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Repeated Welding on Copper Block

Repeated Welding on Copper Block

Repeated Welding on Copper Block

(OP)
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.

RE: Repeated Welding on Copper Block

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.

RE: Repeated Welding on Copper Block

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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