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<p>Bus bars, made of tough-pitch copper, are exposed to severe corrosion and cyclic stresses, which often lead to joint degradation and failure. There are two general ways to solve this problem. Replace the entire bus bar, which restores functionality but requires a long downtime and high cost. Localized welding repair involves removing the damaged section and replacing it with a newly fabricated piece. This study investigates the causes of copper bus bar welding failures occurring in the electrorefining cells of the Sarcheshmeh Copper Complex. It proposes an optimized welding repair procedure. To improve welding quality and durability, a series of controlled TIG welding experiments were conducted by varying the preheating temperature, welding current, and travel speed. The experiments were designed using the central composite design (CCD) approach combined with response surface methodology (RSM) to develop predictive models for tensile strength and electrical conductivity. The optimized parameters, consisting of a preheating temperature of 550&#xa0;°C, a welding current of 280&#xa0;A, and a travel speed of 110&#xa0;mm/min, produced a weld with 94% electrical conductivity and 204&#xa0;MPa tensile strength. The results indicate that welding current has the most significant effect on electrical conductivity, while preheating temperature strongly influences tensile strength. The developed models and optimized parameters provide a reliable basis for improving the performance and service life of copper welds in industrial electrorefining systems.</p>

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Copper Bus Bar Welding Process Optimization Using Central Composite Design Method of Experiments

  • 期刊论文

  • 发表日期：

    2025年12月10日

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  • Mahdi Jafari Mohammadabadi,
  • Gholam Reza Khayati,
  • Saman Nemat,
  • Hadi Memarzadeh,
  • Morteza Akbarzadeh

摘要

Bus bars, made of tough-pitch copper, are exposed to severe corrosion and cyclic stresses, which often lead to joint degradation and failure. There are two general ways to solve this problem. Replace the entire bus bar, which restores functionality but requires a long downtime and high cost. Localized welding repair involves removing the damaged section and replacing it with a newly fabricated piece. This study investigates the causes of copper bus bar welding failures occurring in the electrorefining cells of the Sarcheshmeh Copper Complex. It proposes an optimized welding repair procedure. To improve welding quality and durability, a series of controlled TIG welding experiments were conducted by varying the preheating temperature, welding current, and travel speed. The experiments were designed using the central composite design (CCD) approach combined with response surface methodology (RSM) to develop predictive models for tensile strength and electrical conductivity. The optimized parameters, consisting of a preheating temperature of 550 °C, a welding current of 280 A, and a travel speed of 110 mm/min, produced a weld with 94% electrical conductivity and 204 MPa tensile strength. The results indicate that welding current has the most significant effect on electrical conductivity, while preheating temperature strongly influences tensile strength. The developed models and optimized parameters provide a reliable basis for improving the performance and service life of copper welds in industrial electrorefining systems.