AWS Class ERCuAI-A2 MIG & TIG
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ERCuAl-A2 Aluminum Bronze TIG & MIG Welding Wire Supplier in India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified supplier and stockist of ERCuAl-A2 aluminium bronze welding wire based in Mumbai, India. We supply this copper-aluminium filler metal batch-tested in accordance with AWS A5.7 / ASME SFA-5.7 with MTC 3.1 per EN 10204.
ERCuAl-A2 is the most versatile aluminium bronze filler wire in the AWS A5.7 / ASME SFA-5.7 family, classified under EN ISO 24373 as Cu 6180 (CuAl10Fe), W.Nr. 2.0937. This iron-bearing copper-aluminium wire contains approximately 88–91% Cu, 8.5–11.0% Al, and 0.5–1.5% Fe. The “ER” prefix confirms its role as an electrode and rod for TIG and MIG welding. ERCuAl-A2, the industry-standard aluminium bronze consumable, is excellent for joining and overlaying. An iron level of 0.5-1.5% refines the alpha-phase grain structure, reduces grain expansion, and increases strength. A narrow solidification range of ~5°C provides excellent hot cracking resistance. Weld deposits reach a tensile strength of 545 MPa (79 ksi) and a hardness of 140 HBW.
This wire is specifically engineered to join dissimilar metals, such as steel-to-copper, and it creates a strong bond between cast iron and bronze and adds a wear-resistant layer for marine, pump, and valve parts. As a trader and importer, Nicorex Alloys stocks ERCuAl-A2 in TIG rod and MIG spool form across all standard diameters with an EN 10204/3.1B certificate and traceability.
Aluminium Bronze ERCuAl-A2 Welding Wire Specifications
See the table below for a full list of technical specifications and industry standards for ERCuAl-A2 aluminium bronze.
| AWS Classification | ERCuAl-A2 |
|---|---|
| ASME SFA Specification | SFA-5.7 |
| UNS Number (Filler Wire) | — |
| Welding Processes | GTAW (TIG), GMAW (MIG), Plasma Arc, Arc Spray |
| Polarity | (GTAW): DCEN (DC-) (GMAW): DCEP Spray Transfer (DC+) |
| TIG Rod Diameters | 1.6, 2.4, 3.2, 4.0, 4.8 mm |
| MIG Wire Diameters | 0.8, 0.9, 1.2, 1.6 mm |
| TIG Rod Length | 914 mm (36 in.) |
| MIG Spool Sizes | D200, D300, 12 in spool; 100 kg, 200 kg drums |
| Shielding Gas | (GTAW): 100% Argon or 100% Helium (GMAW): 100% Argon or 75% Ar / 25% He |
What Does ERCuAl-A2 Mean? - AWS A5.7 Classification Explained
Consult this table for a detailed breakdown of the alphanumeric AWS A5.7 classification system for ERCuAl-A2 filler metals.
| Prefix / Suffix | Meaning |
|---|---|
| E | Electrode – consumable electrode in arc welding |
| R | Rod – hand-fed filler rod |
| Cu | Copper – primary base element |
| Al | Aluminum – principal alloying element |
| -A2 | Second variant in the copper-aluminium family (AWS A5.7) |
The “ER” prefix marks this as an arc welding consumable (GTAW/GMAW), distinct from “R” prefix brazing rods used in gas welding only.
Weld Deposit Chemical Composition of ERCuAl-A2
Please see the table below for the precise elemental percentages and chemical concentration limits found in ERCuAl-A2 weld deposits.
| Element | Copper + Silver (Cu+Ag) | Aluminum (Al) | Iron (Fe) | Zinc (Zn) | Silicon (Si) | Lead (Pb) | Other Elements (total) |
|---|---|---|---|---|---|---|---|
| AWS A5.7 Requirement | Remainder (~88–91%) | 8.5–11.0% | 0.5–1.5% | 0.02% max | 0.10% max | 0.02% max | 0.50% max |
Aluminium at 8.5–11% forms a protective Al₂O₃ film, delivering corrosion resistance in seawater and acidic service. Iron at 0.5–1.5% refines the alpha-phase grain and raises hardness. Lead is held to 0.02% max, so even trace Pb causes hot cracking in Cu-Al weld deposits.
