Welding problems with thin brass plates and
tungsten inert gas pulse welding
C. Meran, M. Yuksel, A. Gulsoz and T. Sekercioglu
Brass materials are widely used as engineering
materials in industry because of their high strength,
high corrosion resistance, and high electrical and
thermal conductivity. They are easily shaped and they
possess a pleasant appearance. However, it is difficult
to weld brasses. The main problem with these alloys in
fusion welding is the evaporation of zinc during the
welding process. After welding, the weld metal becomes
porous. Moreover, since the amount of zinc in the alloy
is reduced due to evaporation, the brass material loses
the physical and chemical properties which it normally
possesses. Studies on weldability of brass materials are
very few. There is very little information concerning
the weldability of brass materials in the literature and
general definitions are often seen. It is impossible to
find studies on experimental investigations of the
welding of brass materials apart for a few exceptions.
There are virtually no studies to support experimental
data about whether welding of brass materials is
possible. The purpose of the present study is to
determine suitable parameters by investigating the
weldability of brass materials, and the difficulties
involved. In order to enable low and controlled heat
input into the welding bead, TIG pulse welding is used
during experimental studies. The physical and chemical
properties of welding beads (penetration, tensile
strength, Erichsen deep drawing value, chemical
composition of internal structure) have been deter-
mined and evaluations have been made. STWJ/394
Keywords: brass welding, pulse welding, tungster inert
gas
The authors are in the Department of Mechanical
Engineering, Pamukkale University, Denizli 20020,
Turkey (cmeran@pamukkale.edu.tr). Manuscript
received 28 August 2002; accepted 1 April 2003.
# 2004 IoM Communications Ltd. Published by Maney for
the Institute of Materials, Minerals and Mining.
INTRODUCTION
The main problem occurring in the welding of brasses is the
evaporation of zinc (Zn) and copper (Cu). As a result, the
alloy loses its physical and chemical properties. In addition,
pores appear in the cross-section of the welding bead.
Theoretically, Zn evaporation during welding may be
prevented either by increasing the pressure during welding
or by limiting the heat input into the welding pool.
It may be considered necessary to increase the pressure
over the welding pool in order to prevent Zn evaporation
during welding of brasses. When the pressure over the
welding pool is increased, the evaporation temperature of
the Zn in the alloy will rise. The evaporation temperature of
Zn changes in a non-linear way with pressure over the
DOI 10.1179/136217104225017053
welding pool. Normally the Zn evaporates at 907°C under
a pressure of 1 bar
³ ´
Le 1 1
ln (p2 )~{ { : : : : : : : : : (1)
R T2 Tb
where Le is the latent heat of evaporation (J mol– 1 ), R is the
engineering gas constant (J mol– 1 K– 1 ), Tb the boiling point
of the liquid, and p2 the evaporation pressure of the liquid
at T2 .
From equation (1), it is possible to see that, if the
pressure over the welding pool increases to 12 bar, the
evaporation temperature of the Zn will rise to 2000°C and if
it increases to 22 bar, the evaporation temperature will rise
to 3000°C. The weld pool temperature is between 2000 and
3000°C. Because of this, it may be considered that Zn
evaporation can be reduced during welding by increasing
the pressure over the welding pool (Fig. 1).
Special equipment is needed to increase the pressure over
the welding pool up to 5 bar or more during welding.
However, this situation limits the applicability of the method.
Moreover, because of high pressures, arc ignition would be
more difŽ cult during welding. For this reason, pressure was
not taken as a parameter for the prevention of Zn evapo-
ration during studies.
Jacobi1 has found that Zn evaporation can be decreased
by limiting heat input into the welding pool. For this
reason, the TIG welding method has been preferred because
heat input concentration in TIG welding is lower than in
other methods. Besides this, workpieces have been welded
on Cu plates to reduce the heat input into the welding pool.
Also, several factors in uencing the heat input to the
weld pool have already been examined.2 – 5 Some of these
factors are welding method, welding current, welding speed,
the chemical composition of the workpiece, thermal con-
ductivity coefŽ cient, welding position, arc length, the type
and diameter of the electrode, the  owrate and composition
of shielding gas, the type of current and the polarity.
A certain energy density must occur on the workpiece for
the formation of a good welding bead. So, higher welding
1 Effect of pressure over welding pool on evaporation
temperature of pure Zn
Science and Technology of Welding and Joining 2004 Vol. 9 No. 2 131
132 Meran et al. Welding problems with thin brass plates
