Member of theKME Group

KM

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AGEL

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ELBRODUR® – Alloys

for resistance welding

The KME group ELBRODUR®

Resistance welding electrode materialsQuality managementApplicationsRecommendations on useStandard specificationsMechanical and physical propertiesSpecial applicationsELBRODUR® HFELBRODUR® NELBRODUR® BELBRODUR® G strip/sheet/plateELBRODUR® DSpecial tubes

355677789

101112131415

KME Germany AG — ELBRODUR® 3

The KME group

The KME group is the world’s largest manufacturer of copper and copper alloy products. Nonferrous metals were first processed by the company in osnabrück as early as 1873. Today, kme employs nearly 6,800 people, manufacturing a wide range of semi-finished, finished and special products at 15 locations across europe and asia.

The group’s corporate goal is to develop and manufacture products that meet customer demands, supporting them in finding solutions for their specific applications, andproviding services as a long-term partner. KME’s strategy for accomplishing this goal is based on a highly skilled and experienced workforce. KME has the capacity to invent and develop new materials and innovative production processes, which kme sustains by ongoing advancement and training of its employees and the continual improvement of its organisational structures.

The business unit extruded and drawn products within KME's special products division Is specialized in the manufacture of materials for resistance welding electrodes. For nearly five decades now it has been producing the most varied alloys designed to meet the different requirements of industrial welding techniques.

4

5KME Germany AG — ELBRODUR®

KME has been in the manufacture of materials for resistance welding electrodes for several decades now; it moreover supplies the input material for the highly stressed parts in blowpipes for fusion welding. The performance requirements to be met by resistance welding electrode materials can be briefly described as follows: It is the job of the electrode to transmit the required heavy electric currents to the workpiece. To keep electrode dissipation – due to current being turned into heat – to a minimum the material should have high electrical conductivity. Moreover the electrode should not deform when applying the specific pres-sure which is necessary to bring about the weld.

Because of the inevitable rise in temperature which is experienced in the process, the electrode material should retain adequate hardness at elevated tempera-tures and be highly resistant to softening. Close cooperation with the users, together with its innovative company structure, have enabled KME to develop the high-standard resistance welding materials of today. Its trademarked ELBRODUR® alloys satisfy in perfect fashion the performance demands which such materials are expected to meet:– High electrical and thermal conductivity – High strength – High resistance to softening (high softening temperature) – Retention of high hardness at elevated temperatures (high elevated temperature strength)

ELBRODUR®

High-duty electrode materials

ELBRODUR® Type Alloy Properties and Uses

HF (CH 25)N (CH 23)

CuCr1Zr High-strength, age-hardened electrode material for spot welding, particulary high-cycle continuous or roller spot welding. Suitable for all steels – including alloyed and stainless grades – and for coated and galvanized sheet.Can in certain cases be used for aluminium alloys as well.

B (CH40) CuCo2Be High-strength, age-hardened electrode material featuring particularly great hardness along with medium electrical conductivity; for spot, seam, projection and butt welding. Suitable for alloyed, high-strength and corrosion resistant steels as well as nickel and nickel alloys.

D (CH75) (CuNi2,5SiCr) High-strength, age-hardened material for projection and butt welding electrodes: A beryllium-free alternative to ELBRODUR®B. Also suitable for high-strength sections and plungers of die casting machines.

HF (CH25) CuCr1Zr Special tubes/contact tubes for welding applications (e.g. contact nozzles).

The above listing of the usual fields of use is given without any warranty as to completeness.

KME Germany AG — ELBRODUR®6

ELBRODUR® is used in all known methods of resistance welding:

— ELBRODUR® HF / N Spot welding, projection and butt welding — ELBRODUR® B Spot welding, projection and butt welding — ELBRODUR® D Projection and butt welding

Quality management system

Quality is the very basis of reliability – quality in every detail, in every step of work. For decades now, KME has been consistently putting into action the corporate idea of quality and with it, gained the reputation of being a reliable supplier throughout the world. The fulfilment of our customer's expectations as to KME products and services in all respects is the declared corporate policy. To assure this, KME qua- lity management has been set up, implemening and certifying the row of DIN EN ISO 9000 by Lloyd's Register Quality Assurance.

