The Harris 0ALB2F8 is an aluminum bronze MIG GMAW welding wire classified ERCuAl-A2 per AWS A5.7/A5.7M. Packaged as 0.035 in (0.9 mm) diameter on a 30 lb spool, it is engineered for welding aluminum bronze base metals, dissimilar metals, braze welding steel, and hardfacing applications requiring a corrosion-resistant, wear-resistant bronze deposit. Harris Products Group, a Lincoln Electric company, manufactures this ERCuAl-A2 filler to provide the hardness, tensile strength, and bronze wearing surface needed for demanding industrial applications. WeldingMart is an authorized Harris distributor.
Aluminum bronze alloys — containing 6–8.5% aluminum — provide exceptional resistance to corrosion, cavitation, and wear. ERCuAl-A2 deposits are significantly harder and stronger than silicon bronze, making this wire the better choice when wear resistance, cavitation resistance, or protection of parts exposed to abrasion and saltwater erosion is required.
| Specification | Value |
|---|---|
| AWS Classification | ERCuAl-A2 (AWS A5.7/A5.7M) |
| Harris Part Number | 0ALB2F8 |
| Diameter | 0.035 in (0.9 mm) |
| Package | 30 lb (13.6 kg) spool |
| Al content | 6.0–8.5% |
| Fe content | 0.5–3.0% |
| Cu content | Balance |
| Tensile Strength | ≥ 60,000 psi (414 MPa) |
| Yield Strength | ≥ 25,000 psi (172 MPa) |
| Elongation | ≥ 15% |
| Hardness (typical) | 130–160 HB |
| Polarity | DCEP |
| Shielding Gas | 100% Ar or 75% Ar / 25% He |
AWS A5.7/A5.7M governs copper and copper-alloy bare rods and electrodes for gas-shielded welding. Full data sheets at harriswelding.com and aws.org/standards.
- Marine propellers and pump casings: ERCuAl-A2 resists seawater corrosion, biofouling, and cavitation erosion — the same alloy system used in naval propulsion components.
- Dissimilar metal applications: Welding brass to steel, bronze to steel, and aluminum bronze base metals to cast iron or stainless steel where matching filler chemistry maintains joint corrosion resistance.
- Hardfacing and surface overlay: Building a bronze wearing surface on steel tooling, dies, and wear plates where a lower coefficient of friction and corrosion resistance are needed.
- Braze welding steel and cast iron: Joining steel and cast iron assemblies with a stronger, harder deposit than silicon bronze for applications requiring better load-bearing capacity.
- Hydraulic component repair: Rebuilding worn aluminum bronze hydraulic pump bushings, valve seats, and cylinder liners.
- Oil and gas piping: Welding aluminum bronze fittings and flanges in sour-gas and saltwater service where H₂S corrosion resistance matters.
| Parameter | 0.035 in ERCuAl-A2 Typical Range |
|---|---|
| Shielding Gas | 100% Ar or 75 Ar / 25 He |
| Flow Rate | 30–40 CFH |
| Polarity | DCEP |
| Wire Feed Speed | 200–320 IPM |
| Voltage | 20–26 V |
| Current (typical) | 120–200 A |
| Transfer Mode | Short-circuit or spray (depending on thickness) |
| Preheat (steel base ≥ 1/4 in) | 200–400 °F recommended |
Aluminum bronze wets well on clean steel and iron surfaces. For dissimilar metal applications, clean base metals thoroughly. When welding brass or aluminum bronze base metals, use 100% argon shielding and avoid excessive heat input that causes aluminum burn-off. The wire is more susceptible to wire-feeding problems than steel wire — use U-groove or smooth-groove drive rolls.
Store in original sealed packaging at 40–120 °F in a dry location. Use Teflon or nylon conduit liners in MIG guns to prevent ferritic contamination that causes weld deposit defects. Clean drive rolls with a dry cloth regularly to remove bronze shavings. Oxidized wire should be discarded — surface aluminum oxide increases porosity risk in the weld pool.
Harris 0ALB2F8 ERCuAl-A2 works on any constant-voltage MIG machine rated for 0.035 in wire. Use pure argon or Ar-He blends — avoid CO₂ blends which oxidize the aluminum in the deposit. See also Harris Silicon Bronze MIG Wire 0.035 in, Harris ERCu MIG Wire 0.045 in, and all welding wire.
