Repeated Welding on Copper Block

[dforce]

I had a question about the re-welding of electrolytic tough pitch (ETP) copper (99.90% Cu, 0.04% O). Currently, we use cast blocks of this with internal water for cooling material in our process. Over time, the blocks become worn and the copper is re-welded (build-up with Cu filler metal). Practise has been to re-weld one time and then when it wears again discard the entire block and replace with a new one.

I was wondering if anyone had experience or sees issues with re-welding copper several times. Problem I can see is the oxygen in material which causes porosity and reduces weld strength as it can congregate at grain boundaries. However, the filer metal used (ERCu) will have P and Si in it (oxygen stabilizers) so the second and third re-builds should have even less issues with oxygen. Any comments would be helpful.

 

[metengr]

dforce;
I don't see any technical reason why you cannot re-use these welded blocks. Sounds like a good way to save your company some money.

 

[arunmrao]

A similar concept is used in arc furnaces,where a zone which undergoes maxximum refractory wear has chillblocks placed. Time to time this needs attention and always salvaging is done,never did I see a new one being placed.

I am now in the process of making water cooled inserts for electrode holders in arc furnace. For this application annually a replacement is done.

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