Hi,
I'm new to this community and saw your comments about welding silicon bronze. Do you use Everdur alloy C65500 with filler metal ERCuSi-A ? I have MIG welded steel rod sculptures for years and am interested in using the same process with bronze with the option of welding on cast pieces as well.

After doing some research online I have found a lot of different alloys and wonder which would be the best to use. The expense is another consideration, as is the level of toxicity. So I welcome any advice!

Thanks,
Alexandra Limpert, Sculptor

Alexandra,

I have been doing bronze foundry work and finishing for 20 years.
As to your question about welding silicon bronze,,,, Everdure is all that I cast/use and I use Everdure bronze filler rod. I use TIG but would consider MIG for some work, but all in all, I feel TIG has the benefit of being able to weld, without adding filler material which at times is invaluable for my operation/setup.

As to the different alloys, Everdure and Herculoy are the 2 most common bronze alloys in the art casting industry. Problem with the Herculoy (I my opinion) is that it contains zinc and 1: it fumes, spits and sputters upon welding, and 2: when heated to welding temperature the zinc burns off and thus the alloy components in the weldment changes and most all the time the weldment material takes the patina differently than the rest of the material, NOT good in an art casting. The alloy components of Everdure are copper and silicon,,,,,,,, nothing to burn out and thus the filler material is NOT different than the body materials, thus both take patination equally. Herculoy is supposed to pout more easily than Everdure (because of the zinc) but as I have never poured Herculoy I do not know this for a fact, but I am sure there it is correct. However, a bit better pouring from the zinc does not seem to out way far easier working/welding metal matching,,, again, just MY opinion. Also, Everdure does NOT have zinc fuming off while welding, but as with ALL copper alloys, you still have the toxicity of the copper to deal with as you see fit.

As welding bronze materials into your pieces,,,,,,, give it a try, with both. There are also other bronzes (mang., alum, phosphor, etc.) and there are even more types of brass. "Old" sculpture was often cast in a copper tin alloy (ancient bronze) does take patina very well but I have never had to weld this alloy (but was sure fun on the patina table!!!).

Hope this is help.

John Dach
MLCE.net

John,

It was great to read your post, and way more valuable to me to hear about your experience than to read pure technical advice in a manual. This is also the first I've heard of Herculoy Bronze. You answered a lot of questions.

Many thanks,

Alexandra Limpert, Sculptor