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Copper and Nickel Alloy Weld Materials

Copper and Nickel Alloy Weld Materials

Nickel, nickel-alloy products and copper based alloys, developed to join and overlay nickel, copper, bronze and many
dissimilar ferrous and non-ferrous alloys. To meet a variety of needs for welding cast iron and joining cast iron to steel with nickel or nickel alloys.

Weld Mold® 4000-A

Typical applications are joining Inconel® alloys to carbon steel, stainless steel, Nickel 200, Monel® alloys and copper-nickel alloys, and joining Nickel 200, Monel alloys and carbon steel to stainless steel. This alloy is also used for joining Incoloy® alloy 800 and 9% nickel steel to themselves.

Specification: AWS-ENiCrFe-2
Available forms: SMAW & FCAW

Weld Mold® 4010

The most versatile aluminum bronze welding alloy in this series. For welding and joining many ferrous and nonferrous metals and dissimilar combinations including the more weldable grades of cast iron, high- and low-carbon steels, copper, bronzes and copper/nickel alloys. Also for overlaying bearings and corrosion-resistant surfaces. Hardness values will increase somewhat when using the MIG process. Also available as an AC electrode.

BHN 119 (aluminum bronze); BHN 137 (steel)

Specification: AWS-ECuAl-A2
Available forms: SMAW, GTAW & GMAW

Weld Mold® 4046

An aluminum/nickel/manganese bronze, for the joining, repair or surfacing of dissimilar metals or aluminum bronzes containing nickel. Also used for welding on Ampco® 483, 45 and D-4 alloys. Commonly used on ship propellers (NiBrAl), turbines, valves, thrust bearings, stirrer blades, guides and other applications. Also available as a composite electrode.

BHN 190
Specification: AWS-ECuNiAl
Available forms: SMAW, GMAW & GMAW

 

Weld Mold® 4061

For welding 200 and 201 nickels. 4061 is also used for welding cast iron and build-up on steels. This product will also join many dissimilar combinations such as high nickels to stainless steels, inconel®, carbon steels and incoloy® alloys, monel® and copper-nickel alloys.

Specification: AWS- ERNi- 1

Available forms:SMAW & GMAW

Weld Mold® 4082

Welding Inconel® alloy 600, 601 and Incoloy® 800 to themselves or to each other. Dissimilar welding applications include joining Inconel® 800, 600 and 601 to carbon steels, stainless steel, joining nickel 200 to stainless and joining stainless steel to carbon steel.

Specification: AWS- ERNiCr-3
Available forms:SMAW & GMAW

Weld Mold® 4115

For cryogenic applications down to -195°C. Also used to construct and repair of transportation and storage tanks of liquid natural gas that are made our of 3, 5 and 9% Ni-steels.

Specification:AWS-NiCrMo-6
Available forms: SMAW

Weld Mold® 4150

An aluminum bronze alloy used to weld Ampco® 18 alloy. Also for piston overlay and deposition of bearing surfaces requiring high strength and good ductility. Hardness values will increase somewhat when using the MIG process.

BHN 166 as-welded
Specification: AWS-ECuAl-A3
Available forms:SMAW & GMAW

Weld Mold® 4190

For welding of Monel® alloys 400 and 404 to themselves or each other and for overlaying on steel. Dissimilar-welding applications include joints between Monel® alloys and carbon steel, low-alloy steel, copper, and copper/nickel. (Also available in composite form, as in Weld Mold® 4190-C

Specification: AWS-ENiCu-7
Available forms: SMAW, GTAW & GMAW

Weld Mold® 4250

Aluminum bronze alloy used for overlay and hard-facing. Recommended for repair of Ampco® 21 alloy. High yeild strength and hardness but lower tensile strength and ductility than 4200. Excellent for high-pressure bearing surfaces, especially when operating against hardened steel surfaces. Unusually high wear-resistance qualities. Hardness values will increase when using the TIG process. Also available as a composite electrode.

BHN 250 (steel); BHN 260 (aluminum bronze)
Specification: AWS-ECuAl-D
Available forms: SMAW, & GTAW

Weld Mold® 4320

A phosphor bronze alloy for dense, porosity-free copper and copper alloys such as phosphor bronze, tin bronze, brass and silicon bronzes. Also for iron-based metals and alloys such as cast iron and galvanized; for dissimilar metals like tin bronze and steel, brass and steel and cast iron and steel.

BHN 89
Specification: AWS-ERCuSn-C
Available forms: SMAW, FCAW, GTAW & GMAW

Weld Mold® 4333

An exceptionally smooth-running, highly deoxidized copper alloy designed to join and overlay conventional grades of copper and its alloys. Primarily used to fabricate and repair deoxidized, and electrolytic copper. It may also be used to weld galvanized steel and copper to mild steel where high strength is not required. Polycupro® 4333 is also used to resist mild corrosion.

