Weld Jig Material

[meterbox]

We have several weld jigs for flat .250 thick 6061-t65 aluminum. Weld from 1 side only, approx 4.000 weld bead, .093 gap between the 2 pieces, with a C110 copper insert .031 below the opposite side. My problem is with the copper insert. They only last approx 2 weeks before needing resurfaced. Is there a material more suitable than copper?

 

[evelrod]

You could try a ceramic backup or use thicker copper strip.
I think you are getting your moneys worth if the copper backup is lasting two weeks. The ceramic strips require a little bit of 're training' and are somewhat more fragile, but do a great job if a little expensive. Try Lincoln as they have some literature on them. I like the copper and use it on most everything---yes, I do have to resurface it from time to time. I don't know how difficult yours is to resurface but, every two weeks, assuming full production welding, sounds pretty good to me! Have you tried 'open root' welds , sans backup?

Rod

 

[meterbox]

Thanks for the advice! I need to add that the purpose of the backing plate is to limit "blowthru" on that side to a max of .060, to prevent electrical clearance problems (in the final assy)without having to grind every weld.