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CuNi Fabrication Info PDF
CuNi Fabrication Info PDF
FABRICATION
Handling I Welding I Properties
Resistance to corrosion and biofouling
Important applications
NiDI
Nickel Development Institute Copper Development Association
CDA
Copper Development Association Inc
Introduction
Copper-nickels have been specified for seawater use for over 50 years;
they are the materials of first choice for seawater pipework and
condenser service for many of the world's navies and merchant ships.
They are used in desalination, power plants and offshore fire water
systems, and for the sheathed protection of oil and gas platform legs and
risers. In all such applications, their durability is proven. Fabrication of
copper-nickels is not difficult, although a higher degree of cleanliness is
required than for steel. They are ductile and easily formed. Their
machinability is similar to that of aluminium bronzes, phosphor bronzes
and other copper alloys that do not have special free-cutting additions.
Copper-nickels can be welded by most standard processes.
1999
The material presented in this publication has been prepared for the general information of
the reader and should not be used or relied on for specific applications without first securing
competent advice.
The Nickel Development Institute, the Copper Development Association, the Copper
Development Association Inc, their members, staff and consultants do not represent or
warrant its suitability for any general or specific use and assume no liability or responsibility
of any kind in connection with the information herein.
2 Copper-nickel fabrication
Contents
The alloys 4
Standards | Composition | Mechanical and physical properties
General handling 6
Cutting and machining | Forming | Heat treatment | Descaling | Painting
Welding 8
Mechanical properties | Preparation | Tack welding | Weld preparations
Welding consumables | Manual metal arc | Gas-shielded tungsten arc
Gas-shielded metal arc | Post-weld treatment | Inspection
Clad plate 13
Cutting | Welding
Brazing 14
Boat hulls 17
Linings 19
Desalination plants 20
Biofouling resistance 25
Bibliography 27
Hull
construction
of the
Sieglinde
Marie using
6-mm-thick 90-
10 copper-
nickel plate
3 Copper-nickel fabrication
The alloys
Composition
The chemical composition ranges for the
two alloys vary among the different
standards. If the product is to be welded
subsequently, the ranges should preferably
be within the limits given in Table 2. The
maximum limits for some specific
impurities are tightened because of their
effects on hot ductility, and thus hot
workability and weldability. These same
detrimental elements can arise from
external contamination and so precautions
are necessary when the alloys are handled
during forming and welding.
70-30 Rem* 29-33 0.4-1 0.5-1.5 0.5 0.05 0.02 0.02 0.02 0.1
Standards
Single figures are maxima
Table 1 gives some of the more common * Remainder
international designations for both alloys. ** Total other impurities
4 Copper-nickel fabrication
The alloys
exchanger tubing is normally produced and Table 3 Typical mechanical properties of annealed copper-
nickel sheet and plate (taken from EN 1652:1997)
ordered in the light drawn rather than
annealed condition. For design purposes,
0.2% Proof Tensile Elongation
Hardness
precise values should be taken from Alloy strength min strength min
HV
N/mM2 * min N/mM2 * %
relevant international standards based on
product form and size. 90-10 100 300 30 90
Thermal
W/mK 50 29 50
conductivity
Coefficient of linear
10-6 /K 17 16 12
expansion 10-300C
Electrical microhm/
19 34 30
resistivity cm
Modulus
GPa 135 152 210
of elasticity
Modulus
GPa 50 56 81
of rigidity
James Robertson Ltd
5 Copper-nickel fabrication
General handling
6 Copper-nickel fabrication
General handling
7 Copper-nickel fabrication
Welding
The appropriate welding process depends this is necessary to ensure that the base
on the skills and equipment available, metal is dry. To avoid microfissuring, the
although a large project may justify new interpass temperature is maintained below
equipment and special training. It is highly 150C.