All-Weld-Metal Mechanical Properties of ERCuAl-A2
Refer to the following table for typical mechanical performance data, including Brinell hardness and tensile strength values.
| Property | Tensile Strength | Yield Strength (0.2%) | Elongation (% in 50 mm) | Reduction of Area | Hardness (HBW 10/3000) |
|---|---|---|---|---|---|
| Value | 545 MPa (79 ksi) | 241 MPa (35 ksi) | 28% | 28% | 140 HBW |
AWS A5.7 does not mandate minimums for the ERCuAl-A series; values are typical. First-layer overlay on steel will be iron-diluted, with higher hardness and lower ductility. Subsequent layers approach nominal properties.
Base Metal Compatibility for ERCuAl-A2 Aluminium Bronze Wire
The following is a list of copper alloys, as well as other metals that are suitable with ERCuAl-A2 aluminium bronze wire:
| Base Metal | Joint Type | Notes | P-Number |
|---|---|---|---|
| Aluminum Bronze (C95200–C95800) | Joining | Plate fabrication, casting repair | P35 |
| Silicon Bronze (C65100, C65500) | Joining / Overlay | DCEN / Argon | P33 |
| Manganese Bronze (C86200, C86300) | Joining | Casting repair | P32 |
| Copper (C10200, C11000) | Joining / Overlay | Preheat thick sections | P31 |
| Carbon Steel (A36, 1018) | Braze weld / Overlay | Base metal stays solid in overlay | P1 |
| Cast Iron (grey, malleable) | Joining / Repair | Preheat 150–205°C | N/A |
| Galvanised Steel | Joining | Less zinc burn-off | P1 |
| Dissimilar: Cu-alloy to steel | Transition joint | Cu-Al deposit bonds to both | Varies |
Recommended TIG and MIG Welding Parameters for ERCuAl-A2
The following table outlines the optimised current, voltage, and gas flow settings for successful TIG and MIG welding applications.
GTAW (TIG) Parameters
| Filler Dia. | Tungsten | Amps | Volts | Argon Flow |
|---|---|---|---|---|
| 1.6 mm | 1.6 mm | 80–170 A | 12 V | 10 L/min |
| 2.4 mm | 2.4 mm | 140–275 A | 12 V | 10 L/min |
| 3.2 mm | 3.2 mm | 200–375 A | 12 V | 12 L/min |
| 3.2–4.0 mm | 4.8 mm | 260–475 A | 12 V | 14 L/min |
GMAW (MIG) Parameters
| Wire Dia. | Amps | Volts | Argon Flow |
|---|---|---|---|
| 0.8 mm | 130–160 A | 21–24 V | 10–14 L/min |
| 0.9 mm | 155–190 A | 23–25 V | 12–14 L/min |
| 1.2 mm | 210–235 A | 26–28 V | 14–17 L/min |
| 1.6 mm | 250–310 A | 27–31 V | 17–19 L/min |
Cast iron and thick copper require specific preheating to ensure proper weld integrity.
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Industrial Applications of ERCuAl-A2 Aluminium Bronze Welding Wire
The following are the industrial applications for ERCuAl-A2.
- Marine & Shipbuilding: The primary choice for repairing and rebuilding ship propellers. The weld surface forms a protective film that provides exceptional resistance to saltwater corrosion on rudders and hardware.
- Pump & Valve Fabrication: We use this specifically for impellers because it doesn't just sit there, as it fights back against erosion and corrosion every single day.
- Bearing Surface Overlay: used on shafts, rolls, and bushings in steel and paper mills. The deposit delivers excellent metal-to-metal wear resistance while remaining ductile enough to prevent cracking under heavy loads.
- Dissimilar Metal Joining: Acts as a vital bridge for "impossible" connections, such as steel-to-copper or copper-to-cast iron. It is essential for process piping where copper components must integrate with steel systems.
- Cast Iron Repair: Utilised for joining and surfacing iron castings like machine bases and gearboxes. The alloy creates a strong metallurgical bond to the iron, ensuring a reliable repair for heavy machinery.
- Galvanised Steel Fabrication: Preferred for joining galvanised sheets when high strength is needed. It minimises zinc burn-off, helping to maintain the protective coating near the weld zone better than steel fillers.
- Thermal Spray & Metallising: Serves as high-quality feedstock for spray processes. It applies a durable, corrosion-resistant bronze coating onto large steel components to extend their operational lifespan in harsh environments.
