version 10_2006

AMPCO WELDING PRODUCTS

Welding Wire and Covered Electrodes

• Aluminum Bronze• Nickel Aluminum Bronze• Manganese Nickel Aluminum Bronze• Copper • Silicon Bronze

TYPICAL APPLICATIONS FORAMPCO WELDING PRODUCTS• Surfacing for Bearing Surfaces• Joining & Fabricating Copper Alloys• Surfacing for Resistance to Corrosion & Erosion• General Maintenance and Repair• Joining Dissimilar Metals

COPPER HARDFACING ALLOY SYSTEM

Copper Base Alloys

Bronze: The Other Surfacing Material

COPPER-ALLOY FAMILIES• Copper-Zinc (Brass):

– For very soft bearing surfaces and mild corrosion– CuZn-C: 90HB

• Copper-Silicon:– For corrosion-resistant surfaces– CuSi-A: 80HB, SG-CuSi3

• Copper-Tin:– For soft bearing surfaces and corrosion-resistant

surfaces. – CuSn-A: 75HB, CuSn-C: 90HB, SG-CuSn6

• Copper-Aluminium:– For bearings of higher hardness and corrosion, erosion,

cavitation and wear resistant surfaces.

WELDING PROCESSES & SETTINGS

• Gas Metal Arc Welding (GMAW)– DCEP (DC Electrode Positive)

• Gas Tungsten Arc Welding (GTAW)– DCEN (DC Electrode Negative)

• Shielded Metal Arc Welding (SMAW)– DCEP

SUGGESTED GAS SELECTION

• GTAW (TIG)– 100% Helium 30 – 40 CFH (14-19 L/min.)– 100% Argon 30 – 40 CFH (14-19 L/min.)

• GMAW (MIG)– 100% Argon 40 – 55 CFH (19-26 L/min.)

SELECTION OF A FILLER METAL

• Base metal composition • Mechanical property requirements• Deposition characteristics• Service requirements

PRINCIPLE COPPER ALLOY FILLER METALS• Copper • Silicon Bronze• Phosphor Bronze• Copper Nickel• Aluminum Bronze• Nickel-Aluminum Bronze• Manganese-Nickel Aluminum Bronze

CLASSIFICATIONFOR COPPER ALLOYS

• AMPCO-TRODE 7 CuAl-A1 SG-CuAl8• AMPCO-TRODE 10 CuAl-A2 SG-CuAl10Fe• AMPCO-TRODE 150 CuAl-A3• AMPCO-TRODE 160 CuAl-B• AMPCO-TRODE 40 CuMnNiAl SG-CuMn13Al7• AMPCO-TRODE 46 CuNiAl SG-CuAl8Ni6• COPR-TRODE Cu SG-CuSn• SIL-TRODE CuSi-A SG-CuSi3

METAL TO METAL WEAR

• Displacement and detachment of metallicparticles from a metallic surface caused by contact with another metallic substance

* Mate a nonferrous with a ferrous metal or alloy

TWO TYPES OF METAL TO METAL APPLICATIONS

• The cladding surface is to wear in preference to the mating surface

• The cladding surface is to resist wear fromthe mating surface

(Oil Platform Jacking Rig Component, AT10)

(Mining Machine Component, AT10)

PREFERENTIAL WEAR APPLICATIONSBEARING OVERLAY

(Steel Mill Coupler, AT150)

PREFERENTIAL WEAR APPLICATIONSBEARING OVERLAY

(Hydraulic Piston, AT10 & AT150)

PREFERENTIAL WEAR APPLICATIONS

(Steel Mill Coiling Component, AT150)

BEARING OVERLAY

(Bearing Overlay, AT10)

(Bearing Overlay, Forge Press Piston, AT150)

PREFERENTIAL WEAR APPLICATIONS

SURFACING FOR CORROSION RESISTANCE

CORROSION RESISTANCE

• Corrosion is the gradual attack on a metal or alloy by oxidation or chemical action

– Saltwater– Alkaline solutions– Acids (Reducing types)

CORROSION APPLICATIONS

(Marine Propellers,AT40 & AT46)

(Nickel Aluminum Bronze Propeller Blades, AT46)

SURFACING FOR CORROSION RESISTANCE

(Ampco 8 Fabrication, Power Plant Service Water Component)

FABRICATIONS

(Ampco 8 Fabrication, Potash Industry,Corrosion Application, AT10)

(Aluminum Bronze Fabrication,Propulsion Gear - US Navy, AT10)

(Nickel Aluminum Bronze Fabrications,Naval Submarines, AT46)

FABRICATIONS

FABRICATIONS

(Nickel Aluminum Bronze Fabrication, AT46)

FABRICATIONS

(High Conductivity Copper Fabrication, COPR-Trode)

MAINTENANCE AND REPAIR

(Steel Mill Electric Arc Electrode Holder Repair, COPR-Trode)

(Ampco 8 Fabrication, AT10)

JOINING OFDISSIMILAR METALS

(Steel to Aluminum Bronze, AT10)

NEW AMPCO FILLER METALS

AMPCO-CORE® 200AMPCO-CORE® 250AMPCO-CORE® 300

• Special Aluminum Bronze Cored Wire for GMAW (MIG) Welding

AMPCO-CORE® APPLICATIONS

• Mining machines– shovel boom components, cable drums

• Steel Mills– wear plates, deflection rolls

• Deep/shallow draw die applications– forming stainless steel elbows, pipe, sinks.

AMPCO-CORE® 200

AMPCO-CORE® 250

AMPCO-CORE® 250

AMPCO-CORE® 300

TECHNICAL DATA SHEETS