desirable that welders are given a period of
familiarization with the material and the Welding by TIG (GTAW) without filler
techniques used in handling it. Insurance metal autogenous welding is not
and inspection bodies may require recommended because of possible weld
qualification of both welders and welding porosity from a reaction with the
procedures with appropriate test pieces. atmosphere. Filler metals contain
additives to prevent this. Although it is
The most widely available welding method possible to weld copper-nickel alloys
is the manual metal arc (MMA or SMAW) using the oxyacetylene process, it is not a
process using flux-coated stick electrodes. practicable or desirable process for
This process is quite suitable for welding fabrication.
copper-nickel alloys and has the advantage
of using relatively inexpensive equipment. Mechanical properties of welds
The gas-shielded tungsten arc (TIG or A 70-30 copper-nickel filler material is
GTAW) process can give very high quality recommended for welding the 90-10 and
welds even in complex joints. The gas- 70-30 copper-nickel alloys. Because of
shielded metal arc (MIG or GMAW) the higher nickel content, the weld metal
process, using a continuous wire feed, is is stronger and more noble galvanically
faster and can be closely controlled with than the 90-10 copper-nickel base metal.
modern sophisticated equipment. Relevant When evaluating the results of test welds,
features of these three processes are a transverse bend test is not appropriate
described starting on page 10. because deformation is concentrated in
the relatively soft material adjacent to the
The general guideline for welding weld. A longitudinal bend test should be
conditions is to avoid high levels of heat used instead. Table 5 shows typical
input. Manufacturers of flux-coated properties of all-weld metals.
electrodes specify recommended current
ranges. But it is not always helpful to
recommend particular levels for the gas-
shielded processes since welding Table 5 Typical all-weld metal mechanical properties
(not to be used for design purposes)
conditions depend on the particular type of
joint and sequence of runs and for the 0.2% proof Tensile
Elongation Hardness
MIG (GMAW) process, on the mode of Welding process strength strength
5d%** HV
N/mm2* N/mm2*
metal transfer. Weld procedure trials are a
better means of determining appropriate
TIG or GTAW
conditions than following data given in a 200 385 40 105
(bare wire)
table.
MMA or SMAW (flux
270 420 34 120
There is no need to pre-heat the base metal coated electrode)
8 Copper-nickel fabrication
Welding
Weld preparations
It is possible to weld copper-nickel up to
3mm thick with a square butt preparation.
TIG (GTAW) Preparation for welding Above this thickness, a bevelled
welding a 90-10
As with heat treatment, all traces of the preparation must be used; the included
copper-nickel
assembly elements which cause cracking (sulphur, angle of the V should be larger than for
phosphorus, lead etc.) must be removed. carbon steel typically, 70 or above
This includes crayons, paints, because the molten weld metal is not as
temperature indication markers, cutting fluid as with carbon steels, and needs
fluids, oil and grease. (Fittings of other manipulation of the electrode or torch to
alloys, such as gunmetal copper-tin- ensure fusion with the side walls. Figure 1
zinc alloy are also a source of shows some weld preparations.
detrimental elements and should not be
welded to copper-nickel alloys.)
Tack welding
Because of their high coefficient of
thermal expansion relative to carbon
steel, copper-nickels have a greater
potential for distortion when welded.
Welding fixtures can help, but their use
is limited to subassemblies. So tack
welds should be made to maintain a
9 Copper-nickel fabrication
Welding
10 Copper-nickel fabrication
Welding
Manual metal
arc welding of a
boat hull
Copper Development Association Inc
Any weaving should not be more possible to ensure that the shielding
than three times the electrode gas protects the weld pool
diameter. adequately.
A long arc should be avoided, since Direct current should be used.
this results in weld porosity
through reaction with the Gas-shielded metal arc
surrounding atmosphere. (MIG or GMAW)
Start/stop positions can be The higher capital cost of equipment and
unsound: reversing the electrode the need to buy complete spools of filler
direction to remelt initially wire make MIG (GMAW) more
deposited weld metal or the crater appropriate for extensive welding
at the end of a run can help to avoid operations, such as the construction of
problems. complete boat hulls. High-quality
Slag must be removed between runs welding is made considerably easier by
by chipping and brushing to leave a modern power sources and controls.
clean surface for the next run.