BHN 54
Specification: AWS-ECu
Available forms: SMAW, GTAW & GMAW

 

Weld Mold® 4637

For joining and particularly for the overlay of Udimet® alloys 500 and 520. It has high resistance to high temperatures and impact and maintains high strength and toughness at elevated temperatures. Primarily used for repair and reclamation of rapid-blow rotary forge dies. Also used for build-up and repair of Waspaloy.®

Rc 30-35 as-welded, work-hardens to Rc 45+
Specification: DIN 2.4976
Available forms: SMAW & FCAW

Weld Mold® 4940

A high performance, high thermal conductivity copper alloy commonly utilized by the injection and blow molding industries as well as others in the molding industry as an alternative product for welding beryllium copper. Also used for welding Ampco® 940 molds.

Available Forms: GMAW & GTAW

Weld Mold® 641

A nickel-base hard-surfacing alloy with the addition of boron. Provides great metal-to-metal wear and excellent corrosion resistance. Good alloy for high abrasive and moderate impact situations.

Rc 55-60
Specification: AWS-ERNiCr-C
Available forms: GTAW & Oxy-Acetylene

Weld Mold® 672-C

A low carbon version of the 673 product, it is more ductile and crack-resistant when used for fabrication. Primarily used for welding Hastelloy® C-276 to itself and to many other nickel-based and stainless alloys.

Rc 15-20 as-welded, work-hardens to Rc 35+
Specification: AWS-ENiCrMo-4
Available forms: SMAW, FCAW & GTAW

Weld Mold 675

Used in the chemical industry when the following salts and acids are present; mineral acids, sea water, acetic anhydrite, brine solutions, solvents, chlorine, formic and acetic acids.

Rc 14-16 as-welded, work-hardens to Rc 35-40
Specification: AWS-NiCrMo-7
Available forms: SMAW

Weld Mold® 702

An excellent AC/DC straight-polarity product for welding cast iron with minimum heat output. The high conductivity of its commercially pure nickel core assures low temperature fusion with minimum dilution of the cast iron base metal.

Specification: AWS-ENiCI
Available forms: SMAW

Weld Mold® 750

A 55% nickel alloy with fluxing agents and precisely extruded coating for non-porous, homogeneous, nickel-iron deposits. For welding of ductile, malleable and grey cast irons. Used to overlay cast iron before surfacing with a more wear-resistant alloy and for joining cast iron to steel.

Specification: AWS-ENiFeCI
Available forms: SMAW, FCAW & GTAW

Weld Mold® 4000-B

Used for shielded metal-arc welding of 9% nickel steel. It is similar to 4000-A except it is designed for use with AC current only where magnetic forces (arc blow) are a problem.

Specification: AWS-ENiCrFe-4
Available forms: SMAW & FCAW

Weld Mold® 4040

A manganese/nickel/aluminum bronze for welding cast ship propellers, usually constructed of Ampcoloy® 495. Provides high resistance to corrosion, erosion, and cavitation. Also used for welding cast iron. Hardness values will be higher when using the MIG process.

BHN 185, BHN 217
Specification: AWS-ECulMnNiAI
Available forms: SMAW, GMAW & GTAW

Weld Mold® 4060

has good resistance to corrosion and good strength in areas such as reducing acids, seawater and salts. Used for joining or build-up on nickel and other selected alloys. Also used for welding Monel® alloys 400, R-405 and K-500.

Specification: AWS- ERNiCu-7
Available forms:GTAW & GMAW

Weld Mold® 4067

Weld Mold 4067 is a high copper material for joining dissimilar combinations of copper and nickel alloy materials. Has excellent resistance to seawater corrosion. Weld Mold 4067 is for welding ®Monel alloy 450 and other copper-nickel alloys such as Nickel 200.

Specification: AWS- ERCuNi
Available forms:SMAW & GMAW

Weld Mold® 4112-C

For welding of Inconel® alloys 625 and 601 and Incoloy® alloys 800 and 801. Also for overlays on carbon steel. Dissimilar-welding applications include joining Incoloy® alloy 825 to stainless steels, carbon steel and low-alloy steels; joining Inconel® alloy 625, Monel® alloy K-500 and Incoloy® alloys 800 and 825 to Inconel® alloys 706, 718, and X-750; and joining Incoloy® alloy 800 to Incoloy® alloy 825.

Specification: AWS-ENiCrMo-3
Available forms: SMAW & FCAW

Weld Mold® 4132-C

For joining Inconel® alloy 600 to itself and to Inconel® alloy 601.

Specification: AWS-ENiCrFe-1
Available forms: SMAW & FCAW

Weld Mold® 4182

Used for welding Inconel® alloys 600 and 601 to themselves or each other. This alloy can produce weld deposits that meet stringent radiographic requirements. Dissimilar-welding applications include joining Inconel® alloy 800 to carbon steel, stainless steel, Nickel 200 and Monel® alloy 400 to carbon steel; joining Monel® alloy 400 to carbon steel; joining Nickel 200 to stainless steel; and joining stainless steel to carbon steel. (Also available in composite form, as Weld Mold® 4182-C.)