KME quality management comprehends process- integrated quality controls, international product and system audits, the systematical training of all employees and the operating of computer aided statistical methods. The result of KME production gives convincing proof: our results have been sur- passing the requirements of national and interna-tional standards for years.

KME Germany AG — ELBRODUR® 7

Recommendations on use

ELBRODUR® N should be used, instead of ELBRODUR® HF, if the electrodes employed for projection, butt and spot welding are > 30 mm in diameter or > 25 mm in width across flats. Along the same lines, wheels of ELBRODUR® G should be used for seam welding. If you want to join dissimilar metals, pick the type of ELBRODUR® which is best suited for the job. The graph on this page gives some helpful clues.* If you want to weld coated sheet, it is important that the coating should be even and uniform. When joining aluminium alloys, it is essential to remove all oxide films from the surface prior to welding. Welds between steel and aluminium can only be made by using bi-metal electrodes.

* see also DVS leaflet 2903

Depending on the particular type of alloy, ELBRODUR® materials are supplied either in cold-worked condition, or in cold-worked and age-hardened condition. A rise in temperature above the softening tempe-ratures indicated for the different electrode materials will significantly lower their mechanical and physical properties. Where brazed joints are inevitable, careful consideration should be given to the likely loss of hardness in alloys of the age-hardened type, and to the fact that localized rises in temperature (hot spots) in non-symmetrical bodies can lead to cracking. This is why such alloys should preferably be transformed by machining or cold forming - extrusion, bending. If the material is to undergo extrusion or bending, a special grade of the HF, N and B types of ELBRODUR® can be furnished featuring somewhat lower hardness.

Applications

Application standards: resistance welding electrode materials

KME Europe International U.S.A. U.K. France

Germany: DIN ISO 5182 ISO 5182 RWMA - Alloys BS 4577 NFA 82 – 100

* Composition may differ slightly from other standard specifications.

National and international standard designations of ELBRODUR® - alloys

KME Europa International U.S.A.

ELBRODUR®

TypeAlloy EN 12163/Rods

EN 12165/Forging EN 12166/Wire EN 12167/Profiles

ISO 1336ISO 1187

UNS No

HF/N CuCr1Zr CW106C CuCr1Zr C 18150* C 18200* C 18400*

B CuCo2Be CW104C CuCo2Be C 17500

D CuNi2,5SiCr – – C 18000

KME Germany AG — ELBRODUR®8

Mechanical and physical properties (nominal values)

KME Alloys ELBRODUR®

HF (CH 25)ELBRODUR®

N (CH 23)ELBRODUR®

G (CH 27)ELBRODUR®

B (CH 40)ELBRODUR®

D (CH 75)

Density at 20°C g/cm3 8.9 8.9 8.9 8.8 8.9

Melting temp. (liquidus) °C 1075 1075 1075 1056 1060

Mean coefficient of linear ther-mal expansion (20°C - 300°C)

10-6/K 18.0 18.0 18.0 17.8 18.0

Modulus of elasticity KN/mm2 120 120 120 120 140

Thermal cond. at 20°C W/(m · K) 330 350 330 230 220

Softening temperature °C 475 475 475 500 475

Composition wt. - % Cr 0,65Zr 0,08Cu rem.perm. otherelements:0,2 max.

Cr 0,65Zr 0,05Cu rem.perm. otherelements:0,2 max.

Cr 0,65Zr 0,1Cu rem.perm. otherelements:0,2 max.

Co 2,2Be 0,55Cu rem. perm. other elements:Ni + Fe 0.5 max.; others 0.5 max.

