Copper-Coated vs. Non-Copper-Coated ER70S-6 Welding Wire: Which Should You Choose?
SunJames
When it comes to Gas Metal Arc Welding (GMAW), ER70S-6 remains one of the most widely used solid wires for carbon steel due to its excellent deoxidizer formulation and smooth arc characteristics. However, one key decision users face is whether to choose copper-coated or non-copper-coated variants of ER70S-6. While both fall under the same AWS classification, their performance, maintenance, and cost implications can vary significantly.
In this article, we’ll break down the technical differences, benefits, and trade-offs of each type, helping you make an informed choice based on your welding environment and application requirements.
🧪 What is ER70S-6?
ER70S-6 is a solid wire electrode classified under AWS A5.18. It offers:
- High deoxidizer content (Si and Mn) for welding on slightly contaminated or rusty steels
- Excellent feedability and arc stability
- Smooth weld bead appearance
- Compatibility with CO₂ or Ar/CO₂ shielding gases
Typical applications include:
- General fabrication
- Automotive frames
- Construction and shipbuilding
- Pipe welding and pressure vessels
🔩 Copper-Coated ER70S-6: Benefits and Considerations
Features:
Surface is electroplated with a thin layer of copper
Advantages:
- Enhanced Electrical Conductivity – Lower contact tip wear, more stable arc
- Improved Corrosion Resistance – Reduces wire oxidation during storage
- Better Feedability – Lower friction in liners and contact tips
- Reduced Spatter – Cleaner weld zone under proper conditions
Potential Drawbacks:
- Copper flaking – Can contaminate feed systems and contact tips
- Environmental concerns – Plating involves chemical processes
- Fumes during welding – Minor copper vapor may be emitted
⚙️ Non-Copper-Coated ER70S-6: Modern Innovation
Features:
Surface treated via mechanical or nano-coating techniques, not copper-based
Advantages:
- Cleaner Welding Environment – No copper fumes, better for robotic cells or high-volume shops
- Stable Feeding – New surface technologies reduce friction comparable to copper
- Consistent Arc Performance – Less contamination, especially in automated processes
- Eco-Friendly – No heavy metals, more sustainable production
Challenges:
- Initial perception – Users may assume poorer feedability, though modern wires outperform expectations
- Slightly higher cost – Depending on technology used in coating
🧰 Which One Should You Use?
| Factor | Copper-Coated | Non-Copper-Coated |
|---|---|---|
| Electrical Conductivity | ✅ High | ⚪ Medium–High |
| Feedability | ✅ Excellent | ✅ Excellent (modern wires) |
| Oxidation Resistance | ✅ Yes | ✅ Yes (via proprietary coatings) |
| Robotic Welding | ⚪ Risk of flaking | ✅ Ideal |
| Manual Welding | ✅ Widely accepted | ✅ Also suitable |
| Environmental Impact | ⚠️ Higher | ✅ Lower |
| Cost | ⚪ Usually lower | ⚪ Slightly higher |
Recommendation:
For manual or light fabrication, copper-coated ER70S-6 is cost-effective and proven.
For robotic or automated welding, or where cleanliness and sustainability matter, non-copper-coated wire offers superior operational advantages.
🔍 Conclusion
Both copper-coated and non-copper-coated ER70S-6 wires have their place in the welding world. The right choice depends on your shop conditions, automation level, and long-term maintenance goals.
At Bridge Brand, we offer high-performance ER70S-6 wires in both formats, meeting AWS and ISO standards. Whether you prioritize traditional consistency or modern innovation, we have the solution for you.
💬 Need help deciding? Contact our technical team for expert advice: globaltrade@tjbridge.com
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