{"id":1165,"date":"2019-01-16T08:40:05","date_gmt":"2019-01-16T13:40:05","guid":{"rendered":"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/?p=1165"},"modified":"2022-06-06T18:08:33","modified_gmt":"2022-06-06T22:08:33","slug":"understanding-the-basics-of-metal-cored-wire","status":"publish","type":"post","link":"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/understanding-the-basics-of-metal-cored-wire\/","title":{"rendered":"Understanding the Basics of Metal-Cored Wire"},"content":{"rendered":"<div class=\"m-entry__feedback\"><div class=\"m-feedback-prompt\">\n\t\t  <h4 class=\"m-feedback-prompt__header\">Was this article helpful?<\/h4>\n\t\t  <a href=\"#\" class=\"m-feedback-prompt__button m-feedback-prompt__social m-feedback-prompt__social_thumbsup yes\" data-analytics-link=\"feedback-prompt:yes\">\n\t\t    <i class=\"fa fa-thumbs-up\">&nbsp;<\/i>\n\t\t  <\/a>\n\t\t  <a href=\"#\" class=\"m-feedback-prompt__button m-feedback-prompt_form no\" data-analytics-link=\"feedback-prompt:no\">\n\t\t    <i class=\"fa fa-thumbs-down\">&nbsp;<\/i>\n\t\t  <\/a><br>\n\t\t  <div class=\"m-feedback-prompt__display m-feedback-prompt__social yes\">\n\t\t    <p class=\"m-feedback-prompt__text\">Awesome, share it:<\/p>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon facebook fa fa-facebook\" href=\"https:\/\/www.facebook.com\/sharer\/sharer.php?u=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/understanding-the-basics-of-metal-cored-wire\/\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">Share<\/span>\n\t\t    <\/a>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon twitter fa fa-twitter\" href=\"https:\/\/twitter.com\/intent\/tweet?url=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/understanding-the-basics-of-metal-cored-wire\/&text=Understanding the Basics of Metal-Cored Wire\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">Tweet<\/span>\n\t\t    <\/a>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon googleplus fa fa-google-plus\" href=\"https:\/\/plus.google.com\/share?url=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/understanding-the-basics-of-metal-cored-wire\/\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">Google Plus<\/span>\n\t\t    <\/a>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon linkedin fa fa-linkedin\" href=\"https:\/\/www.linkedin.com\/shareArticle?mini=true&url=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/understanding-the-basics-of-metal-cored-wire\/&title=Understanding the Basics of Metal-Cored Wire\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">LinkedIn<\/span>\n\t\t    <\/a>\n\t\t  <\/div>\n\t\t  \t<div class=\"m-feedback-prompt__display m-feedback-prompt__form no\">\n\t\t  \t<div class=\"thanks feedback-nodisplayall\"><h2>Thanks!<h2><div class=\"m-contact\"><p>Thanks for getting in touch with us.<\/p><\/div><\/div>\n\t\t    <form id=\"contact-form\" class=\"new_support_request\" action=\"\" accept-charset=\"UTF-8\" method=\"post\">\n\t\t    <input type=\"hidden\" id=\"authenticity_token\" name=\"authenticity_token\" value=\"ae6595b8ba\" \/><input type=\"hidden\" name=\"_wp_http_referer\" value=\"\/sandbox\/airgasthinks\/wp-json\/wp\/v2\/posts\/1165\" \/>\n\t\t      <input value=\"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/understanding-the-basics-of-metal-cored-wire\/\" type=\"hidden\" name=\"currenturl\" id=\"currenturl\">\n\t\t      <input value=\"Understanding the Basics of Metal-Cored Wire\" type=\"hidden\" name=\"currenttitle\" id=\"currenttitle\">\n\t\t      <label class=\"is-required\">Help us improve. Give us your feedback:<\/label>\n\t\t      <textarea class=\"p-input__textarea\" name=\"feedbackmessage\" id=\"feedbackmessage\"><\/textarea>\n\t\t      <label class=\"is-required\">Your Full Name:<\/label>\n\t\t      <input class=\"p-input__text\" type=\"text\" name=\"feedbackfullname\" id=\"feedbackfullname\">\n\t\t      <label class=\"is-required\">Your email address:<\/label>\n\t\t      <input class=\"p-input__text\" type=\"text\" name=\"mailinglistemail\" id=\"mailinglistemail\">\n\t\t      <div class=\"feedback-message\" id=\"feedback-message\"><\/div>\n\t\t      <div class=\"__submit\">\n\t\t        <input type=\"submit\" name=\"commit\" value=\"Submit\" class=\"p-button\" id=\"submit-contact-form\" data-analytics-link=\"feedback-prompt:submit\">\n\t\t      <\/div>\n\t\t\t<\/form>\n\t\t\t<\/div>\n\t\t\t<\/div>\n\t\t\t<\/div>\n<p>In the right welding applications, metal-cored wire can minimize costs, improve quality and increase productivity. Like any filler metal, it has unique characteristics, benefits, limitations and applications where it works best. Knowing when and how to use metal-cored wire can help you achieve success. <br><\/p>\n\n\n\n<h4><strong>The technology and applications<\/strong><\/h4>\n\n\n\n<p>Metal-cored wire is a tubular wire filled with metallic powders, small amounts of arc stabilizers that provide specific benefits. These include wider penetration profiles, higher tolerance to dirty or hot-rolled base metal and fewer silicon islands in the final weld. Metal-cored wire offers higher deposition rates than solid wire for a given heat input.&nbsp; Metal-core wire does not produce slag like flux-cored wires do. The lack of slag makes metal-cored wire more efficient, because more wire deposits in the joint as weld metal. No slag also reduces interpass and post-weld cleaning. &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; <br><\/p>\n\n\n\n<p>Metal-cored wire is easily alloyed and available in many different chemistries, so you can weld with it on a range of base metals. You can use metal-cored wire in many of the same applications as solid wire, but it excels for welds that are six inches or longer, in flat or horizontal position using spray or pulsed gas metal arc welding (GMAW) transfer. Spray transfer maximizes the benefits of metal-cored wire in two key ways: 1) You can weld faster, and2) It generates little to no spatter, so you can reduce post-weld cleanup. Other applications well suited to metal-cored wire include: those prone to burn-through; components presenting poor fit-up; and jobs where aesthetics are important.<br><\/p>\n\n\n\n<h4><strong>Benefits of metal-cored wire <\/strong><\/h4>\n\n\n\n<p>The\ncombination of metal-cored wire\u2019s tubular structure and the use of spray\ntransfer creates a broad, cone-shaped arc and a wide penetration profile. This\narc shape generates a consistent bead profile that bridges gaps easily and\naccurately without burn-through. Other key benefits of metal-cored wire\ninclude:<\/p>\n\n\n\n<ul><li>It produces smaller droplets of liquid metal across the\narc, which reduces turbulence in the weld pool. <\/li><li>It offers fast travel speeds and high deposition rates (compared\nto solid wire), so you can increase productivity. <\/li><li>It can minimize weld defects like lack of fusion and\nundercut, allowing you to reduce rework.  <\/li><li>It can weld through mill scale and rust and still produce\nvery little spatter, which reduces the need for pre-weld grinding, sand\nblasting or applying anti-spatter compound. <strong>&nbsp;&nbsp;&nbsp; <\/strong><\/li><\/ul>\n\n\n\n<h4><strong> Cost factors to consider<\/strong><\/h4>\n\n\n\n<p>Metal-cored\nwire is more expensive per unit than solid wire. You\u2019ll need to consider\nwhether your application can offset that extra cost by making your welding\noperation more efficient. If you weld often in short circuit mode, out of\nposition or for a low percentage of time, metal-cored wire may not be the most\ncost effective. Metal-cored wire is most productive welding in position for\nlonger periods of time and provides the best long-term savings