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W E L D I N G

G U I D E L I N E S

of

CuNi90/10





Joining:
Metallurgically is solid-solution alloy with no deleterious second phases and experience no
phase transformation during heating and cooling.
Elements such as lead, which may occur as impurities both in the parent alloy and in welding
consumables, are controlled to very low levels so that cracking caused by the presence of
these elements is eliminated. It is also essential that the surfaces adjacent to the joint must be
clean and free from oxide.
Substances such as oil, grease and paint, which may contain sulphur and other deleterious
compounds, must be removed before joining takes place.
To remove oxide and other contaminants, an area approximately min. 10 mm wide on each
side of the joint should be prepared by scratch-brushing with a clean, stainless steel brush
used only for copper alloy. This is followed by degreasing with a non-toxic non flammable
solvent.
No pre-heat is required, but the material must be free from moisture. In cold or humid
conditions, it should be warmed to about 25C. Interpass temperature should be controlled an
should not exceed 120C.
The main welding technique is TIG ( Tungsten Inert Gas) for CuNi90/10.



Welding:
Tack welds should be kept to a minimum and as short as possible. Tack welds should be
deposited in the opposite direction to the subsequent weld run and each tack must be
thoroughly cleaned before welding commences. If there is any danger that porosity or cracks
are present in a tack weld, the tack weld must be removed before welding over the area. Use
as many tackwelds as you need, but limit their quantity as down as possible.
TIG is preferred for metal thicknesses up to an including 6 mm. TIG welding may also be
used for the root runs in thicker material, the fill-up runs being deposited by the manual metal
arc process.
For CuNi90/10 direct current and a negative electrode is required. The welding power
equipment should work with down slope and high-frequency initiation (pulsed current). The
tungsten electrode have to be sharpened and to stand out of the nozzle for app. 5-10 mm. The
shielded gas is 99,99% pure argon which is also used as the back purging gas (counter gas).
The root pass and first filler pass should be carried out with counter gas. For all further passes
no counter gas is required.
Nitrogen must not be used as it reacts with the deposited metal, giving a porous layer on the
surface of the under-bead.
Weld soundness is dependent to large extent on good gas coverage and arc length. To ensure
good gas coverage it is necessary to protect the weld from all draughts, which would
otherwise disturb the argon shield. After opening of the counter gas valves wait for a few
minutes until the Argon has been replaced by the normal air. The torch has to be held with an
angle of approx. 75 to the surface of the piece to be welded.
The arc should be kept as short as possible. (A rough rule: the distance between electrode and
seam should be the same as the electrode diameter. The electrode should always be held
slightly inclined in the direction of the weld). During the welding process the torch should not
be made to oscillate (drawing line beads). Interruptions during the welding should be kept to a
minimum to limit the danger of pore formation in the endcraters. During the welding process
the welding wire has to be moved in a "Droping"-movement. A stringer bead technique is


used. Runs must be as long as possible to minimise the number of end craters where porosity
is a danger. The protective gas should be allowed to flow for a short period over the deposited
weld metal at the end of each run, to prevent oxidation. In order to avoid oxiditing of the
welding wire, never leave the torch in front of the nozzle.
The use of a crater-filling (down slope) device is recommended to avoid pores and cracks in
the end crater. If such a device is not available, the finish of the weld run should be tapered
and the arc broken at the side of the weld pool.
If the electrode is accidentally withdrawn from the argon while still hot, the highly oxidised
point must be removed completely and reground to shape before welding is restarted.
In the case of an interruption of the weld process oxidised wire ends should be cut off and the
weld seam must be cleaned of oxidation residues.

Pipe welding raises the problem of having to weld in all positions. This contributes to the
choice for welding CuNi90/10.
The root penetration must be 100% without excessive penetration, as any protrusion might
cause turbulence of fluid in service.
When TIG welding is used, the bore of the pipe must be purged with argon to prevent
oxidation of the root bead. Removable dams may be used to give economical argon usage, by
restricting the volume of gas necessary. Alternatively, backing inserts may be used, but these
are only acceptable if they can be completely removed from the pipe after welding.

Welding Parameter for welding of CuNi90/10 pipes with additional material CuNi70/30

Wall
Thickness
Diameter of Electrode
mm
Diameter of Welding
Rod mm
Current
Amp
Algon
L/min.
mm Root Interpass/
Top
Root Interpass/
Top
Root Interpass
/Top

1,5 1,6 - 1,6 - 55-65 - 6
2,0 1,6 - 2,0 - 60-80 - 7
2,5 1,6 1,6 1,6 2,4 90-100 80-90 7
3,0 1,6 1,6 1,6 3,2 115-130 105-125 8
4,0-5,0 1,6 2,4 1,6 3,2 160-180 150-170 8

Weld Preparation

S< 3mm: square joint

S 3,0 mm to S 5,0 mm







a s


a = 0 - 1 mm = 35 - 40




























Welding equipment

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