Ni 2,5Si 0,65Cr 0,3Cu rem.perm. otherelements:0,3 max.

270

210

150

90

30

170

160

150

140

130

120

110

100

52

51

50

49

48

47

46

45

270

210

150

90

30

102 103 104 sec.

1 5 10 30 60 300 600 min.

9KME Germany AG — ELBRODUR®

Special applications

High-temperatureNominal hardness at elevated temperatures.

Resistance to softening Nominal hardness at ambient temperature after heating for 30 minutes to the temperatures shown.

Resistance to softeningNominal hardness and electrical conductivity of ELBRODUR® HF at ambient temperature, as a function of time at 600°C.

0 100 200 300 400 500 600

Temperature (°C)

ELBRODUR® B

ELBRODUR® D

ELBRODUR® HF

ELBRODUR® N

E-Cu (comparison)

Brin

ell h

ardn

ess

(HBW

2.5

/62

.5)

electrical conductivity

HBW 2.5/62.5

Brin

ell h

ardn

ess

(HBW

2.5

/62

.5)

ELBRODUR® B

ELBRODUR® HF

ELBRODUR® N

E-Cu (comparison)

0 100 200 300 400 500 600

Temperature (°C)

Brin

ell h

ardn

ess

(HBW

2.5

/62

.5)

elec

tric

al c

ondu

ctiv

ity M

S/m

ELBRODUR® B

ELBRODUR® HF

ELBRODUR® N

E-Cu (comparison)

ELBRODUR® B

ELBRODUR® D

ELBRODUR® HF

ELBRODUR® N

E-Cu (comparison)

electrical conductivity

HBW 2.5/62.5

Time at temperature

C

AB B

AB B

KME Germany AG — ELBRODUR®

ELBRODUR® HF

Dia. (mm)

5 10 25 –30

Rod

Rod Width a/f (mm)

5 10 20 – 25

Nominal composition

Percentages are by weight:Cr 0.65 %Zr 0.08 %Cu rem.

perm. other elements 0.2 % max.

ELBRODUR® HF (CuCr1Zr) is a high-strength age-hardened electrode material for spot welding, in particular high-cycle continuous or roller spot welding. Suitable for all steels – including alloyed and stainless grades – and for coated and galvanized sheet.

Mechanical and physical properties

A B C

Tensile strengh Rm MPa 540 – 640 ≥ 490 ≥ 460

Yield strengh Rp0.2 MPa 470 – 570 ≥ 440 ≥ 400

Elongation A5 % 10 – 20 ≥ 10 ≥ 16

Reduction of Area Z % 50 – 70 50 – 70 60 – 80

Hardness HBW 2.5/62.5 160 –185 155 –180 140 –165

Hardness HV30 165 –190 160 –185 145 –170

Hardness HRB 81 – 90 79 – 89 73 – 83

El. conductivity MS/m 44 – 50 44 – 50 46 – 52

El. conductivity % IACS 76 – 86 76 – 86 80 – 90

Special grade for cold bending. Further sizes and special grades on inquiry. Coils/wire up to 10 mm O.D. or width a/f.

Shapes, Sizes and Tempers

A

C

A CB

A CB

11KME Germany AG — ELBRODUR®

ELBRODUR® N

Dia. (mm)

30 50 60 165

Shapes, sizes and tempers Bar

0 4 8 20 40 80 100 200

Thic

knes

s (m

m)

Width (mm)

Rod

200

80

100

40

8

4

0

55

20

2

Nominal composition

Percentages are by weight:Cr 0.65Zr 0.05 Cu rem.

perm. other elements 0.2 % max.

ELBRODUR® N (CuCr1Zr) is a age-hardened electrode material for spot, projection and butt welding. Suitable for carbon steels, galvanized sheet, brass, bronze and nickel. Can in certain cases be used for aluminium alloys as well.

Further sizes and special grades on request.