- What is ERCuAl-A2 aluminum bronze MIG wire used for?
- ERCuAl-A2 is the AWS A5.7 classification for aluminum bronze filler metal. It is used for welding aluminum bronze base metals, braze welding steel and cast iron, hardfacing, and protecting parts exposed to cavitation, wear, and saltwater corrosion. Key difference from silicon bronze: ERCuAl-A2 is significantly harder (130–160 HB vs ~80 HB for silicon bronze) and stronger (60,000 psi vs 50,000 psi tensile).
- Can I use aluminum bronze MIG wire for dissimilar metal welding?
- Yes. ERCuAl-A2 is specifically rated for dissimilar metal applications joining aluminum bronze, brass, and copper to steel or cast iron. The wire's chemistry provides good wettability on ferrous base metals while depositing a corrosion-resistant bronze overlay. For copper-to-steel joints in marine environments, ERCuAl-A2 offers better wear resistance than ERCuSi-A silicon bronze.
- What shielding gas should I use with aluminum bronze MIG wire?
- 100% Argon is strongly preferred. Helium additions (75 Ar / 25 He) improve penetration on thick sections. Avoid CO₂ blends — CO₂ oxidizes the aluminum in the alloy, producing aluminum oxide slag inclusions and degrading deposit chemistry and corrosion resistance.
- How does aluminum bronze MIG wire compare to silicon bronze for cast iron?
- Both can braze weld cast iron. Silicon bronze (ERCuSi-A) is softer and flows more easily, making it better for cosmetic repairs and thin sections. Aluminum bronze (ERCuAl-A2) is harder, stronger, and more wear-resistant — better for load-bearing cast iron repairs, pump components, and structural joints requiring the bronze wearing surface to withstand service loads.
- What is the hardness of aluminum bronze weld deposits?
- ERCuAl-A2 deposits typically achieve 130–160 Brinell hardness (HB), equivalent to approximately 70–80 HRB. This is 2–3× harder than silicon bronze deposits (60–80 HB) and provides meaningful wear resistance for bushing, bearing, and hardfacing applications.
- Is preheat required for aluminum bronze MIG welding?
- Preheat is recommended when welding aluminum bronze onto heavier steel sections (over 1/4 in) to prevent stress cracking from rapid quenching. Preheat to 200–400 °F. For thin-gauge steel and light fabrication, preheat may not be necessary.
- Can I weld aluminum bronze wire to stainless steel?
- Yes, ERCuAl-A2 can be deposited onto stainless steel in certain dissimilar metal applications. The bond is primarily mechanical (braze-type) rather than a true fusion weld. For high-stress structural joints, verify joint qualification per applicable code before production welding.
When selecting aluminum bronze MIG wire for dissimilar metal applications, the key decision is comparing ERCuAl-A2 against silicon bronze (ERCuSi-A) and phosphor bronze alloys. ERCuAl-A2 provides significantly better wear resistance and tensile strength (60,000 psi vs 50,000 psi for silicon bronze), making it the right choice for protect parts exposed to abrasion, cavitation, and saltwater. Bronze wearing surface applications — pump impellers, bushing overlays, and wear plates — specifically require the hardness (130–160 HB) that ERCuAl-A2 delivers. For joining brass and welding brass components, ERCuAl-A2 provides better joint strength than silicon bronze in applications involving yellow brass (60/40 and 85/15 alloys). The aluminum bronze base metals in marine and chemical service are commonly joined using ERCuAl-A2 to maintain the corrosion resistance and mechanical properties of the parent metal through the weld zone.
Harris 0ALB2F8 aluminum bronze A2 MIG wire (AWS ERCuAl-A2) at 0.035 in diameter, 30 lb spool is the standard specification for GMAW of aluminum bronze components in marine propeller systems, pump housings, valve bodies, and chemical plant equipment. The ERCuAl-A2 classification (AWS A5.7) designates a copper-aluminum alloy with 8–9% Al, producing deposits with 70,000 psi minimum tensile strength — significantly higher than silicon bronze (50,000 psi) and approaching the strength range of high-strength steel filler metals.