MIG (GMAW) can be operated over a
Gas-shielded tungsten arc range of currents to provide various
(TIG or GTAW) transfer modes.
Unlike MMA (SMAW), separate control Dip (or short circuiting) transfer Low
of heat input via the arc and filler heat input, used for thinner sections.
material addition gives TIG (GTAW) a Spray transfer Relatively high heat
degree of flexibility which is an input and suitable only for thicker
advantage when welding shaped joints materials say, above 6 mm thickness -
or inserting root runs in thicker joints. and down-hand welding.
Filler material should be Pulsed-arc transfer A more advanced
incorporated and simple fusion of technique in which metal transfer is
the base metal avoided. closely controlled, providing a
Argon and argon + 1.5% hydrogen combination of low overall heat input
are suitable shielding gases. and adequate fusion to the base metal. It
The arc should be kept as short as is suitable for a range of thicknesses,
11 Copper-nickel fabrication
Welding
Post-weld treatment
Arc Machines Inc
12 Copper-nickel fabrication
Clad plate
Thicker plate sections e.g., tube sheets respective weld metals being mixed.
and water boxes can be constructed Otherwise, cracking is likely from the
economically using steel plate which has copper in carbon steel weld metal or the
been roll-clad with 90-10 or 70-30 iron in copper-nickel weld metal. The
copper-nickel. Plate 8 mm thick (2 mm region beside the interface between the
copper-nickel, 6 mm steel) has been backing material and the cladding is
successfully used to build four fire boats welded with 65% nickel-copper filler
in Italy. This type of material can have material which can cope with iron pickup
advantages, but is not so readily available from the carbon steel side. When the clad
as solid copper-nickel plate. plate thickness is less than about 10 mm,
65% nickel-copper filler metal is often
Clad plate should be handled with the used for the complete weld.
care appropriate to copper-nickel alloy,
not that for structural steel. When it is possible to weld from either
side on plates 12 mm and thicker, the
Cutting usual procedure is to weld the steel side
Unlike solid copper-nickel plate, it is first with a steel filler metal. The alloy
possible to use oxyacetylene equipment side is prepared for welding by
for cutting clad plate if the ratio of steel to backgouging to sound metal and welded
clad thickness is 4:1 or greater (20% clad with a first pass of 65% nickel-copper
or less). The clad side of the plate is face alloy followed by 70-30 copper-nickel.
down so that cutting starts from the steel Figure 2 shows the sequence.
side and the slag stream from the backing
steel is a cutting agent for the cladding. When access is possible only from the
This is not necessary for plasma-arc steel side, the joint is prepared to give
cutting, but trials may be needed to find access to the copper-nickel cladding, so
the most suitable settings for either that it can be welded like a solid alloy.
cutting procedure. The cut face must be The weld joint in the steel backing is
ground or machined to clean metal before then made with the 65% nickel-copper
welding. followed by the steel filler runs.
Welding
When designing weld procedures for
13 Copper-nickel fabrication
Brazing
Copper-nickel alloys are readily brazed over manual feeding better control of
by all processes, although torch brazing quality and minimal use of flux (residues
is commonest. Since the process relies of which must always be removed after
on wetting the surfaces to be joined by the joint has been made, usually by
the brazing alloy, absolute cleanliness washing with hot water). The larger the
is essential. Fluxes alone are not pipe size, the more difficult it is to
capable of removing all contamination, achieve uniform heating around the
particularly those containing lead or diameter to reach the brazing
sulphur, and oils, paint, etc which temperatures. Some organizations limit
should be removed carefully with brazing to pipe diameters up to and
solvents and degreasing agents. Oxides including about 50 mm.
and dirt can be eliminated with emery
paper or a chemical cleaning process. Furnace brazing is possible, and better
where significant numbers of assemblies
If parts have been cold formed, they are to be joined.
may contain significant internal
stresses, which promote intergranular Exothermic, endothermic or dissociated
penetration by molten filler material ammonia atmospheres are suitable,
during brazing - resulting in cracking at together with inert gas. Because of the
the joint. Removal of stresses by full high vapour pressure of some brazing
annealing is not necessary; heating to alloy constituents, vacuum brazing is less
600-650C for a few minutes is suitable.
sufficient for adequate stress relief and
this can be done simply with an oxyfuel
torch, taking care that the part is heated
uniformly.