Width a/f (mm)

25 40 60 100

Rod

Mechanical and physical properties

A B C

Tensile strength Rm MPa 440 – 540 ≥ 390 ≥ 370

Yield strength Rp0.2 MPa 390 – 510 ≥ 270 ≥ 255

Elongation A5 % 10 – 25 ≥ 12* ≥ 18

Reduction od Area Z % 40 – 70 40 – 70 40 – 70

Hardness HBW 2.5/62.5 135 –170 130 –155 120 –150

Hardness HV30 140 –175 135 –160 125 –155

Hardness HRB 71 – 85 69 – 79 65 – 77

El. conductivity MS/m 47 – 52 47 – 52 47 – 52

El. conductivity % IACS 81 – 90 81 – 90 81 – 90

* ≥ 16% for cold bending material Dimension Range Ø ≥ 30mm < 60mm ≥ 25mm < 60mm

0 4 40 50 100

200

100

50

10

4

0

20

A B

A B

B

A

KME Germany AG — ELBRODUR®12

ELBRODUR® B

Forms, sizes and tempers

Thic

knes

s (m

m)

Width (mm)

Dia. (mm)

5 60 100

Width a/f (mm)

5 50 100

Rod

Rod

Nominal composition

Percentages are by weight:Co 2.2Be 0.55 Ni + Fe ≤ 0.5 Cu rem.

perm. other elements 0.2 % max.

ELBRODUR® B (CuCo2Be) is a high-strength age-hardened electrode material featuring parti-cularly high hardness along with medium electrical conductivity. For spot, projection and butt welding. Suitable for high-strength, corrosion-resistant alloyed steels as well as nickel and nickel alloys. Special grades for bending and for chain welding electrodes, on request.

Mechanical and physical properties

A B

Tensile strength Rm MPa 740 – 880 690 – 860

Yield strength Rp0.2 MPa 610 – 740 570 – 690

Elongation A5 % 10 –18 12 – 20

Reduction of Area Z % 25 – 45 15 – 40

Hardness HBW 2.5/187.5 230 – 270 220 – 260

Hardness HV30 240 – 300 230 – 290

Hardness HRB 99 –106 97 –104

El. conductivity MS/m 26 – 32 26 – 32

El. conductivity % IACS 45 – 55 45 – 55

Bar

13KME Germany AG — ELBRODUR®

ELBRODUR® G strip/sheet/plate

Strip of ELBRODUR® G

Thickness (mm) Width (mm) Coll Weight Tempers

≥ 0.2 – < 2.0 20 min. 1 kg/mm width R 440, R490

Plate and sheet of ELBRODUR® G

Thickness (mm) Width (mm) Length (mm) Tempers

≥ 2.5 – < 4.0 > 60 – ≤ 100 2000 R 440, R 490

≥ 4.0 – < 10 > 100 – ≤ 1000 3000 R 440

≥ 10 – < 60 > 100 – ≤ 1500 3000 R 370, R 440

≥ 60 – < 70 > 100 – ≤ 1500 3000 R 370

≥ 70 – < 80 > 100 – ≤ 1200 3000 R 370

≥ 80 – < 100 > 100 – ≤ 1000 3000 R 370

Mechanical and physical properties

R 370 R 440 R 490

Tensile strength Rm MPa 370 – 450 ≥ 440 ≥ 490

Yield strength Rp0.2 MPa 270 – 390 ≥ 390 ≥ 450

Elongation A5 % 18 – 25 10 – 20 ≥ 10

Reduction of Area Z % 40 – 70 40 – 70 -

Hardness HBW 2.5/62.5 120 –150 ≥ 135 ≥ 150

Hardness HV30 125 –160 ≥ 140 ≥ 155

Hardness HRB 66 – 77 ≥ 71 ≥ 77

El. conductivity MS/m 47 – 52 45 – 51 44 – 50

El. conductivity % IACS 81 – 90 77 – 88 76 – 86

A

A B

A

14 KME Germany AG — ELBRODUR®

ELBRODUR® D

Nominal composition

Percentages are by weight:Ni 2.5 Si 0.65 Cr 0.3Cu rem.

perm. other elements 0.2 % max.

