How to Form Copper Welds

Welding copper requires careful attention to the metal's melting process.

Many welders prefer to work with copper and copper alloys, since the substance provides an adequate surface for heat conductivity. In fact, forming copper welds is one of the most common welding processes for fusing two metal items together. The proper tools and techniques must be applied to the copper weld for a secure connection.

Things You'll Need

• Copper electrodes
• Measuring tape
• Wire brush
• Degreaser
• Gas metal arc welding machine
• Welding helmet
• Welding apron
• Welding gloves
• 2 metal items

Instructions

1. Place the two metal items alongside each other on a solid surface. Make sure there is a gap between the metal pieces of approximately 2 to 4 millimeters by measuring the spacing with a measuring tape.

2. Brush both metal pieces with a wire brush and clean the surface with a degreaser to remove any impurities.

3. Place the welding helmet on your head for safety. Put on the welding apron and gloves.

4. Preheat the metal items with the gas metal arc welding machine's torch. Heat the surface until it reaches 167 degrees Fahrenheit. The machine should have a gauge built into its assembly for temperature verification.

5. Place the copper electrode at an angle beside the junction of the metal items. Heat the electrode and the metal items with the welder's torch until the copper flows into a smooth weld.

6. Remove the electrode and torch from the metal items. Turn off the welding machine. Visually inspect the weld for a secure connection.

Tips & Warnings

• For thicker metal items, the surface should be preheated to higher temperatures to create the best welding conditions. Consult the welding machine owner's manual for specific temperature values.

• Along with the welding helmet, protective gloves and aprons should be worn during the copper forming process. Welding creates dangerous heat that can easily burn a person. Additionally, observers should not be present during the welding process; the bright light that emanates from the torch can cause flash burns to the eye.

References

• Aufhauser Corporation: Copper Welding Procedures