The 30 lb spool format suits continuous production GMAW operations: propeller blade surfacing, pump housing overlay, and valve seat rebuilding applications where wire consumption is high and spool changes are production bottlenecks. The A2 grade (ERCuAl-A2) is the most commonly specified aluminum bronze GMAW wire, balancing strength, corrosion resistance, and weldability.
| Parameter | 0.035 in ERCuAl-A2 Typical Range |
|---|---|
| Shielding Gas | 100% Argon (required; no CO₂) |
| Flow Rate | 30–40 CFH |
| Polarity | DCEP |
| Wire Feed Speed | 180–300 IPM |
| Voltage | 19–25 V |
| Current | 100–200 A |
| Transfer Mode | Short-circuit or spray |
| Preheat | Not required for most applications; 200 °F for thick sections > 1/2 in |
| Interpass Temp | ≤ 300 °F |
Use 100% argon only. CO₂ additions react with aluminum in the alloy, producing excessive porosity and aluminum oxide inclusions in the deposit. Aluminum bronze is sensitive to oxidation — even 2% CO₂ degrades weld quality noticeably. Argon provides both arc stability and adequate protection for the aluminum-bearing weld pool.
ERCuAl-A2 aluminum bronze deposits combine properties that no single other filler metal offers:
- Seawater corrosion resistance: Aluminum bronze resists seawater corrosion, cavitation erosion, and crevice corrosion substantially better than silicon bronze or plain copper. The dense, adherent aluminum oxide film formed at the deposit surface provides the protective barrier.
- High strength: 70,000 psi minimum UTS (ERCuAl-A2) vs. 50,000 psi for silicon bronze. Suitable for structural components under load in marine environments.
- Cavitation resistance: Aluminum bronze is a standard material for ship propellers, pump impellers, and hydraulic turbine blades precisely because of its resistance to cavitation erosion — the micro-impact mechanism that erodes softer metals in high-velocity fluid applications.
- Low magnetic permeability: ERCuAl-A2 deposits are essentially non-magnetic — important for minesweepers, scientific vessel fittings, and medical equipment.
- Compatibility with seawater piping systems: Aluminum bronze overlays on carbon steel flanges, valve seats, and pump casings provides cathodic protection and corrosion resistance without the cost of solid aluminum bronze castings.
Surfacing carbon steel with ERCuAl-A2 for corrosion and cavitation protection is a common MIG application in shipyard and pump repair operations:
- Base metal preparation: Grind or blast to white metal (Sa 2.5 or SSPC-SP5). Surface contamination causes porosity and debonding in copper alloy overlays.
- First pass (buttering layer): Run a thin buttering layer at low current (100–130 A) to minimize dilution from the carbon steel base. High dilution (iron pickup) produces iron-aluminum intermetallic compounds that reduce ductility and corrosion resistance.
- Subsequent passes: Build to required overlay thickness (typically 1/4–1/2 in for wear resistance). Maintain 100% argon shielding and short interpass time to prevent atmospheric oxidation between passes.
- Post-weld finish: Grind to final dimension. Aluminum bronze machines and grinds easily. Color should be golden-bronze throughout — gray or porous areas indicate dilution or shielding failures.
Harris 0ALB2F8 aluminum bronze A2 MIG wire is available at WeldingMart as an authorized Harris Products distributor. See also Harris Silicon Bronze 0.035 in MIG Wire for lighter braze welding applications, and all copper alloy welding wire products.
Harris 0ALB2F8 aluminum bronze A2 MIG wire (AWS ERCuAl-A2) at 0.035 in diameter, 30 lb spool is the standard specification for GMAW of aluminum bronze components in marine propeller systems, pump housings, valve bodies, and chemical plant equipment. The ERCuAl-A2 classification (AWS A5.7) designates a copper-aluminum alloy with 8–9% Al, producing deposits with 70,000 psi minimum tensile strength — significantly higher than silicon bronze (50,000 psi) and approaching the strength range of high-strength steel filler metals.
The 30 lb spool format suits continuous production GMAW operations: propeller blade surfacing, pump housing overlay, and valve seat rebuilding applications where wire consumption is high and spool changes are production bottlenecks. The A2 grade (ERCuAl-A2) is the most commonly specified aluminum bronze GMAW wire, balancing strength, corrosion resistance, and weldability.
| Parameter | 0.035 in ERCuAl-A2 Typical Range |
|---|---|
| Shielding Gas | 100% Argon (required; no CO₂) |
| Flow Rate | 30–40 CFH |
| Polarity | DCEP |
| Wire Feed Speed | 180–300 IPM |
| Voltage | 19–25 V |
| Current | 100–200 A |
| Transfer Mode | Short-circuit or spray |
| Preheat | Not required for most applications; 200 °F for thick sections > 1/2 in |
| Interpass Temp | ≤ 300 °F |
Use 100% argon only. CO₂ additions react with aluminum in the alloy, producing excessive porosity and aluminum oxide inclusions in the deposit. Aluminum bronze is sensitive to oxidation — even 2% CO₂ degrades weld quality noticeably. Argon provides both arc stability and adequate protection for the aluminum-bearing weld pool.
