How to Weld Copper Wire
Copper is one of the most common materials used for making wire. It conducts electricity extremely well and almost all electrical wiring is composed of pure copper. Wires made of copper alloys also are used extensively for applications requiring a high thermal conductivity, corrosion resistance and wear resistance. Copper wire can be welded effectively but it requires some adjustments if you're accustomed to welding steel.
Other People Are Reading
Instructions
-
-
1
Use a filler metal that contains at least 30-percent nickel. Welding normally requires the composition of the filler metal to be as close to that of the base metal as possible. However, a 30-percent minimum nickel content is required to provide the needed strength for base metals with a high copper content.
-
2
Make test welds. This is especially important for copper wire because the filler metal can have a significantly different composition than the base metal. Conduct longitudinal-bend tests on the test welds to evaluate their strength.
-
-
3
Clean the copper wire thoroughly. There are a number of elements that can cause copper welds to crack, especially lead, phosphorus and sulfur. These elements are common in substances such as paint, grease, oil and cutting fluids. Copper-tin-zinc alloys also are a potential source of these contaminants.
-
4
Preheat thick wires of pure copper to 60 degrees Celsius before welding. Copper alloys normally don't require preheating.
-
5
Use a larger angle between copper wire and the other base metal. Copper-filler metal is not as fluid as those used for steel and will require more movement with the electrode to get it to fuse to the joint walls. The included angle for copper alloys will usually be greater than 70 degrees.
-
1
