- 1). Use a copper alloy filler similar to that of the base metal to be welded. This filler will produce the strongest welds and a longitudinal bend test should be used to evaluate the strengths of the test welds.
- 2). Remove all traces of elements such as lead, phosphorus and sulfur which can cause welds to crack. This includes common materials like grease, oil and paints that may contain these additional elements. Copper/tin/zinc alloys should not be used to weld copper/nickel alloys, since they commonly contain contaminants.
- 3). Provide shielding gas on the side of the metal opposite the weld (the root side). This is essential in the case of TIG welding with copper, since it prevents the weld from becoming contaminated with oxidation and pits.
- 4). Use wider joints than those for steel. Copper requires wider joints in order achieve an adequate fusion and penetration of the weld due to its higher conductivity of heat.
- 5). Select the proper shielding gas. Argon is the best choice for copper sections up to 1.6 mm thick. Thicker sections should use a helium mixture in order to achieve the necessary penetration.
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