Specification: AWS-ENiCrFe-3
Available forms:SMAW, FCAW, GTAW & GMAW

Weld Mold® 4200

An aluminum bronze alloy used primarily for overlay and hard-surfacing to take heavy loading. Recommended for the repair of Ampco® 20 alloy. Welds are strong and have good hardness coupled with ductility. Hardness values will increase somewhat when using the MIG process. Also available as a composite electrode.

BHN 200 (steel); BHN 212 (aluminum bronze)
Specification: AWS-ECuAl-C
Available forms: SMAW, FCAW, GTAW & GMAW

Weld Mold® 4300

Aluminum bronze alloy designed for hard-surfacing and cladding. Welds have the highest yeild strength and hardness in the Weld Mold® family of aluminum bronzes. Freedom from galling, scratching and metal pick-up make this product ideal for hard-facing iron-base dies used to form or draw stainless steels. Also used to repair and overlay Ampco® 22 and 25 alloys. Also available as a composite electrode.

BHN 300 (steel) BHN 316 (aluminum bronze)
Specification: AWS-ECuAl-E
Available forms: SMAW, FCAW & GTAW

Weld Mold® 4325

A silicon bronze alloy for welding galvanized iron, cast and malleable iron, copper-based alloys, steel and silicon bronze. Excellent for welding cast iron to steel and when welding dirty, oily or burned cast or malleable iron.

BHN 85
Specification:AWS-ERCuSi-A
Available forms: SMAW & GTAW, GMAW

Weld Mold® 4625

Used primarily to weld Inconel® 625 and 601, Incoloy® 800 and 802 and 9% nickel steel. Unsurpassed as a wear-resistant overlay on hot-work tools such as extrusion dies.

Specification: AWS-ENiCrMo-3
Available forms: SMAW, FCAW, GTAW & GMAW

Weld Mold® 4718-C

For welding Inconel® alloys 718, 706, and X-750. Uses include joining and overlays on forging pres dies, H.I.P. dies, cryogenic equipment and high-strength aircraft components.

Specification:AMS-5832
Available forms: SMAW, FCAW, GTAW & GMAW

Weld Mold® 620-C

For surfacing and rebuilding of Hastelloy® X, especially when it is necessary to maintain the composition and properties of the original material. Excellent resistance to oxidation, corrosion, thermal shock and fatigue. Uses include overlays for furnace and incinerator parts, pollution-control equipment and petrochemical components.

Specification: AWS-ENiCrMo-2
Available forms: SMAW, GTAW & GMAW

Weld Mold® 670-C

A nickel-base alloy used to join and overlay Hastelloy® W, dissimilar cobalt and nickel-base alloys and other alloys used in high-temperature service.

Specification: AWS-EMiMo-3
Available forms: SMAW, FCAW & GTAW

Weld Mold® 673

A nickel/chrome/moly alloy that resists high heat, impact corrosion, metal-to-metal wear and thermal shock. This alloy is also available in composite form as Polyface® 673-C. deposits rapidly work-harden from Rc 18-22 as-welded to Rc 40-42. Uses of these alloys include overlays of Hastelloy C, hot forge dies, trimmers and punches, hot shear blades, extrusion dies and blast-furnace bleeder valves.

Rc 30-32 as-welded, work-hardens to Rc 40-45
Specification: AWS-ENiCrMo-5
Available forms:SMAW, FCAW, GTAW, OXYGAS

Weld Mold® 676

Nickel base alloy used for wearfacing and corrosion resistant applications. Designed primarily for high corrosion resistance and wearfacing applications in the chemical industry. Used on agitators, heating and cooling coils, pump parts, and valves are prime examples.

Available form: AWS ENiMo-1
Available forms: SMAW

Weld Mold® 700

A 99% pure nickel-core wire, developed to operate on any current. Provides outstanding, easily machinable weld deposits for the buildup or joining of cast iron and cast iron to steel.

Specification: AWS-ENiCI
Available forms: SMAW, GTAW & GMAW

Weld Mold® 705

For a wear-resistant, machinable buildup and overlay on grey, nodular, meehanite and special alloy cast irons. All cast irons mentioned can be surfaced without buffer layers. Used primarily for welding flame-hardenable, automotive cast iron stamping and forming dies (Non-Heat-treatable).

Rc 37 – 40
Specification: NA
Available forms: SMAW & FCAW

Weld Mold® 755

A 55-45 copper/nickel alloy for excellent color match on cast iron with the ultimate in machinability. May be used as a first layer on high-sulphur steels.

Specification: NA
Available forms: SMAW, GTAW & GMAW