CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys

asnt2012

CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys

Cost-Effective Manufacturing:
Joining of Copper and Copper Alloys
Lou Brown
CDA Publication No 98, 1994


Contents
Summary .....................................................................................................................................................4
Section 1 - Introduction..............................................................................................................................5
Section 2 - Selection of a Joining Process ..................................................................................................6
Section 3 - Bolting and Riveting .................................................................................................................6
Section 4 – Adhesive Bonding.....................................................................................................................9
Section 5 - Soldering.................................................................................................................................10
Recommended Solder Fluxes for Engineering Materials.............................................................................11
Copper, solid or plates, tin-bronzes, gunmetals.......................................................................................11
Copper-nickel alloys ...............................................................................................................................11
Copper-aluminium alloys (aluminium bronzes) ......................................................................................11
Gilding metals (CuZn10 and CuZn20) ....................................................................................................11
Commercial brasses (CuZn30 and CuZn40) ...........................................................................................11
Soft Solder Filler Metals.............................................................................................................................11
Resistance Soldering...................................................................................................................................11
Section 6 - Brazing and Silver Soldering .................................................................................................17
The Brazing Process ...................................................................................................................................17
Basic Principles......................................................................................................................................17
Brazing Filler Metals ..................................................................................................................................17
Copper-Silver Alloys..............................................................................................................................21
Copper-phosphorus-silver alloys.............................................................................................................22
Joint Design................................................................................................................................................22
Joint Clearance.......................................................................................................................................22
Joint Overlap ..........................................................................................................................................23
Brazing Alloy Pre-placement ..................................................................................................................23
Physical and Metallurgical Factors..............................................................................................................24
The Coppers ...........................................................................................................................................24
Alloys Heavily Cold-worked, or with High Softening Temperatures......................................................24
Precipitation-hardening Copper Alloys ...................................................................................................25
Alloys Containing Aluminium.................................................................................................................26
Alloys Containing Lead...........................................................................................................................27
Alloys Containing Tellurium or Sulphur .................................................................................................27
Section 7 - The Bronze Welding Process .................................................................................................28
Basic Principles ..........................................................................................................................................28
Filler Metals................................................................................................................................................28
Joint Design................................................................................................................................................29
Section 8 - Welding...................................................................................................................................31
Gas-shielded Arc Welding..........................................................................................................................31
Basic Principles and Processes................................................................................................................31
Pulsed Current TIG Process ............................................................................................................................... 31
Plasma Arc Process ............................................................................................................................................ 31
Fine-wire MIG Process ...................................................................................................................................... 32
Pulsed-current MIG Process............................................................................................................................... 32
Filler Metals ...........................................................................................................................................33
Shielding Gases......................................................................................................................................34
TIG Welding: ..................................................................................................................................................... 34
MIG Welding ..................................................................................................................................................... 34

Joint Design and Preparation .................................................................................................................. 34
Edge Preparation ................................................................................................................................................ 34
Pre-weld and Inter-run Cleaning ......................................................................................................................... 36
Jigging and Backing Techniques ......................................................................................................................... 36
Preheating and Inter-run Temperatures ............................................................................................................... 36
Process Applications.............................................................................................................................. 37
Copper ................................................................................................................................................................ 37
Copper Alloys..................................................................................................................................................... 39
Copper-silicon Alloys (Silicon Bronzes)............................................................................................................. 39
Copper-aluminium Alloys (Aluminium bronzes) ................................................................................................ 40
Copper-nickel Alloys (Cupro- nickels)................................................................................................................ 41
Copper-tin Alloys (Phosphor Bronzes and Gunmetals)....................................................................................... 42
Copper-zinc Alloys (Brasses and Nickel- silvers) ............................................................................................... 42
Work-hardening and Precipitation-hardening Copper-rich Alloys...................................................................... 43
Electron Beam Welding .............................................................................................................................. 43
Joint Design and Preparation .................................................................................................................. 44
Laser Welding ............................................................................................................................................ 44
Friction Welding ........................................................................................................................................ 44
Ultrasonic Welding .................................................................................................................................... 45
Ball Bonding.......................................................................................................................................... 45
Wedge Bonding ..................................................................................................................................... 45
Section 9 - Joining and Repairing Castings ............................................................................................ 47
Copper-based Casting Alloys ...................................................................................................................... 47
General Principles, Joint Design and Preparation ....................................................................................... 47
Selection of Welding Process and Welding Techniques ............................................................................. 48
Metallurgical Factors in Welding Castings ................................................................................................. 48
Selection of Filler Metals........................................................................................................................ 48
Metallurgical Behaviour of Cast Alloys ...................................................................................................... 48
Copper Aluminium Alloys ...................................................................................................................... 48
High Tensile Brasses.............................................................................................................................. 49
Gunmetals and Tin Bronzes.................................................................................................................... 49
Section 10 - Joining Dissimilar Metals and Weld Surfacing.................................................................. 50
Availability of Pre-clad Material................................................................................................................. 50
Weld Surfacing........................................................................................................................................... 50
Metallurgical Factors in Joining Dissimilar Metals..................................................................................... 51
Copper to Steel ...................................................................................................................................... 51
Copper Nickel to Steel........................................................................................................................... 52
Aluminium Bronzes to Steel ................................................................................................................... 52
Copper to Aluminium ............................................................................................................................. 52
Copper and Alloys to Other Copper Alloys ................................................................................................ 52
Copper to Copper-Nickel........................................................................................................................ 52
Copper to Aluminium Bronze................................................................................................................. 53
Aluminium Bronze to Copper Nickel ..................................................................................................... 53
Illustrations............................................................................................................................................... 58
References and further reading ............................................................................................................... 61
References .................................................................................................................................................. 61
Further Reading.......................................................................................................................................... 61
Copper Development Association Publications ...................................................................................... 61

wuqitao0000

CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys

yuwen

CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys

xhqian

非常感謝你的分享..

CCY

谢谢楼主无私分享！

ntlcg

谢谢分享CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys

whngomj

谢谢楼主无私分享！

阿谢克那·李

CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys

WASPCN

谢谢楼主无私分享！

qustlcl

CDA - Publication No. 98 1994 Joining of Copper and Copper Alloys