Beryllium-copper wire is widely used in the casting and machining of metal parts due to its excellent production and processing properties. However, when processing copper alloys, many workers often fail to properly handle the pores during copper alloy welding, which affects the quality and appearance of beryllium-copper wire products. So, why is it so easy for copper wire processing to produce pores? What should be done to reduce or avoid the occurrence of pores?

Let's first take a look at the reasons for the formation of pores during the welding of copper and copper alloys. Pores are a major problem in the welding of copper and copper alloys. As long as a certain amount of hydrogen and water vapor is added to the argon gas, pores will appear in the weld seam. The tendency to form pores is much more severe than that in carbon steel. The reasons are as follows: The thermal conductivity of beryllium copper wire is more than 7 times higher than that of low-carbon steel. Therefore, the crystallization of the copper weld seam occurs very quickly, and the molten pool is easily saturated with hydrogen and forms bubbles. In the case of rapid solidification and crystallization, the bubbles are not easily released, which promotes the formation of pores in the weld seam.

Meanwhile, the solubility of hydrogen in the beryllium-copper wire increases with the rise in temperature, reaching the maximum value at the melting point when hydrogen is fully dissolved in copper. As the temperature continues to rise, the liquid copper begins to evaporate, and the solubility of hydrogen decreases. During argon arc welding, nitrogen is also a cause of porosity formation. As the nitrogen content in the nitrogen gas increases, the number of pores also rises.

Finally, when welding the beryllium-copper wire, in order to prevent the formation of pores, first of all, prevent the weld metal from absorbing hydrogen and oxidizing. Before welding, the surface of the weldment should be free of hydrogen and oxidation. The surface of the weldment should be cleaned of oil, moisture, etc. The welding rods and flux should be dried before use. The surface of the welding wire should not have moisture. Secondly, strengthen deoxidation of the weld seam by adding deoxidizing elements such as silicon, aluminum, iron, and manganese. During welding, enhance protection. In addition, select appropriate welding process parameters, reduce the cooling speed, and the weld penetration should not be too large. Avoiding the formation of pores can improve the quality of beryllium-copper wire products.

I. Causes of Gas Porosity

The causes of gas porosity during copper alloy welding are diverse. The main factors include the following points:

Gas pollution during the welding process

During the welding process, there may be a large amount of gases such as oxygen and water vapor around the welding area. These gases will enter the molten pool, causing the formation of bubbles.

2. Poor quality of welding materials

The quality of the welding material has a significant impact on the welding quality. If the welding material is of poor quality and contains excessive impurities, it can also lead to the formation of pores.

3. Excessive or insufficient temperature during the welding process

During the welding process, if the temperature is too high or too low, it will affect the quality of the weld seam. If the temperature is too high, it will cause gas expansion in the welding area, resulting in pores; if the temperature is too low, the molten pool will not solidify properly, which will also cause pores.

II. Solutions

To address the aforementioned issues, we can take the following measures:

Strengthen purification

Before welding, the welding area should be thoroughly purified to avoid the presence of excessive amounts of gases such as oxygen and water vapor. Inert gases such as Argon can be used for protection to prevent the entry of oxygen and other gases into the molten pool.

2. Replace with the appropriate welding materials

Select high-quality welding materials and try to avoid those containing excessive impurities. The quality of the welding materials has a significant impact on the welding quality. Therefore, the appropriate welding materials should be selected based on specific circumstances.

3. Control the welding temperature

During the welding process, the welding temperature should be controlled properly to avoid excessive heat or insufficient heat. Preheating or cooling methods can be employed to keep the welding temperature within an appropriate range.

4. Strengthen training in welding techniques

For welders, improving their technical skills is also an important measure to prevent the formation of pores. By enhancing training, the technical proficiency of welders can be enhanced, enabling them to better master the welding techniques and reduce operational errors during the welding process.

By implementing the above measures, the problem of pores occurring during the welding of copper alloys can be effectively avoided, the welding quality can be improved, and the stability of product quality can be ensured.