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Classification and operating points of copper and copper alloy welding wires

The thermal conductivity of copper and copper alloys is more than 5 times that of carbon steel. Welding is prone to pores, lack of fusion, and thermal cracks. The selection of welding wire directly determines the conductivity, corrosion resistance, and wear resistance of the weld. Based on the national standard GB/T 9460-2008 and AWS A5.7 standards, this article systematically introduces six categories of copper and copper alloy welding wires: pure copper, brass, silicon bronze, tin bronze, aluminum bronze, and white copper. It includes grade comparison, composition characteristics, base metal matching, and a full set of TIG/MIG/gas welding process parameters. It is suitable for welders and process engineers in the pressure vessels, power busbars, ships, refrigeration, and mechanical surfacing industries to learn.

I. Copper welding wire national standard & American standard naming rules

1. Chinese national standard GB/T 9460 model rules (HS series)

  • • HS is the code for non-ferrous metal welding wire
  • • The second digit represents copper and copper alloys
  • • The last two digits: subdivided models of the same series, such as HS201, HS221, HS211

2. US AWS classification rules (ER series)

ERCu=pure copper welding wire; ERCuSi-A=silicon bronze; ERCuSn-A/C=tin-phosphorus bronze; ERCuAl-A1=aluminum bronze; RBCuZn=brass welding wire; ERCuNi=white copper nickel copper welding wire

Copper TIG welding wire-Tianqiao

II. Detailed explanation of complete parameters of six categories of copper alloy welding wires

1. Pure copper (red copper) HS201/HS202 (ERCu)

Core component: Cu≥99%, adding Si, Mn, P deoxidizing elements

Core advantages: Extremely high electrical/thermal conductivity, good plasticity

Applicable: T1/T2/T3 copper, oxygen-free copper busbars, transformer bars

Process: TIG argon arc welding; preheat thick plates ≥6mm at 200~300℃

Distinguishing: HS201 has stronger deoxidation than HS202; HS202 for gas welding.

2. Brass welding wire HS221/HS222/HS226 (RBCuZn)

Core component: Cu-Zn alloy, adding Si and Sn to inhibit zinc evaporation

Core advantages: Excellent fluidity, low price, welding + brazing dual purpose

Applicable: H62/H65/H68 brass; carbon steel, cast iron, carbide tools brazing

Note: High-zinc brass produces oxide smoke. Strong ventilation required.

3. Silicon bronze welding wire HS211 (ERCuSi-A)

Core component: Cu-Si-Mn alloy, strong deoxidation, resistant to thermal cracking

Core advantages: Most versatile, first choice for dissimilar metals

Applicable: Brass, copper + carbon steel, copper + stainless steel; hydraulic pipelines

Highlights: Less smoke, no large-area preheating, high MIG efficiency

4. Tin-phosphorus bronze HS212 (ERCuSn-A/C)

Core components: Cu-Sn-P, dense and pore-free weld

Core advantages: Wear/fatigue resistance, seawater/weak acid corrosion resistance

Applicable: Phosphor bronze, red copper; ship seawater pipelines, pump bodies

Use: Surfacing repair of bushings, sliders, and bearing wear layers

5. Aluminum bronze HS213/HS214 (ERCuAl-A1)

Core components: Cu-Al, Ni, Fe (nickel aluminum bronze)

Core advantages: Top-notch strength, hardness, resistance to cavitation

Applicable: Ship propellers, seawater valves, chemical equipment

Process: Preheat thick plate 150~250℃, slow cooling to prevent cracks

6. White copper (copper-nickel) HS234 (ERCuNi)

Core component: Cu-Ni alloy (10%~30% Nickel content)

Core advantages: Acid/alkali/seawater resistance, low temperature toughness

Applicable: B10/B30 white copper, ship heat exchange tubes, chemical pipes

Properties: Extremely low hot cracking tendency, non-magnetic

Copper MIG welding wire-Tianqiao

III. Key points for a complete set of TIG/MIG/gas welding process operations

1. TIG tungsten arc welding (first choice for thin plates/precision parts)

  • Protective gas: Pure argon Ar, 8~15L/min, back must be argon-filled.
  • Preheating: <3mm: None; 3~6mm: 100~200℃; >6mm: 200~300℃.
  • Operation: Left-hand method, short arc, synchronous wire feeding.
  • Applicable: Copper busbars, thin-walled tubes, precision instruments.

2. MIG gas metal arc welding (efficient mass production)

  • Protective gas: Pure argon (thick plates can add small amount of He).
  • Wire diameter: 1.0/1.2/1.6mm, high current for rapid welding.
  • Advantages: Large penetration, high efficiency for structures above 6mm.

3. Oxygen-acetylene gas welding (on-site maintenance)

  • Flux: Copper/bronze flux 301; brass requires special soldering powder.
  • Flame: Neutral flame (Oxidizing flame is strictly prohibited).
  • Shortcomings: Large heat input, coarse grains; prioritize argon arc for conductive parts.
Post time: Jul-10-2026

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