How To Weld Copper Sheet Metal

Stick welding uses a metal filler rod or stick coated with flux.

How to weld copper sheet metal.

In welding copper sheets the heat is conducted away from the welding zone so rapidly that it is difficult to bring the temperature up to the fusion point. If the copper is thicker you will need to adjust the gas and amp by applying helium and upping the. Sheet metal welding techniques. When the copper alloy contains at least 70 percent copper use 70 30 copper nickel filler.

Proper technique will come with practice and experience. These projects will need strong welds i also dont want a brass look where the weld joints are like sweating in plumbing. It is often necessary to raise the temperature level of the sheet in an area 6 0 to 12 0 in. The filler has more nickel than the base metal making it stronger.

You want the weld metal to be stronger than the base metal. Grease oil and paints can cause your weld to crack if they get mixed in. Take the time for proper fit up proper tight part fit up is especially important when welding thin materials. I am looking into patina or burnt copper finish when i am done so it has to look good i can grind down a weld with no problems if the process doesn t add another metal type.

Don t attempt to weld thin materials like sheet metal with flux cored wires which put more heat into the base metal. In order to weld sheet metal or patch panel you have to follow certain rules and use specific techniques. Stick welding otherwise known as shielded metal arc welding smaw stick welding is a two handed method like tig. Forget the larger 1 8 inch tungsten electrode and use a smaller one.

Depending on if you are using tig tungsten inert gas or mig metal inert gas and the thickness of your copper you will need to adjust the ratio of your gas and temperature. As the stick material melts in the heat the flux coating also melts creating both a gas and a liquid slag which act to shield the weld from oxidation. Step 3 remove all problem substances. The backing bar is used commonly by welders to cool the welded metals and they are generally made up of a copper or aluminum metal and clamped to the base of the weld piece whether it is just a piece of thin sheet metal or a body panel you can use it either way.

Use the proper gas ratio. 152 4 to 304 8 mm away from the weld. A 100 argon shielding gas is the most common in mig welding aluminum sheet metal. Tig welding sheet metal.

To weld sheet metal with solid wires use electrode positive ep or reverse polarity. As a general rule of thumb copper under 2 mm should have argon gas and up to 160 a applied. For cv mig welding on sheet metal wire diameters of 035 inch are recommended.