Busbar Welding Procedures

Busbars are heavy-duty conductors used to distribute electrical power from a single source to multiple users, such as an array of machinery or equipment. They are typically made from copper or aluminum.

Gas Metal Arc Welding

Busbars, particularly those made from cast, or electrolytic tough pitch (ETP), are often welded by a procedure known as gas metal arc welding (GMAW). GMAW involves shielding the weld with an inert gas, such as argon or helium, or a mixture or the two, to prevent the detrimental effects of oxygen.

Technique

Ideally, busbar welding should be performed by the forehand method -- where the arc is directed at the base metal ahead of the weld -- in a flat position. If busbars need to be welded overhead, gas tungsten arc welding (GTAW), with a pure tungsten electrode, is preferred to GMAW.

Cleaning

Busbars must be clean, bright and dry before welding commences. Any oxides on the surface should be filed or brushed away.

References

• "Copper and Copper Alloys"; Joseph R. Davis; 2001
• "Copper: Its Trade, Manufacture, Use, and Environmental Status"; Günter Joseph, Konrad J. A. Kundig; 1999