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Job Knowledge 85
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This article looks at the wire consumables used in the gas shielded MIG/MAG, metal cored
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4/30/2020 Welding Consumables - Part 4 - TWI
and they now form a signi cant proportion of the welding wire market - cored wires are
now used not only in the MIG/MAG process but also in TIG, plasma-TIG and submerged arc
welding.
Solid wire for welding of alloy steels is an expensive commodity. The composition of a
ferritic steel welding wire is not the same as that of the steel that it will be used to weld. The
ingot from which the wire is drawn must contain all the de-oxidation and alloying elements
requires only relatively small amounts and these requirements have a signi cant e ect on
the cost. In addition, it can be di cult to draw down the wire to the small diameters
Cored wires for welding carbon and alloy steels, however, can be made from mild steel with
the alloying elements added to the ux lling. This enables small amounts of wire to be
economically produced matching the composition of steels where the usage is limited, eg
high chromium creep resistant steels or hard facing. Non-ferrous and austenitic steel wires,
aluminium, nickel based, stainless steel etc however, generally match closely the parent
metal composition and obtaining ingots for drawing into wire is less of a problem.
MIG/MAG welding solid wires are provided in diameters ranging from 0.6 to 2.4mm, the
As mentioned above, the solid wires are generally formulated to match the composition of
the alloy to be welded. Silicon, 0.5 to 0.9%, and perhaps aluminium, up to 0.15%, are added
to ferritic steel wires to provide de-oxidation; carbon content is generally below 0.1%.
Alloying elements such as manganese, chromium, nickel and molybdenum are added to the
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ingot to provide improved mechanical properties and corrosion resistance. In addition the
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carbon and low alloy steel wires are often copper coated, both to reduce corrosion during
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storage and to improve welding current pick-up in the contact tip.
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The stainless steel and non-ferrous wires are not copper coated. Poor control during the
drawing operation may form laps on the wire surface that trap contaminants and give rise
Porosity from drawing defects can be a particular problem with aluminium alloy wires and
where high quality weld metal is required, then shaving the wire to remove defects on the
The cored wires are small diameter tubes in which are packed uxes and alloying elements.
There are two fundamental types, one containing mostly uxes, the other containing metal
powders. There is a sub-class of the ux cored wires, the self-shielded wires, that contain
gas-generating compounds that decompose in the arc to provide enough shielding gas so
In cross-section, the wires may be seamless tubes packed with the ux and extruded before
being drawn into a wire. Alternatively, they may be or made by rolling a at strip into a 'U',
lling this with the ux or metal power and then folding this into a tube. The edges of the
The seamless and closed butt wires tend to have thicker walls and therefore less ll than
the overlapped wires, perhaps as little as 20% of cross sectional area compared with 50%
for the overlapped wires. This enables the overlapped wires to contain more alloying
elements and they are therefore often used for stainless steel and hard facing welding.
Cored wires have a number of advantages over the solid wires. The reduced current
carrying cross-sectional area of the wire results in greater current density and an increase in
The ux also produces a slag that will control weld bead shape enabling higher welding
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currents to be used in positional welding than can be used with MAG. A 7mm throat llet is
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possible in the horizontal-vertical position, for example. The slag will also react with the
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weldpool and provide better properties than can be achieved with MAG. Good Charpy
impact properties down to -50°C are achievable in carbon steels with the correct wire.
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The wire is mechanically weak and over-pressure on the wire drive rolls may crush the
wire preventing it from feeding through the contact tip.
While solid wires often produce islands of a glassy slag that tend to lie in the nish craters
this does not necessarily prevent a multi-pass weld being made without de-slagging.
This is not possible with ux cored wires, restricting their use in applications such as robotic
welding to single pass welds. Metal cored wires are less of a problem in this context and are
As with MMA electrodes, the ux in the core may be either rutile or basic, the rutile ux
providing a smooth arc, easy slag removal and 'welder appeal', the basic uxes providing
Hydrogen control is less of a problem than with MMA electrodes. Both rutile, basic and
metal cored wires all have very low hydrogen potential levels, allowing lower preheat than
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There are a number of speci cations detailing the requirements for solid and cored wires
for MIG/MAG, FCA and MCA welding and these will be covered in the next article.
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