ERCUAL-A1 Spooled Wire & Bare Filler Metal Rod
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ERCuAl-A1 Aluminum Bronze Spooled Wire & Bare Filler Rod Supplier in India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified Mumbai-based stockist and supplier of ERCuAl-A1 aluminum bronze spooled wire and bare filler rods, classified under AWS A5.7 / ASME SFA-5.7.
This alloy is also specified as Alloy 610, EN ISO 24373 S Cu 6100 (CuAl8), W.Nr. 2.0921.
ERCuAl-A1 is an iron-free copper-aluminium filler metal with approximately 91–94% Cu and 6.0–8.5% Al. The absence of iron makes the deposit softer (125 HBW) and more ductile (47% elongation). Tensile strength reaches 469 MPa (68 ksi) with a melting point of approximately 1030–1050°C. Aluminium forms a protective Al₂O₃ film that resists saltwater, metal salts, and common acids. ASME Section IX classifies ERCuAl-A1 under F-Number F-36. ERCuAl-A1 is intended for overlay and metallising only and is not for joining. The iron-free deposit is susceptible to hot shortness, which causes intergranular cracking in multi-pass joining welds.
MIG spooled wire is available in 0.8, 0.9, 1.2, and 1.6 mm diameters on 12 in (30 lb) spools. TIG bare rods come in 2.4 and 3.2 mm at 914 mm (36 in) length. ERCuAl-A1 supports GTAW with DCEN or ACHF polarity and GMAW with DCEP spray transfer, plus plasma arc metallising and arc spray systems. Industrial uses span bearing overlay, tube sheet surfacing, valve seat hardfacing, and anti-corrosion spray coatings. Every batch ships with EN 10204/3.1B test certificates.
ERCuAl-A1 Aluminum Bronze Wire and Rod Specifications
Refer to this table for a comprehensive summary of the industrial standards and technical specifications governing ERCuAl-A1 aluminium bronze.
| AWS Classification | ERCuAl-A1 as per AWS A5.7 / A5.7M |
|---|---|
| UNS (Base Alloy) | C61000 |
| Processes | GTAW (TIG), GMAW (MIG), Plasma arc, Arc spray |
| Polarity | (GTAW): DCEN or ACHF (GMAW): DCEP (spray transfer) |
| Shielding Gas | 100% Argon |
| Welding Position | Flat preferred; pulsed arc for other positions |
What Does ERCuAl-A1 Mean? - AWS A5.7 Classification Explained
Consult the following table for a detailed breakdown of the alphanumeric AWS A5.7 classification system for ERCuAl-A1 filler metal.
| Component | Meaning & Specification | Component |
|---|---|---|
| E | Electrode: Indicates the filler is spooled wire for GMAW (MIG) processes. | E |
| R | Rod: Indicates the filler is a bare rod for GTAW (TIG) processes. | R |
| Cu | Copper: Identifies the alloy as a copper-base filler metal. | Cu |
Iron refines the alpha-phase grain structure during solidification. Without it, ERCuAl-A1 forms coarse columnar grains with weak boundaries that crack under shrinkage stress with hot shortness. Single-layer overlay tolerates this; multi-pass joints do not. The iron-free composition delivers a purer Cu-Al surface with smoother bearing contact.
Deposit Chemical Composition of ERCuAl-A1
Please see the following data for the precise elemental percentages and chemical concentration limits required for ERCuAl-A1 weld deposits.
| Specification | Copper (Cu)* | Aluminium (Al) | Manganese (Mn) | Silicon (Si) | Lead (Pb) | Zinc (Zn) | Iron (Fe) | Other Elements (total) |
|---|---|---|---|---|---|---|---|---|
| AWS A5.7 Req. (%) | Balance (~91–94) | 6.0–8.5 | 0.50 max | 0.10 max | 0.02 max | 0.10 max | No minimum — trace only (iron-free) | 0.50 max |
* Including silver. The zero-minimum iron separates ERCuAl-A1 from ERCuAl-A2 (0.5–1.5% Fe required). Aluminium at 6.0–8.5% generates a stable Al₂O₃ film protecting against saltwater, brackish water, and dilute acids.