a Surface holes and ZnO form on the welding bead due to
Zn evaporation; b Low penetration and pores which may
be observed after etching in welding bead cross-section
2 Effects of unsuitable welding parameters
current requires a higher welding speed, and lower current
requires a lower welding speed. Otherwise, defects occur in
the welding bead as a result of high energy concentration
and/or evaporation of some alloy elements.
WELDING PROBLEMS WITH BRASS
MATERIALS
Brass materials, as known, are Cu and Zn alloys. The
welding temperature, for example in TIG welding, reaches
almost 4200°C in the electrode (cathode) and nearly 3200°C
in the workpiece (anode) during welding. These tempera-
tures exceed both the melting and boiling temperatures of
both Cu (1083°C/2590°C) and Zn (419°C/907°C).6 In addi-
tion, the melting temperature of zinc oxide occurring as a
result of Zn evaporation is 1970°C. For this reason, during
welding, it is possible for Zn and Cu to evaporate from the
workpiece. Zinc with the lower boiling temperature evapo-
rates more than Cu.7
As a result of this evaporation, pores appear in the
welding bead, zinc oxide precipitates on the surface of the
welding bead and the brass loses its yellowish colour and
takes on a reddish colour (Fig. 2). Zinc evaporation and, in
addition, Cu oxidation are possible at high temperature. In
this condition, the surface becomes grey or, sometimes
black. The reason for this is the oxidisation of Zn and Cu.
Lower Zn in the alloy creates less evaporation and makes
the fusion welding easier.8 The rate of Zn evaporation is
affected directly by the temperature as observed in Fig. 3
and the evaporation rate of Zn in fusion welding takes place
at 10 g cm– 2 s– 1 at nearly 1000°C.1
In order to manufacture high quality welded joints, it is
essential to keep the heat input as low as possible. This
situation helps the formation of a small heat affected zone
(HAZ) in the weld and helps to protect the welding zone
against the surrounding medium. For this purpose, TIG
welding is preferred in various welding applications, since
its energy concentration is lower in the welding pool.
Another welding method used for brass materials is laser
welding. Various studies have been completed in this area.
The effects of welding parameters upon welding bead,
internal defects and the change in the composition of the
Science and Technology of Welding and Joining 2004 Vol. 9 No. 2
3 Change in evaporation rate with temperature for var-
ious metals1
alloy in the laser welding of the brass with high Zn have
been examined in the studies carried out. As a result, it has
been determined that it is essential to control heat input
into the welding pool during the welding process, otherwise
serious spatters occur in the welding pool and, as a result,
holes are formed in the welding bead, a-phase increases,
coarse grains occur, and hardness and strength decrease.
Moreover, it has been determined that higher welding speed
and higher heat input together create a tendency for hot
cracking in brass material.9
Another method used to limit the heat input into the
welding pool in the welding of brass materials is to use Ž ller
materials. When these are used, the arc is concentrated on
the Ž ller material and this reduces the Zn loss from the
brass which is being welded.1 0 It is important that the Ž ller
material to be used during welding does not contain Zn.
Besides these, Ž ller metals containing Si may be preferred
in the welding of brasses. The SiO2 Ž lm layer formed upon
the melted welding pool during welding may reduce Zn
evaporation.1 1
Welding temperature and welding time are very impor-
tant parameters in the welding of brasses. The characteristic
of the welding process of brass materials may be deŽ ned as
low heat input and short welding time.
Other problems in the welding of brass materials are
rather high thermal conductivity, thermal expansion and
contraction. Because of these properties, tensile and com-
pressive stresses appear both during and after welding. As a
result of these, it is possible for the materials welded to be
distorted during solidiŽ cation of the welding bead. Welding
stresses which will probably appear after welding are likely
to be reduced by choosing welding process parameters with
a suitable welding method. Aendenrooer and Ouden,1 2 and
Kim and Na1 3 explain that pulse welding can be used to
limit the heat input into the welding pool.
In TIG pulse welding, the welding current changes
between two different current values (IP and IB ) periodi-
cally. The heat input is dependent upon the average current,
and this is controlled by pulse height, pulse frequency and
pulse time (Fig. 4).
Figure 4 is a schematic representation of an ideal pulsed
current rectangular waveform showing the associated pulse
parameters. For this waveform, the characteristic measures
deŽ ning the current are as follows: the mean current is IM
which represents the same electric effect as a constant
 Meran et al. Welding problems with thin brass plates 133