14 Copper-nickel fabrication
Tube to tubesheet fabrication
Copper-nickel fabrication 15
Tube to tubesheet fabrication
Copper-nickel fabrication 16
Boat hulls
Growth of marine organisms on the steel Several boats have been fabricated from
hulls of marine vessels has a significantly roll-bonded clad plate. Four fireboats in
detrimental effect on their performance by Italy were constructed using plate of 6
increasing drag. It is customary to inhibit mm carbon steel and 2 mm 90-10 copper-
growth with a biocidal coating, replaced nickel alloy. When formulating a welding
from time to time in dry dock. The procedure for clad plate, the cladding and
obvious benefits of copper-nickel alloys in backing steel must be treated as separate
maintaining a smooth hull surface can be components. If it is possible to weld from
achieved by: either side, the steel side is welded first
sheathing a steel hull with copper- and the assembly inverted to allow the
nickel alloy sheet cladding to be prepared and welded. The
construction of the hull from roll- first run on the alloy side is of 65% Ni-
bonded clad plate Cu filler metal and the weld is completed
construction of the hull from solid with 70-30 copper-nickel filler metal.
copper-nickel alloy plate. The sequence has to be modified when
access is possible only from one side, but
Techniques for sheathing a hull mainly the transition region is always welded
involve dissimilar metal welds to the hull. with nickel-copper filler metal to avoid
MIG (GMAW) spot welding can be used cracking. It is possible, and may be
to ensure a close fit of the sheathing to the convenient, to use the 65% NiCu filler
underlying steel. This process operates metal throughout the joint - but there will
automatically, so that the degree of be biofouling on the welds at the surface.
penetration into the backing steel, and thus
the iron content of the weld metal, can be While construction from copper-nickel
controlled reproducibly. In tanker trials, alloy plate is straightforward, welding to
sheathed panels of 90-10 copper-nickel the steel framing requires dissimilar
alloy covering fully submerged, alternate metal joints. These can be made by the
wet/dry and splash zone conditions techniques described, but must be
performed well over a period of two years. protected against galvanic corrosion
There was minimal corrosion and fouling within the hull, usually by painting.
and although the surface of the exposed
steel had roughened the trial panels
remained smooth.
Copper-nickel fabrication 17
Sheathing of offshore structures
Copper-nickel fabrication 18
Linings
Copper-nickel fabrication 19
Desalination plants
90-10 copper-
nickel brine
piping for a
desalination
plant
Copper-nickel fabrication 20
Seawater corrosion resistance
Section through
copper nickel
tube showing
protective
mature surface
oxide film
Copper-nickel fabrication 21
Sea water corrosion resistance
Copper-nickel fabrication 22
Seawater corrosion resistance
Copper-nickel fabrication 23
Seawater corrosion resistance
Ferrous sulphate treatment has been found day from three days before entering until
to suppress corrosion rates of copper- leaving. One treatment a week can be
nickel in both polluted and unpolluted applied throughout prolonged voyages.
conditions. For commissioning, which can Chlorination treatment and ferrous
last from a few weeks to 3 months, the sulphate treatment should not be done
ferrous sulphate content of the cooling simultaneously.
water can be set up to about 2-3ppm,
following practical experience. An An alternative method of adding iron is to
alternative is to encourage good initial use a driven iron anode. This is more to
film formation during fitting-out, then maintain a protective layer than to form
leave fresh water containing 5ppm ferrous one, and reduces biofouling resistance.
sulphate in the system for a day. After
this, the system can be used for normal Other pretreatment compounds have been
fitting-out purposes, but 5ppm ferrous used with variable success. Sodium
sulphate should be added to the system dimethyldithiocarbamate has been used by
and circulated for an hour a day the British and German navies.
throughout the fitting-out period. This is
also useful when systems are retubed or
renewed.