here. <\/p>\n\n\n\n<p>Consider the pros and cons of shielding gas, too. You need high levels of argon (90 percent argon\/10 percent CO<sub>2<\/sub> or 75 to 95 percent argon with the remainder CO<sub>2<\/sub>) to gain the most benefits from metal-cored wire in spray transfer mode. Argon is a more expensive gas, so decide if your productivity and quality gains will reduce costs. Work with a trusted welding distributor or filler metal manufacturer to conduct a time trial to determine your potential savings. &nbsp;<\/p>\n\n\n\n<p>Keep in mind, too, that welding is only one step in the production\nprocess. If you increase productivity with metal-cored wire, can your post-weld\noperations like painting keep up? That is important to realizing overall cost\nsavings. <\/p>\n\n\n\n<h4><strong>Tips and techniques<\/strong><\/h4>\n\n\n\n<p>Welding with metal-cored wire is similar to welding with solid wire, with a few exceptions. <\/p>\n\n\n\n<ul><li><strong>Use V-knurled drive rolls.<\/strong> You can easily crush metal-cored wire when there is too much tension. V-knurled drive rolls have small teeth to grip and guide the wire; you need less tension to feed the wire down the liner. <br><\/li><li><strong>Longer stickouts won\u2019t cause erratic transfer.<\/strong> The contact tip to work distance\u2014the gap between your welding gun and base material\u2014can be slightly longer when you use metal-cored wire. A gap between 1\/2 inch and 1 inch (depending on wire diameter and operating point) works best. Typically, longer tip-to-work distances are recommended as wire feed speed and wire diameter increase. <br><\/li><li><strong>Using a larger wire diameter is OK.<\/strong> When switching to metal-cored wire from solid wire, you can usually use one wire diameter larger. Since metal-cored wire has a broader arc cone, it concentrates heat less and there is less chance of burn-through. The wire also is better at bridging gaps and providing consistent sidewall fusion. &nbsp;<br><\/li><li><strong>There\u2019s less need to manipulate the welding gun and puddle.<\/strong> The wider metal transfer\/arc cone with metal-cored wire allows you to make larger weld beads without weaving. &nbsp;<\/li><\/ul>\n\n\n\n<h4><strong>Equipment and safety<\/strong><\/h4>\n\n\n\n<p><strong> <\/strong>The higher argon levels required for metal-cored wire impact the duty cycle of your gun. Gun manufacturers rate guns for a specific type of gas. Typically, a 100 percent duty cycle rating at a specific amperage refers to using the gun with 100 percent CO<sub>2<\/sub>. Because CO<sub>2<\/sub> does a better job of cooling the gun than argon does, you may experience a 30 to 50 percent reduction in cooling with high argon gas. Select a gun with enough amperage for the job. <\/p>\n\n\n\n<p>The combination of high argon levels and spray transfer results in lower visible smoke generation\u2014that leads to noticeably more radiant light from the arc since there is less smoke to filter it. The ability to weld metal-cored at higher amperages also increases radiant light. Take extra care to cover exposed skin, increase your welding lens shade and, when necessary, place screens around your welding cell. &nbsp;<\/p>\n\n\n\n<h4><strong>Making the right choice <\/strong><\/h4>\n\n\n\n<p>Remember, selecting the right filler metal for the job is an important part of the success of your welding operation. Knowing when it\u2019s advantageous to use metal-cored wire can help increase productivity and save money\u2014you can weld more efficiently, deposit more weld metal, reduce quality issues and spend less time cleaning welds in the right applications. <\/p>\n","protected":false},"excerpt":{"rendered":"<p>Was this article helpful? &nbsp; &nbsp; Awesome, share it: Share Tweet Google Plus LinkedIn Thanks! 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