4 Schematic diagram of ideal pulsed current square

waveform and associated pulse parameters
5 Welding set-up
current of this value1 4
the welding pool and can cause the oxidative gases in the air
t…T
1 (IP |tP )z(IB |tB ) to enter the welding pool. A gas lens was utilised to ensure
IM ~ I :dt~ laminar  ow of shielding gas into the welding pool in the
tT (tP ztB )
0 experimental study.1
The thickness of the brass material used in the experi-
where Ip is the peak pulse current (A), and IB is the base ments was 1 mm. For this reason, the method which limits
current; the pulse cycle frequency, F51/(tP ztB ); % on-time, the heat input into the welding pool using the Ž ller material
r5(tP /tT )6100, of the peak pulse duration tP to the pulse was not used here. Instead, the essential welding parameters
cycle tT 5tP ztB ; the pulse time ratio, tR 5tP /tB , of the peak were Ž rst determined so as to obtain a suitable welding
pulse duration tP to the base current duration tB . bead.
The base material melts when it reaches a high tem-
perature in the high current phase IP . The temperature of
the welding pool decreases in the base current IB , and thus Experiments
it cools and partly solidiŽ es. Both the peak pulse duration One of the most important factors affecting weldability of
tP and the base current duration tB should be selected brass materials is arc length.5 It is imperative that a suitable
carefully in order that both the melting phase and the welding speed and welding current be chosen during welding
cooling phase occur together. Thus, a welding bead made according to the arc length selected; 0.5, 1, 1.5 and 2 mm
up of several spots on top of the other is observed. The base were taken as the arc length in the initial experiments. The
current also enables continuity of the arc. If the base study has indicated that when an unsuitable welding current
current value or % on-time value is high, the heat input into and welding speed are selected, some holes, zinc oxide, and
the welding bead increases.1 5 excess penetration are observed and a welding bead of
A STEL welding machine with digital screen has been desired quality is not formed. The curves joining points
used as the power source. The welding machine can supply where good welding beads are obtained for 0.5, 1, 1.5 and
a current up to 350 A. In addition, the pulse frequency may 2 mm arc lengths are shown in Fig. 6.
be adjusted between 1 and 300 Hz. The peak pulse current As can be seen from Fig. 6, if a welding speed of
IP , the base current IB , and pulse frequency can be adjusted 13 mm s– 1 is chosen for a 1 mm arc length, the welding
precisely on the welding machine. current should average 148 A for a better welding process,
or vice versa. These values were taken as constant in all of
the experiments and only the pulse frequency was varied
EXPERIMENTAL PROCEDURE
(Table 1).
Test apparatus A series of experiments has been made using TIG pulse
Experiments have been conducted with the TIG welding welding whose advantages have been mentioned in the
set-up shown in Fig. 5. The test apparatus is essentially previous sections. Experimental parameters are given in
made up of Ž ve sections. These are the speed control unit, Table 1.
electrode holder, slide, power supply and gas tube.
tP 5tB has been taken during the experiments. The % on-
time was kept constant at 50 in all test runs. So, IM in
equation (2) will be (IP zIB )/2.
Welding has been carried out under direct current. The
workpiece is adjusted as the positive pole and the electrode
as negative pole. CuZn37 (with the chemical composition
37%Zn and the balance Cu) has been used. The sizes of
experimental specimens are 16256150 mm.
Two specimens of 16256150 mm were welded as a
closed butt joint without Ž ller metal. The electrode was 2%
thoriated tungsten with diameter 1.6 mm and tip angle 30°;
torch angle was 90°; nozzle diameter was 10 mm; shielding
gas was argon (99.995%). The shielding gas  owrates at the
back and front sides of welds were 15 L min– 1 .
The shielding gas should exhibit laminar  ow into the 6 Mean welding currents for different welding speeds at
welding region. Turbulence shielding gas  ow may occur in different arc lengths in TIG pulse welding of CuZn37

Science and Technology of Welding and Joining 2004 Vol. 9 No. 2

134 Meran et al. Welding problems with thin brass plates

7 Appearance of upper surface and root side of welding beads produced at various pulse frequencies

RESULTS AND DISCUSSION The welding beads are made up of the spots on top of
In this experimental study, only pulse frequency and arc the other in pulse current welding as seen in Figs. 7
length have been changed because they are very signiŽ cant and 8. The number of these spots depends on the
parameters in uencing welding pool shape. frequency applied and they increase as the frequency

Science and Technology of Welding and Joining 2004 Vol. 9 No. 2


8 Welding bead shapes with various pulse frequencies and arc lengths
increases. It has been observed here that a spot is formed in
each cycle.
Figure 7 shows the upper surface and root side of welding
beads at various pulse frequencies. Although the upper
surface appearance of the welding bead at 5 Hz pulse
frequency is reasonably good, the required penetration was
not reached at the root side. A concave upper surface
Meran et al. Welding problems with thin brass plates 135
appearance of the welding bead was formed at 10 Hz pulse
frequency. The welding bead is able to reach sufŽ cient
penetration at the root side at 10 Hz or greater pulse
frequencies. Better upper surface shapes of the welding
bead and reasonably good penetration have been obtained
at 20 Hz pulse frequency. Undercuts occur at the edge of
the welding bead at 40 Hz or greater pulse frequencies. As a
Science and Technology of Welding and Joining 2004 Vol. 9 No. 2
136 Meran et al. Welding problems with thin brass plates