All-Weld-Metal Mechanical Properties of ERCuAl-A1
Please refer to the table below for typical tensile strength, yield strength, and Brinell hardness values of ERCuAl-A1.
| Specification | Tensile Strength | Yield Strength (0.2%) | Elongation (% in 50 mm) | Reduction of Area | Hardness (HBW 10/3000) |
|---|---|---|---|---|---|
| Typical Value | 469 MPa (68 ksi) | 193 MPa (28 ksi) | 47% | 53% | 125 HBW (on 6.4 mm deposit) |
ERCuAl-A1 has the highest elongation (47%) and lowest hardness (125 HBW) of the three aluminium bronze fillers, which is ideal for bearing overlay, where ductility prevents brittle failure under load.
Recommended TIG and MIG Welding Parameters for ERCuAl-A1
The following table provides optimised operational settings and shielding gas recommendations for achieving high-quality results with ERCuAl-A1 consumables.
GTAW (TIG) Parameters – DCEN or ACHF
| Base Thickness | Tungsten | Filler Ø | Amps DC (A) | Amps AC (A) | Gas Cup | Argon Flow |
|---|---|---|---|---|---|---|
| 1.6 mm (1/16 in) | 1.6 mm | 1.6 mm | 80–120 | 80–120 | 10–13 mm | 7 L/min (15 cfh) |
| 2.4–3.2 mm | 2.4 mm | 2.4 mm | 145–205 | 145–195 | 11–13 mm | 7 L/min (15 cfh) |
| 4.8 mm (3/16 in) | 3.2 mm | 2.4–3.2 mm | 300–350 | 255–300 | 11–13 mm | 10 L/min (20 cfh) |
| 12.7 mm (1/2 in) | 4.8 mm | 3.2 mm | 515–640 | 340–485 | 13 mm | 12 L/min (25 cfh) |
GMAW (MIG) Parameters – DCEP, Spray Transfer
| Wire Ø | Amps (A) | Volts (V) | Argon Flow | Wire Feed Speed |
|---|---|---|---|---|
| 0.8 mm (0.030 in) | 80–140 | 25–26 | 12 L/min (25 cfh) | 8.6–11.4 m/min (340–450 ipm) |
| 0.9 mm (0.035 in) | 130–200 | 26–27 | 14 L/min (30 cfh) | 7.1–10.2 m/min (280–400 ipm) |
| 1.2 mm (0.045 in) | 185–245 | 27–28 | 14 L/min (30 cfh) | 5.1–7.6 m/min (200–300 ipm) |
| 1.6 mm (1/16 in) | 250–400 | 28–30 | 19 L/min (40 cfh) | 3.8–5.3 m/min (150–210 ipm) |
Use stringer beads to limit heat input. Clean oxide between passes with a stainless steel wire brush. Flat position preferred; pulsed arc allows out-of-position work.
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Industrial Applications of ERCuAl-A1 Aluminum Bronze Overlay Wire
The following are the industrial applications of ERCuAl-A1 Aluminum Bronze Overlay Wire:
- Bearing Surface Overlay: Applied to journal bearings and bushings on steel shafts to create a smooth, low-friction surface that prevents metal-to-metal galling and seizing.
- Tube Sheet Surfacing: Used for cladding steel tube sheets in mills to provide a protective barrier against corrosive brackish water and aggressive industrial process fluids.
- Valve Seat Hardfacing: Used on sealing surfaces of marine and chemical valves to provide a strong, corrosion-resistant seal that can withstand high usage.
- Pickling Hook Overlay: Steel hooks for use in acid cleaning baths are designed so that the base metal does not dissolve when they are exposed to concentrated sulfuric and hydrochloric acids.
- Pump Impeller Surfacing: Used on impellers and pump housings in water treatment plants to shield components from the combined effects of fluid erosion and chemical corrosion.