ERCuAl-A2 aluminum bronze deposits combine properties that no single other filler metal offers:
- Seawater corrosion resistance: Aluminum bronze resists seawater corrosion, cavitation erosion, and crevice corrosion substantially better than silicon bronze or plain copper. The dense, adherent aluminum oxide film formed at the deposit surface provides the protective barrier.
- High strength: 70,000 psi minimum UTS (ERCuAl-A2) vs. 50,000 psi for silicon bronze. Suitable for structural components under load in marine environments.
- Cavitation resistance: Aluminum bronze is a standard material for ship propellers, pump impellers, and hydraulic turbine blades precisely because of its resistance to cavitation erosion — the micro-impact mechanism that erodes softer metals in high-velocity fluid applications.
- Low magnetic permeability: ERCuAl-A2 deposits are essentially non-magnetic — important for minesweepers, scientific vessel fittings, and medical equipment.
- Compatibility with seawater piping systems: Aluminum bronze overlays on carbon steel flanges, valve seats, and pump casings provides cathodic protection and corrosion resistance without the cost of solid aluminum bronze castings.
Surfacing carbon steel with ERCuAl-A2 for corrosion and cavitation protection is a common MIG application in shipyard and pump repair operations:
- Base metal preparation: Grind or blast to white metal (Sa 2.5 or SSPC-SP5). Surface contamination causes porosity and debonding in copper alloy overlays.
- First pass (buttering layer): Run a thin buttering layer at low current (100–130 A) to minimize dilution from the carbon steel base. High dilution (iron pickup) produces iron-aluminum intermetallic compounds that reduce ductility and corrosion resistance.
- Subsequent passes: Build to required overlay thickness (typically 1/4–1/2 in for wear resistance). Maintain 100% argon shielding and short interpass time to prevent atmospheric oxidation between passes.
- Post-weld finish: Grind to final dimension. Aluminum bronze machines and grinds easily. Color should be golden-bronze throughout — gray or porous areas indicate dilution or shielding failures.
Harris 0ALB2F8 aluminum bronze A2 MIG wire is available at WeldingMart as an authorized Harris Products distributor. See also Harris Silicon Bronze 0.035 in MIG Wire for lighter braze welding applications, and all copper alloy welding wire products.
Harris aluminum bronze MIG welding wire (ERCuAl-A2) is a versatile filler metal for joining dissimilar metals, welding brass to bronze, overlaying surfaces needing exceptional corrosion resistance, and protecting parts exposed to salt water and certain acidic conditions. Marine hardware exposed to seawater and atmospheric salt spray benefits from aluminum bronze overlay because the aluminum oxide film that forms on the deposit surface is resistant to salt water corrosion — significantly outperforming silicon bronze and plain copper in marine environments.
For joining dissimilar metals — steel-to-bronze, copper-to-steel, or dissimilar steels with copper overlay — aluminum bronze A2 provides a tough alloy deposit that bridges the electrochemical potential between base metals. The copper-aluminum chemistry resists corrosion in certain acidic conditions including dilute sulfuric, phosphoric, and organic acids encountered in food processing, chemical handling, and marine hardware exposed to bilgewater environments. When welding brass (copper-zinc) to steel or bronze, aluminum bronze A2 wets both base metal surfaces and provides compatible joining for marine hardware and valve body applications.
Parts exposed to cavitation erosion in pump impellers, propeller blades, and hydraulic turbine components benefit from aluminum bronze A2 surfacing because the tough alloy work-hardens under impact from collapsing cavitation bubbles — this work-hardening response to cavitation impact extends service life compared to softer copper alloys. Other surfaces needing exceptional corrosion resistance include heat exchanger tube sheets, seawater condenser plates, and marine shaft seals. The 30 lb spool format of 0ALB2F8 supports production surfacing operations on these components without frequent spool changes, keeping total cost per pound of deposit competitive for extended cladding runs.