welding bead after welding. The investigation of the change

9 Points at which chemical analyses have been made by
pulse TIG method (at 20 Hz)
result of these undercuts, the appearance of the surface
shape of the welding bead is poor and notch effects
occur.
Arc length is also one of the important parameters in
welding bead shape in pulse welding. As seen from Fig. 8,
different welding bead shapes occur at different arc lengths
and pulse frequencies, while all other welding parameters
remain the same as can be seen in Table 1. The welding
beads obtained at 0.5 mm arc length are larger and deeper
than those obtained at 1 mm arc length, because the heat
input to the weld pool at 0.5 mm arc length is denser than
at 1 mm arc length. In addition, at low pulse frequencies,
the probability of formation of zinc oxide increases at the
welding bead and around it. The formation of zinc oxide is
greater at 0.5 mm arc length as a result of high heat input to
the welding pool.
To reduce the Zn evaporation, distortion and porosity,
the heat input to the welding pool must be as low as
possible and the welding time as short as possible.
The greyish ZnO formed at the surface of the welding
bead in normal TIG welding does not appear with TIG
pulse welding. This shows that TIG pulse welding reduces
Zn evaporation.
The effects of pulse frequency on the tensile and Erichsen
deep drawing strength of welded joints have been investi-
gated using TIG pulse welding. Since there is no change in
the welding currents, heat inputs into the welding pools do
not change. It has been found that pulse frequency does not
affect tensile strength and Erichsen deep drawing strength.
The break has occurred near the HAZ for all specimens and
no break has occurred in the welding bead.1 6
After the investigation of the physical properties of
welding joints, the change in chemical composition of Cu
and Zn was investigated in the weld metal and near the
in chemical composition of the Cu and Zn in the alloy will
help in the understanding of Cu and Zn evaporation after
welding.
The best mechanical properties and welding bead
appearances have been obtained at 20 Hz. Chemical
analyses of the welding bead at 20 Hz have been studied
in various places in the experimental specimen shown
schematically in Fig. 9. The Ž rst region shows the root side,
the second region shows the HAZ of the root side, the third
region shows the workpiece which is not affected by
welding, the fourth region shows the upper surface and
the Ž fth region shows the HAZ of the surface side. The
chemical distributions of Cu and Zn in the internal
structure of these regions are given in Fig. 10.
As seen from the results of the chemical analyses of the
internal structure in Fig. 10, the chemical compositions of
the root side (regions 1 and 2) and workpiece not affected
by welding (region 3) are the same. The chemical analyses
results for the upper surface of the welding bead (regions 4
and 5) show that there is not much difference in the
quantity of Cu and Zn.
It has been found that if suitable welding parameters are
used from the results acquired, the evaporation of Zn or Cu
in the upper surface and root parts of the welding bead may
be prevented.
CONCLUSION
When the pulse frequency increases, the penetration
increases and vice versa. Limited heat input into the
welding pool given in short welding times has a positive
effect on the weldability of brass materials. The application
of the TIG pulse welding method in the welding of
brass materials is successful. Pulse frequency has a very
important in uence on the shape of the welding bead. In
addition, arc length alters the shape of the welding bead
signiŽ cantly.
The best welding results for the shape of the welding bead
upper surface and the penetration of the root side have been
obtained at 20 Hz pulse frequency. Pulse frequency does
not affect the tensile strength and Erichsen deep drawing
values.
The greyish ZnO formed at the surface of the welding
bead in normal TIG welding method did not appear with
TIG pulse welding. This result shows that TIG pulse
welding reduces Zn evaporation.

Table 1 Experimental parameters for TIG pulse welding of brass material, CuZn37

Experiment Peak pulse Base current, Mean current, % on-time, Welding speed v, Arc length, Pulse frequency,
number current, IP, A IB, A IM, A r mm s–1 mm F, Hz

1 200 96 148 50 13 1 5
2 200 96 148 50 13 1 10
3 200 96 148 50 13 1 20
4 200 96 148 50 13 1 40
5 200 96 148 50 13 1 50
6 200 96 148 50 13 1 100
7 200 96 148 50 13 1 200
8 200 96 148 50 13 1 300
9 200 96 148 50 13 0 .5 5
10 200 96 148 50 13 0 .5 10
11 200 96 148 50 13 0 .5 20
12 200 96 148 50 13 0 .5 40
13 200 96 148 50 13 0 .5 50
14 200 96 148 50 13 0 .5 100
15 200 96 148 50 13 0 .5 200
16 200 96 148 50 13 0 .5 300

Science and Technology of Welding and Joining 2004 Vol. 9 No. 2

 Meran et al. Welding problems with thin brass plates 137

10 Chemical analysis results for welding bead (at 20 Hz pulse frequency)

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