- Metallising Feedstock: Utilised in thermal spray systems to apply protective coatings on large marine structures, preventing saltwater rust and the growth of marine organisms on steel.
- Automotive Tooling: Applied to forming dies and fixtures to provide a soft bronze wear surface that protects steel automotive parts from scratching or sticking during production.
Storage and Handling of ERCuAl-A1 Aluminium Bronze Wire
Store in original sealed packaging at 15–35°C, below 60% RH. Clean rods with acetone if oxidation is visible. Do not contaminate with zinc, lead, or sulphur. Handle with clean gloves. No re-baking required. Shelf life is indefinite when stored dry.
Available Forms, Diameters and Packaging of ERCuAl-A1
Check the table below for various wire diameters, spool sizes, and rod lengths available for ERCuAl-A1
| Form | Diameters | Packaging |
|---|---|---|
| MIG Spooled Wire | 0.8, 0.9, 1.2, 1.6 mm | 12 in spool (30 lb / 13.6 kg) |
| TIG Bare Filler Rod | 2.4 mm (3/32 in), 3.2 mm (1/8 in) | 10 lb (4.5 kg) box, 914 mm (36 in) length |
| Arc Spray Wire | 1.6 mm (1/16 in), 2.4 mm (3/32 in) | Coils / drums |
How to Order ERCuAl-A1 Aluminium Bronze Wire from Nicorex Alloys
To place an order for ERCuAl-A1 Aluminium Bronze Wire from Nicorex Alloys, please provide the following details:
- Wire Type - GMAW/GTAW AWS A5.7 ERCuAl-A1
- Size - 1.2mm spools, 2.4mm-3.2mm cut lengths
- Current Type - DCEP/DCEN + 100% Argon gas
- Welding Position - Flat and horizontal positions
- Material Grade - C60600 / ERCuAl-A1 / 2.0921 / ISO 24373
- Quantity - 15kg spools / 5kg tubes
- Standard - AWS A5.7 / ASME SFA 5.7
- Documentation - MTC EN 10204 3.1, TPI report
- Packaging - Vacuum-sealed foil bags with silica desiccant
- Delivery Destination - International / Domestic
Frequently Asked Questions
What is the Price of ERCuAl-A1 Aluminum Bronze Welding Wire per Kg in India?
Pricing of ERCuAl-A1 depends on copper and aluminium market rates, wire diameter, form, and quantity. Contact Nicorex Alloys for a quotation.
Why is ERCuAl-A1 not recommended for joining?
ERCuAl-A1 is iron-free. Without iron to refine the grain structure, the deposit forms large columnar grains that crack under shrinkage stress with hot shortness. Single-layer overlay tolerates this; multi-pass joints cannot. Use ERCuAl-A2 for joining.
What is the Difference between ERCuAl-A1 and ERCuAl-A2?
ERCuAl-A1 offers iron-free, 47% elongation for overlays, whereas ERCuAl-A2 contains iron, providing 140 HBW for both joining and versatile overlays.
Can ERCuAl-A1 be used with AC Polarity on TIG?
Yes. DCEN and ACHF (AC high-frequency) are both valid. AC provides arc cleaning that helps remove the Al₂O₃ oxide layer. DCEN gives deeper penetration and is standard.
What is the F-Number of ERCuAl-A1 per ASME Section IX?
F-36 filler per QW-432 follows SFA-5.7 standards, but has no A-number assigned since copper-base fillers are excluded from QW-442.
What Sizes are Available for ERCuAl-A1 Spooled Wire and TIG Rods?
MIG wire is available in diameters from 0.8 to 1.6 mm, while TIG rods come in 2.4 and 3.2 mm lengths for precise industrial welding.
When should ERCuAl-A1 not be used?
Do not use for joining, as the iron-free deposit will crack. Not for applications above 130 HBW, choose A2 or A3. Avoid ammonia environments. Avoid service above 260°C (500°F), where dealuminification may occur.