Shihang copper-nickel filler wire featuring copper-nickel 90/10 filler wire or copper-nickel 70/30 filler wire. In different grades, copper-nickel filler wire offers superior corrosion resistance, especially in seawater applications. They are also often used in offshore and marine applications.

Shihang copper-nickel filler wire is relatively soft and low friction liners are essential. It may be required if the welding is taking place some distance from the wire drive unit.

Shihang is one of the most trusted suppliers of copper-nickel filler wire to the mechanical engineering industry. We can manufacture and design copper-nickel filler wire for transistor caps, electronic components, and anodes in electronic tubes. They offer resistance against acids and heat. Also, Shihang copper-nickel filler wire offers good mechanical properties and excellent corrosion resistance.

Aside from superior mechanical properties, our copper-nickel filler wire also have a perfect finish, without any flaws. Shihang copper-nickel filler wire has great strength and extended wear life.

Our copper-nickel filler wire is a great choice for heat exchangers, marine structures, and pipe systems as they can readily be welded and fabricated.

As a certified manufacturer, we have full capacity to custom copper-nickel filler wire according to your ideas and specifications.

Our professional team spent time researching and fabricating the products to the highest quality. We want the best out of your business, so we strive our best in whole fabrication procedures.

We took advantage of advanced equipment and high-technology. Shihang also equipped with advanced production facilities to manufactured high-class copper-nickel filler wire. Therefore, you can assure that Shihang copper-nickel filler wire is in good condition.

For more information about our copper-nickel filler wire, don’t hesitate to contact us today!

Copper Nickel Filler Wire: The Ultimate FAQ Guide

In this guide, you will learn the vital aspects you need to know when choosing copper nickel filler wire.

These will include uses, welding techniques, right packaging, and benefits, among other factors.

Keep reading to learn more.

What is Copper-nickel Filler Wire?

Copper-nickel filler wire is a filler material whose function is to join two separate metal surfaces together.

The joining process can either be through brazing, welding, or soldering.

The copper-nickel filler material has unique characteristics that make it suitable for welding in extreme applications.

Copper nickel filler wire

Copper nickel filler wire

Where can you use Copper-nickel Filler Wire?

You can use copper-nickel filler wire in welding methods by applying it around the welding surface to form a joint.

The welding process involves melting the filler wire around the joint.

Conventional welding methods that allow for copper-nickel filler wire use are:

Flux-cored arc welding
Submerged arc welding
Gas metal arc welding
Gas tungsten arc welding

Other applications of copper-nickel filler wire are in the brazing and soldering.

In soldering, part of the copper-nickel filler wire melts into the gap of two base materials forming a joint.

In brazing, you have to melt the copper-nickel filer wire and allow it to flow on the joining surfaces for a proper joint.

What is the Importance of Copper-nickel Filler Wire during Welding?

The importance of using copper-nickel filler wire include:

· Anti-rust

Copper-nickel filler wire is resistant to rusting.

This prevents your joints from leaking due to rusting.

· Durable

These joints don’t quickly disintegrate due to their tight welding capability.

You, therefore, have a welding joint that offers service to your application.

The long-term benefit if this is it reduces the overall cost of maintenance of your piping application

· High Electric Conduction

Copper-nickel has a high thermal conductivity, which is critical during the welding process.

Thermal conductivity maximizes the welding ability while reducing the electricity costs associated with welding.

What is the Difference Between a Copper-nickel Filler Wire and a Welding Rod?

A copper-filler wire is one that melts upon heating and flows into the gap between two joining parts.

This forms a soldered joint on these two parts.

These joints have unique characteristics which make them suitable for normal operations.

During the joining process, copper-nickel filler wire is consumed and becomes part of the two surfaces.

A welding rod can either be consumed or non-consumable, whose function is to join two base metals.

A consumable welding rod disintegrates and bonds with the two base materials.

A non-consumable welding rod does not disintegrate.

Instead, it acts as a catalyst in the bonding of the base metals using atmospheric oxygen.

A welding rod is typical in the shielded metal arc welding method.

Welding copper nickel tube

Welding copper nickel tube

What are the Benefits of using a Copper-nickel Filler Wire?

Using copper-nickel filler wire offers the following benefits:

· Temperature Regulation

Using a copper-nickel filler metal regulates the temperature of your welding process.

