT 19

WELDING OF COPPl~R

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 UNIT: 19
WELDING OF COPPER

Structure

19.1 Introduction

19.2 Objectives

19.3 Grades of Copper

19.4 Uses of Copper

19.5 Properties of Copper

19.6 Fusion Welding of Copper

19.7 Arc Welding of'Copper

19.7.1 Technique
19.7.2 After Treatment

19.8 Intext Questions '

19.9 Practicals

19.10 What you have learnt

19.11 Terminal Questions

19.12 Feedback on Intext Questions

19.1 INTRODUCTION

Copper is derived from mines. It is available in three grades. High conductingldeoxidised

copper, oxidized copper and arsenical copper. Deoxidised copper is 99.9% pure-and
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contains 0.015 to 0.08% phosphorus. It is a non-ferrous metal. Non - ferrous metal is

one which does not contain iron as its basic element. It is malleable and ductile having
reddish colour. It is available in the form of copper plates, tubes/pipes, strips, complicated
shapes of copper casting, wires, armoured cables and domestic utensils. Copper alloys
are brass and bronze. In this unit copper, its properties and welding of copper both by
gas and arc, are discussed.

19.2 OBJECTIVES

After the completion of this unit, the student will be able to:

* understand what about copper- non-ferrous metal.;

* Properties of copper.

* Welding of copper by gas and arc welding process.

19.3 GRADES OF COPPER

Copper is available in three grades which are :-

(l) Deoxidised copper

(2) Oxidised copper

(3) Arsenical copper.

Deoxidised copper is 99.9% pure. It contains 0.015% - 0.08% phosphorus. Oxidized

and arsenical copper are not suitable for fusion welding due to formation of cuprous oxide
which leads to porosity and cracking in weld metal.

19.4 USES OF COPPER

Because of very high electrical conductivity it is used in generator bus bars, power lines,
switches, electric motors, welding machines electric traction and so on. Deoxidized copper
containing phosphorus (0.08%) is used for domestic water pipes, boilers, utensils, heat
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exchangers, automobile radiators, petrol and oil lines, copper tubes for refrigeration and
air-conditioning and many others industrial uses.

19.5 PROPERTIES OF COPPER

Copper has a very attractive colour and appearance. Copper absorbs hydrogen inmolten
condition but hydrogen is insoluble in copper. That is why porous weld metal is obtained
an cooling after weld. Its melting point is 10830 C. No flux is used for the welding of pure
copper/deoxidized copper.

It is malleable. Due to this property it can be rolled into strips less than one thousandth of
an inch thick without rupture. It can be bronze welded by arc welding & gas welding. It
is ductile. Due to this property it can be drawn into wire of one thousandth of inch in
diameter without break.

It can be pressed, forged-and beaten or spun into complicated shapes without rupture.

It has high conductivity of heat and electricity per unit volume which is higher than any
other known substance except silver.

It can be joined easily by soldering, brazing and welding.

Due to its excellent soldering and brazing properties and its high heat conducting, it is also
use the radiators of modem cars/aeroplanes.

It can be drilled.

It can be hardened by cold work.

Its hardness due to cold work can be changed into softness by heating and then cooling in
open air (annealing) brazing because by fusion welding. The weld metal is brittle and
porous.
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19.6 FUSION WELDING OF COPPER

Copper can be welded satisfactorily by oxy-acetylene flame. Welding technique of copper

is similar to that of steel. A neutral flame is used. No flux is require because the melting
point of its oxide is less than the base metal.

Due to the high conductivity of copper, a larger size welding nozzle should be employed
for the same thickness as compared with steel and the work should be preheated with
flame before commencement of welding to eliminate/overcome distortion. Deoxidized
copper filler rod of 4.5 mm dia or a strip cut from the parent metal should be used. The
speed of welding should be faster because copper sets very quickly and in molten condition
it is hot short (week).

19.6.1 PROCEDURE

After assembling the apparatus, open the cylinder valves slowly using two or three turns.
Then working two pieces each of 150 x 50 x 4.5 mm thick should be set in flat position on
fire clay bricks fitted on welding table making square butt joint & keeping 2 mm gap
between edges. The torch should be lighted and a neutral flame should be adjusted.

The work pieces should be preheated (heating before welding) with flame and then fusion
welding should be commenced in right ward method (which means direction of travel is
from left to right). Practice should be repeated till the skill is acquired. After treatment,
check the Job for defects and quality of work.

19.6.2 PRECAUTIONS

Edges should be prepared according to thickness ofjob, Single 'V' or double 'V' making
an included angle of 90°.

Work pieces should be clean and free from oil & grease. Asbestos or fire clay bricks,
steel bar or steel back strips should be used to support the work pieces to prevent the
puddle from running away through the joint.
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Small jobs should be preheated from 4000 C to 5000 C with flame before starting welding.

19.7 ARC WELDING OF COPPER

1. Copper may be welded very successful by carbon arc welding.

2. The edges of work pieces above 4.5 mm thickness should be bevelled making an
including angle of90° of single 'V' or double 'V' joint.

3. 2mm gap/space should be kept between the root face edges.

4. High voltage and long arc should be used. (40-60 volts)

5. Straight polarity (electrode negative) should be used.

6. Copper joint should be backed by a steel bar/plate during welding operation to

prevent run away of puddle through joint.

9.7.1 TECHNIQUE

1. After setting the apparatus set the job in flat position using steel back bar/steel
back strip.

2. Straight polarity should be used.

3. Work should be preheated to 300-4000 C. No tack weld is done.

4. Deoxidized or pure copper should be welded by carbon arc welding only using
the same technique as used for steel welding.

5. The job should be hammered gently during and after welding.

19.7.2 AFTER TREATMENT

1. Let the job be cooled slowly in an open air.

2. Remove the flux residuals and clean the job using wire brush including etching.
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3. Check the job for defects by bending and cutting the weld metal.

19.8 INTEXT QUESTIONS

1. Name different grades of copper?

2. What type of oxy-acetylene flame is used for copper?

3. Name the type of copper which cannot by welded by fusion process?

19.9PRACTICALS

1. Set the oxy-acetylene welding apparatus using suitable size of tip for copper welding
steps.

(1) Heavy section should be preheated (heating before welding) upto 40Q - 5000 C.

(ii) No edge preparation is required upto 4 mm thickness.

(ill) Tack weld is not possible to kept the copper pieces in set position due its tendency
of conducting of heat to whole job causing much more expansion and cracking of
tacks.

(iv) Copper alloys can be bronze welded only. Set the job pieces in flat position after
edge preparation and proceed for welding after preheating. ••

19.10 WHAT YOU HAVE LEARNT

Copper - its grades - pure copper/deoxidized copper, oxidized copper; arsenic copper;'
uses of copper, properties of copper, welding of copper by oxy - acetylene flame and
carbon arc welding, techniques of welding and after treatment precautions.

19.11 TERMINAL QUESTIONS

1. Is copper a non-ferrous metal?

 Welding of Copper :: 247

2. What is the melting point of copper?

3. What is the melting point of copper oxide?

4. In what forms is copper available in the market.

5. Which grade of copper cannot be welded by fusion process?

6. Is flux used for welding deoxidized copper and why?

7. Why it recommended to use blow pipe tip of comparing with steel thickness.

8. What is preheating?

19.12 FEED BACK ON INTEXT QUESTIONS

1. Different grades of copper are pure or deoxidized copper, oxidised and arsenical
copper.

2. Neutralflame.

3. Oxidized copper and arsenical copper can not be welded by fusion welding process.