Storage and Handling of ERCuAl-A2 Welding Filler Metal
Proper storage reduces surface oxidation and contaminants that cause weld deposit porosity.
- Store in original packaging, clean and dry (15–35°C, below 60% RH).
- TIG rods: sealed tubes. Clean with acetone if discolouration appears.
- MIG spools: sealed plastic wrap. Protect from moisture and metal dust.
- Avoid zinc and lead contamination, as zinc causes porosity; lead causes hot cracking.
- No re-baking required. Shelf life is indefinite when stored dry.
Available Forms, Diameters and Packaging of ERCuAl-A2
See the table below for the different physical forms, wire diameters, and standard packaging options available for ERCuAl-A2 consumables.
| Form | Diameters | Packaging |
|---|---|---|
| TIG Rod | 1.6, 2.4, 3.2, 4.0, 4.8 mm | 5 kg / 10 lb tubes, 914 mm (36 in) |
| MIG Spool | 0.8, 0.9, 1.2, 1.6 mm | D200 (5 kg), D300 (12.5 kg), 12 in (30 lb) |
| MIG Drum | 0.9, 1.2 mm | 100 kg, 200 kg |
| Coil (arc spray) | 1.6 mm | 10–200 kg coils |
How to Order AWS Class ERCuAl-A2 MIG & TIG from Nicorex Alloys
When ordering ERCuAl-A2 aluminium bronze wire, specify these details in your RFQ:
- AWS Classification: ERCuAl-A2 per AWS A5.7 / ASME SFA-5.7
- Diameter: GTAW: 1.6 mm / 2.4 mm / 3.2 mm; GMAW: 0.9 mm / 1.2 mm / 1.6 mm
- Quantity: GTAW: specify kg or packs; GMAW: specify spool count
- Testing / Certification: MTC EN 10204 3.1/3.2; PMI Report; AWS A5.7 compliance; TPI
- Base Metal: Aluminium bronze / manganese bronze / cast iron / steel - specify
- Material Grade: Al-Bronze A2; UNS C61800; W.Nr. 2.0921 ; EN ISO 24373: S Cu 6180
- Third-Party Approvals: DNV / ABS / BV / LR / CCS - specify per application
- Applicable Code: ASME IX; AWS D1.2; AWS D1.1 dissimilar - specify
- Delivery: Domestic / International - specify port or address
- Remarks: Shielding: 100% Ar or 75% Ar / 25% He confirmed marine/overlay/dissimilar joint application
As a distributor, Nicorex Alloys stocks the full aluminium bronze range ERCuAl-A1, ERCuAl-A2, and ERCuAl-A3—plus ERCuSi-A, ERCuNi, and ERCuSn-A filler metals.
Frequently Asked Questions
What is the Difference between ERCuAl-A1, ERCuAl-A2, and ERCuAl-A3?
All three are copper-aluminium fillers per AWS A5.7, differing in iron content. ERCuAl-A1 (alloy 610) is iron-free (~7% Al)—overlay only. ERCuAl-A2 (alloy 618) has 0.5–1.5% Fe (~9–10% Al)—joining and overlay, including dissimilar metals. ERCuAl-A3 (alloy 624) has 2.5–4.0% Fe (~10–12% Al)—highest strength, for matching castings.
What Shielding Gas is Recommended for GMAW (MIG) Welding with ERCuAl-A2?
100% Argon or 75% Ar / 25% He with DCEP, spray transfer. Ar/He runs a hotter arc for better wetting on thick copper alloys. Avoid CO₂ mixtures, as CO₂ oxidises aluminium in the deposit, causing porosity.
Can ERCuAl-A2 be used to Join Steel to Copper?
Yes. Steel-to-copper, steel-to-aluminium bronze, and copper-to-cast iron transitions are primary applications. Direct the arc onto the steel side and let the pool flow onto the copper. Preheat thick copper sections to avoid a lack of fusion.
When should ERCuAl-A2 not be used?
Avoid ERCuAl-A2 above ~260°C (500°F) in oxidising atmospheres (dealuminification risk); for high-strength Ni-Al bronze castings like C95500 (use A3); in ammonia service (stress corrosion cracking); and where a yellow brass colour match is needed (use RBCuZn-D).