Inlet/outlet
manifolds for
seawater course
filtration unit in
90-10 copper-
nickel
Copper-nickel fabrication 24
Biofouling resistance
Directly welded
Rubber insulated
Copper-nickel fabrication 25
Checklist
70-30 copper-nickel consumables used for similar welds in 90-10 and 70-30
copper-nickel
The 70-30
copper-nickel
hull of the
Asperida after
12 years in
service
Copper-nickel fabrication 26
Bibliography
CDA Publication TN 31. 90/10 and 70/30 Metallic coatings for corrosion control for
Alloys Technical Data marine structures. D Peters, H Michels,
C Powell. International workshop on Control
Copper-nickel and Aluminium bronze for Marine Structures and Pipelines.
Datadisk. Available from CDA Galveston, 1999
Guidelines for the use of copper alloys in
seawater. A Tuthill. NiDI publication 12 003
Boat hulls
The application of copper-nickel alloys in
marine systems. Technical report Corrosion and Biofouling Protection of Ship
(compendium) available from CDA Inc Hulls Using Copper-Nickel. Proceedings of
International Conference on Marine
Corrosion Prevention A reappraisal for the
Fabrication next decade. C Powell. Oct 1994. London.
Royal Institute of Naval Architects
Fabrication of copper-nickel alloys for
offshore applications. DE Jordan, C Powell. Copper-Nickel Sheathing Costing Study
Welding in Maritime Engineering, Oct 1998 Phase 3. MARAD Report 770 87026. US
Croatia Dept. of Transportation. August 1987
Guide to Welding of Copper-Nickel Alloys. CA 706 Copper-Nickel Alloy Hulls: The
NiDI Publication 1280 Copper Mariners Experience and
Economics. Monzolillo, Thiele and Tuthill.
Copper-Nickel Alloys. Engineering The Society of Naval Architects and Marine
properties. NiDI Publication 4353. Engineers. 1976
Machining Brass, Copper and Its Alloys. Use of Copper-Nickel Cladding on Ships and
CDA Publication TN 44 Boat Hulls. CDA Publication TN 36. 1985
Fabrication of copper-nickel pipework. M
Jasner, Brazil, March 1997. KME
Biofouling
Welding Copper-Nickel Clad Steel. CDA Inc
Application Data Sheet Preventing Biofouling with Copper Alloys.
1995. CDA Publication 113
Corrosion and Biofouling Resistance of
Piping systems, heat exchangers and Copper-Nickel in Offshore and Other Marine
condensers Applications. UK Corrosion and Eurocorr 94,
The Design and Installation of 90-10 Copper- Oct 1994, Bournemouth, UK
nickel Seawater Piping Systems. NiDI Seawater corrosion resistance of 90-10 and
Publication 11 007 70-30 copper-nickel 14-year exposures.
Heat exchanger and Piping Systems from K Efird and Anderson. Material Performance,
Copper Alloy Commissioning, Operating November 1975
and Shutdown. M Jasner et al. KME The Interrelation of Corrosion and Fouling
publication 1998 of Materials in Seawater. K Efird. NACE
Successful welding of tubes to tubesheets. Corrosion-75. Toronto, 1975
D Reynolds, J Kratz, J Kiefer. 2nd Controlling biofouling on ferry hulls with
Symposium of Shell & Tube Heat copper-nickel. L Boulton, C Powell. 10th
Exchangers, Houston, September 1981 International Congress on Marine Corrosion
and Fouling. Melbourne, 1999
Copper-nickel fabrication 27
Further information and advice
Copper Development Association (CDA)
Verulam Industrial Estate
244 London Road
St Albans
Hertfordshire ALI 1AQ
UK
Phone +44 1727 731200
Fax +44 1727 731216
Website www.cda.org.uk