ELBRODUR® D (CuNi2.5SiCr) is a beryllium-free high-strength, age- hardened electrode material featuring a higher softening temperature and high electrical conductivity – partly serving as an alternative to ELBRODUR® B. Suitable for the resistance welding of bus conductors, for projection welding, and for consumable and butt welding electrodes. Also suitable for high-strength sections and plungers of die casting machines.

Shapes, sizes and tempers

Thickness = 2 – 10 mm, Width = 10 – 75 mm

Thickness to Width Ratio 1 : 20 max.

Dia. (mm)

10 45 145

Width a/f (mm)

10 37

Further sizes and special grades on request.

Mechanical and physical properties

A B

Tensile strength Rm MPa ≥ 660 ≥ 570

Yield strength Rp0.2 MPa ≥ 570 ≥ 460

Elongation A5 % ≥ 10 ≥ 10

Reduction of Area Z % ≥ 25 ≥ 25

Hardness HBW 2.5/187.5 180 – 230 180 – 220

Hardness HV30 190 – 245 190 – 230

Hardness HRB 89 – 99 89 – 97

El. conductivity MS/m 25 – 30 25 – 30

El. conductivity % IACS 43 – 52 43 – 52

Bar

Rod

Rod

KME Germany AG — ELBRODUR® 15

Special PartsELBRODUR® – special tubes/contact tubes

Use the advantages of this quality product:– narrow tolerances– high strength– high electrical conductivity– high heat conductivity– high fusing temperature (approx. 500°C/930°F)

– economical processing– regular high quality

Unequal wall thickness ≤ +/- 4 %We reserve the right to make technical changes.

– Tubes with outer hex. form may also be supplied. Here the width across flats is in comparison to the outside diameter. Manufactured length 2–5 meters.– Fixed lengths according to agreement. Minimum quantity of each dimension 500 kgs.– Tubes made of ELBRODUR® HF, which are primarily used for wire contact nozzles in robotics production, are a speciality of KME.– Due to the high quality, calibrating of drilling is unnecessary.

Standard range of measurements (selection)

ID in mm AD in mm6.35 7.0 8.0 9.0 10.0 12.0 13.0

0.80 X X0.93 X X X X X1.00 X X X X X X X1.16 X X X X X X1.20 X X X X X X1.39 X X X X X X X1.62 X X X X X X1.93 X X X X X2.05 X X X X X

Alloy characteristics and standards

ELBRODUR® Type Composition (approx, value, weight-%)

Standards

EN ISO USA NF

HF (CH25) Cr 0.65 12163 1336 RWMA A82 –100

Zr 0.08

Cu rem. CW106C CuCr1Zr Kl. 2 A2/3

ELBRODUR® Type Composition (approx, value, weight-%)

Hardness el. conductivity MS/m (% IACS)

heat conductivity W/mK

HBW 2.5/62.5 HV 30 HRB

HF (CH25) Cr 0.65

Zr 0.08 155 –190 160 –190 83 – 95 44 – 50 310 – 335

Cu rem. (76 – 86)

Tolerances (in mm)

middle AD middle ID

Round tubes +/- 0.05 mm +/- 0.03 mm

hexagonal tubes +/- 0.05 mm +/- 0.075 mm

® = registered trademark

All changes reserved.Owing to limitations in printing technology, the colours reproduced in this brochure should be regarded as approximate equivalents to the colours described.

0407.012.0506

KME Germany AGExtruded and Drawn ProductsP.O. Box 332049023 OSNABRÜCKKlosterstraße 2949074 OSNABRÜCKGERMANYT +49 541 321-2130F +49 541 321-2107www.kme-extrusion.cominfo-extrusion@kme.com

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