This is through minimizing the welding application area by forming an arc around this area.

· Filling the Welding Gap

Welding causes the edges to melts, which reduces their sizes.

The use of a copper-nickel filler metal fills this gap giving you a tight joint.

Are there Limitations to the use of a Copper-nickel Filler Wire?

Yes. There are few limitations when using copper-nickel filler wire.

The process of using a copper-nickel filler wire is a complex one that requires expertise.

This can prove a challenge in cases where such expertise is not available or expensive to hire.

The purchasing cost of copper-nickel filler wire is high compared to other filler materials.

This requires proper budgeting before buying them.

You need to have the correct protective gear when using copper-nickel filler wire, such as heat resistant hand gloves.

This is to prevent injuries due to spatter that comes from the melting of the filler wire.

What are the Properties of a Copper-nickel Filler Wire?

The following are the characteristics of copper-nickel filler wire that you need to look out for:

Welding with copper nickel filler wire

Welding with copper nickel filler wire

· Anticorrosion

Copper-nickel filler wire is highly anti-corrosive.

This is due to the chemical properties of nickel present, which prevents corrosion.

The anti-corrosive properties give durability to your joining processes, such as welding, soldering, and brazing.

· High Ductility

The flexibility of copper-nickel filler wire allows for their use in different positions of your base materials.

This is due to its lightweight and ease of use.

You, therefore, can use it if you have vertical or horizontal base materials.

· Low Melting Point

The low melting point of copper-nickel filler wire allows for easy joining when in use.

Once it melts, the resulting joint is tough and durable.

· Inhibits Micro-fouling

This characteristic prevents the growth of algae and other marine plants around the joint.

Such growth has the effect of facilitating corrosion, which reduces the quality of the connection.

· High Thermal Conductivity

Thermal conductivity is critical when analyzing how fast a given filler wire melts and bonds with the base metal.

A copper-nickel filler wire has a high thermal conductivity, which reduces the energy cost of bonding with other metals.

· Easily Compatible

Copper-nickel filler wire is compatible with different base metals, which is a necessity for better-joining characteristics.

Copper-nickel wire quickly melts and bonds with the base metals forming a durable joint.

How do I Select a Copper-nickel Filler Wire?

The process of selecting a copper-nickel filler involves the following considerations:

· Welding Position

A copper-nickel filler wire should allow for all-round welding of a particular material irrespective of the position.

That is, when you are welding, you should do so with the material in a flat position.

· Regulatory Specifications

The type of welding surface dictates which copper-nickel filler wire to use.

That is, the copper-nickel filler wire should have a tight welding property on the surface.

· Base Material

the bonding of the two materials depends on their chemical compatibility with the copper-nickel filler wire.

Mechanical properties like yield strength and tensile should also match for better welding results.

· Shielding Gas

The shielding gas you use during welding should be compatible with the copper-nickel filler wire you are using.

The different shielding gas available offer different welding effect on your copper-nickel filler wire.

· Pre- and Post-Welding Heat Treatment

Different surfaces have different heat treatments for better welding results.

Some of these heat treatments negatively affect your copper-nickel filler wire.

It is, therefore, vital to check on the pre- and post-heat of your surface before selecting a perfect copper-nickel filer.

· Welding Equipment

The type of welding equipment and its size determine which copper-nickel filler wire to use.

This equipment should provide enough power to properly weld the filler wire on the surfaces for adequate bonding.

What Constitutes Copper-nickel Filler Wire?

Copper nickel rod

Copper nickel rod

Copper and nickel are the two main chemicals present in a copper-nickel wire in different proportions. The main types of copper-nickel filler wire are:

Copper-nickel 90/10 filler wire where copper element constitutes an average of 90% and nickel an average of 10% of the total mass.
Copper-nickel 70/30 filler wire where an average of 70% is copper and 30% is nickel.

The difference in element constitution in these copper-nickel filler wires offer unique characteristics for their use.

What is the Difference Between a Copper-nickel Filler Wire and an Electrode?

An electrode refers to a rod whose function is to carry electrical current necessary for copper nickel welding.

They consist of a flux covering.

An electrode is of similar material as that of the welding surface.

