Introduction
Wire Selection Simplified
One very important process in various industries today would be welding, one thing that even people who have never been inside a working shop knows is that you must need to have wire in order to weld.
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This is very true; however, learning which type of wire to use is one of the hardest things to learn. With cored wires, solid wires, and metal cored wires all available it can be tough to figure out the best for the specific application. In this article, the necessary process and equipment information shall help you simplify your choice.
What type of wire type do you need to get your welding job done?
What type of metal do you plan on welding?
Which process will you choose?
By identifying what you’re welding, next is choosing the right wire.
Solid Wire Electrode
Solid wire electrodes are considered to be the oldest type of welding wire and still remains the most popular type, making up over 90% of the welding wire used today. Oilers (oil) used to prevent wire corroding. However, flux can act as a cleaning agent, but leaves behind a residue. Where this is not as big a concern, like in auto repair, high heat applications and heavy metals. When programmed correctly, MIG can burn away excess flux while still using flux wire.
Advantages
-cleans off rust or grease easily
-simple to use
-relatively inexpensive
-low hydrogen levels when no oils are added to the shops.-thirds cleaner than older chemistries.
-high welding speeds
-can be painted over easily
Flux-Cored Electrodes
Flux-cored arc welding (FCAW) can be identified as two types: gas-shielded and self-shielded. These names are somewhat confusing, as you’d think that gas-shielded means no flux and self-shielded means with flux. There are slight differences like gas shielded can use either gas or flux, but typically most Flux Cored runs on flux. Many Systems run on both gas and flux. Furthermore, most of the wire used for both types ofFCAW is normally stainless steel. Like all stainless steels, your main concern will be corrosion so make sure to select the proper shielding gas for your system. Over 60% of the stainless steel-wire used today is classified as modified 308 alloy. Concentrated CO2 and Ar/C02 oxygen <1%
Advantages
-Can weld very thick materials
-Very high deposition rates
-All position capabilities
-Higher allowable travel speed
-Known similar to arc welding
-Found with the Power Wave® C series power supplies
Metal Cored Electrodes
Metal-cored wire is similar to flux-cored wire in that both have tubular constructions and offer a higher deposition rate than solid wire. However, unlike flux-cored wire, metal-cored wire does not contain any slag producing elements. The lack of slag makes metal-cored wire more efficient, because more wire deposits in the joint as weld metal. No slag also means that arc characteristics suffer if the parameter settings are not properly handled (see troubleshooting below). Approximately 75 to 80% of the metal-cored wire used today is composed of a mild-steel sheath with a powdered-metal-flux-and-alloying-agent core. TItanium, Iron
Advantages
-Can weld with .052 – 1/16 diameters
-Can weld thicker material
-High deposition rates