It works by creating an electric arc on its end, while an electrode holder holds the opposite end.

Proper selection is vital in ensuring there is bead quality, weld strength, and minimal spatter.

If you are not using electrodes, you need to store them in a moisture-free environment.

A copper-filler wire is one that melts upon heating and flows into the gap between two joining parts. This forms a soldered joint on these two parts.

These joints have unique characteristics which make them suitable for normal operations.

During the joining process, copper-nickel filler wire is consumed and becomes part of the two surfaces.

Which Welding Methods can you use with Copper-nickel Filler Wires?

The following welding methods are compatible with copper-nickel filler wire:

· Flux-cored Arc Welding

This method requires the cleaning of your metal surfaces and the copper-nickel filler wire before using it.

You also have to wear protective gear due to the high spatter that the method produces.

The advantage of this method is it allows you to use your copper-nickel filler wire in any position of the metal surfaces.

That is, the metal surfaces can either be vertical, horizontal, overhead, or in a flat position.

The copper-nickel filler wires her uses less current during the process.

· Submerged Arc Welding

The effective use of copper-nickel filler wire in submerged arc welding depends on several factors.

Or instance, the feeding speed of the copper-nickel filler wire, the arc voltage, and the contact tip necessary for working.

This process is advantageous as it emits low welding fumes, has a high rate of deposition and allows for deep welding penetration.

· Gas Metal Arc Welding

Voltage and copper-nickel filler wire feeding speed are the two main variables that affect the quality of your welding process.

Having protective gear is essential here due to the high spatter and heat that it produces.

It requires a high number of copper-nickel filler wire compared to other welding methods.

This is due to the toughness of the process and the characteristics of the base metals.

· Gas Tungsten Arc Welding

Variables that affect the use of copper-nickel filler wire in this method are; welding current and voltage, working distance, and the feeding speed.

You need to prepare the surface for both the base metals and the copper-nickel filler wire.

The amount of energy you use in this process is higher due to the toughness of the base metals and the time it takes to weld.

How do you Feed Copper-nickel Filler Wire in a Particular Welding Process?

The position of your base metals determines how you are going to feed copper-nickel filler wire during the welding process.

Factors that affect the feeding rate during the welding process include the base metals, energy requirements, surface cleanliness.

Harder metals have a high feed rate due to the high penetration level.

This results in the high consumption of your copper-nickel filler wires.

High energy requirements consume less of your filler wires compared to low energy requirements.

This is due to the melting period it takes for your filler wires.

A dirty surface uses more copper-nickel filler wire compared to a clean surface.

This is because of the interaction of the contaminants and the filler wire.

In some instances, a dirty surface forms a weak weld while, in other cases, the process cannot materialize.

It is, therefore, best that you clean the surface before welding.

What are the Types of Copper-nickel Filler Wire?

Copper-nickel filler wire is available in two types:

Copper-nickel 90/10 filler wire where the copper element constitutes an average of 90% and nickel an average of 10% of the total mass.
Copper-nickel 70/30 filler wire where an average of 70% is copper and 30% is nickel.

The difference in element constitution in these copper-nickel filler wires offer unique characteristics for their use.

How do you Enhance the Effectiveness of a Copper-nickel Filler Wire?

You can enhance the effectiveness of copper-nickel filler wire by cleaning the surface of the base metals before welding.

Also, check on the compatibility of the base metals and the copper-nickel filler wire.

How do you Pack Copper-nickel Filler Wires?

Packing of copper-nickel filler wire involves wrapping them in PVC materials such as nylons.

This prevents contamination from the environment, which reduces their effectiveness.

What are the Considerations for a Copper-nickel Filler Wire?

Copper-nickel filler wire has the following considerations:

· Welding Surface

You need to check on the surface cleanliness of the welding surface before you start using copper-nickel filler wire.

This facilitates the welding process, especially in welding methods that require a clean surface.

· Base Material

The base material for the surface should be of the same material as that of copper-nickel filler wire.

Certain chemical properties like tensile and melting point make this a necessity.

· Welding Position

An appropriate welding position allows for the melting copper-nickel filler wire to flow into the joint area.

This helps in ensuring the welding is secure and durable.

As you can see copper nickel filler wire plays an integral role in Cupronickel tube and copper nickel pipe fabrications.