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Manufactory building welding flux-cored wire

Manufactory building welding flux-cored wire

Flux-cored wires are available in self-shielded and gas-shielded varieties for welding base materials, including mild steel, low-alloy steel, stainless steel, and nickel alloys. This graphic details their operation. No single filler metal is suitable for every job. The mechanical and chemical properties of the base material, the required welding position, the available equipment, and the welding operator's skill set, among other considerations, all factor in making the best selection. When you are seeking to increase productivity through higher deposition rates, flux-cored wires often are a viable option.

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US5821500A - Process for manufacturing welding wire - Google Patents

VIDEO ON THE TOPIC: Manufacture of seamless cored wire: voestalpine Böhler Welding

Kind code of ref document : A1. Effective date : In manufacturing of welding wires, rough surfaces are formed on the product wires to ensure retention of applied lubricants for satisfactory feeding performance. For this purpose, steps of dry hole die drawing with application of powder lubricants, roller dies drawing, and wet hole die drawing are executed, at least in a part of a sequence of wire drawing processes.

As a result of denting of the powder lubricants on the surfaces of the wires during the dry hole die drawing, rough surfaces are formed on the drawn wires. Conventionally in welding like CO 2 gas shielded arc welding and MIG welding, solid wires and cored wires of small diameters such as 0.

Solid wires are homogeneous through the diameter and cored wires are filled with fluxes and others in the core of steel tube shell, then also called flux cored wires. These welding wires are provided in spools or, for requirement of continuous supply of long wires, in pail packs. In usual welding operation, a wire feeding machine set near to the spool and or the pail pack produces a driving force on wires, and then feeds out wires through a conduit tube as far as to the electrode tip in a welding torch at the position of welding.

The wire feeding machine is composed of a wire-feeding roller driven by a motor and a free-rotating pinch roller to grip and press the wire between the wire-feeding roller. At the central part of the conduit tube which contacts the wire, a liner made by spiral steel wires is provided for flexible guide for the wire.

Though the conduit tube is usually in a length of 3 to 6 m, for welding of wide areas a tube as long as 20 m is required; the length of conduit tube is selected in accordance with distance to the welding position.

By proper choice of the long conduit tube, welding operation can be easily conducted by moving only a light-weight welding torch even in a narrow space and a high or low place such as in the field welding for ship building. On the other hand, the long conduit tube has a problem to increase a resistance in feeding of welding wires. Wires are pushed into the liner inside of the conduit tube by a driving force of the feeding machine, and are subjected to the resistance in feeding due to friction in contact with the inside wall of liner.

Although for a straight conduit tube high feeding forces are not required, for a conduit tube with a small radius of curvature or with a number of deflection positions, the resistance to feeding is large especially when the tube is long. In order to perform stable welding operation without occurrence of defects, it is necessary to feed the welding wire at a predetermined constant speed to the welding spot, that is, good feeding performance.

However, if the resistance to feeding is high, the balance with driving force of feeding machine is difficult to be kept, leading to bad feeding performance. Application of some lubricants is necessary to reduce the feeding resistance of wires through the conduit tubes.

For this purpose solid lubricants such as MoS 2 are applied to the liner of the conduit tube. However, since the effects are not satisfactory, application of additional lubricants like oil on the surface of wires is necessary. The application of oil on wires could be made in the neighborhood of wire feeding machine, however, accurate control of coating amount of oil requires excessive burden of welding operators; it is difficult in the actual welding operation.

If the amount of oil is not enough, naturally satisfactory lubrication cannot be achieved resulting in bad welding performance. On the other hand if the amount of oil is excessive, slipping occurs between the wire and the wire-feeding roller leading to unstable wire feeding speed and also an increase in hydrogen content by pick-up in weld metal is anticipated.

Besides, since the wire driven out of the feeding roller is subjected to compression, for prevention of buckling, the wire is lead into a guide tube connected to the conduit tube immediately after departure from the wire feeding roller. Thus application of oil on the wire must be done before the entry into the feeding roller and the problem of slipping is inevitable.

Accordingly, makers of welding wires are requested to supply wires with an adequate amount of lubricants and such wire products are available now. For instance, Japanese published patent No. Sho discloses welding wires coated with lubricants on smooth and fine surfaces.

However, uniform coating of a given amount of lubricants on the smooth surfaces was revealed to be difficult. To overcome the difficulty and obtain wires with sufficient lubrication, amounts of coating lubricants should be increased, resulting in slipping of wire-feeding rollers and picking-up of hydrogen in the weld metal.

As a countermeasure for the above difficulty a proposal was made to coat lubricants stably and uniformly along the longitudinal direction of wires by depositing lubricants on dents by increasing roughness of wire surfaces. Hei discloses a method of increasing roughness of wire surfaces by drawing wires after annealing in a particular atmosphere.

The method is not usually applicable since the chemical compositions in wires must sufficiently include the elements having a stronger affinity for oxygen than iron, such as Ti, Si and Mn, at the annealing temperature. On the other hand, Japanese published patent No. Sho discloses a method for obtaining rough surface by drawing wires through hole dies under forced lubrication by increased pressure on lubrication oils.

Although the method decreases the flatness of wire surface, it can hardly obtain deep dents to retain lubricants. Therefore, improvement of feeding performance is not expected if a coating amount of lubricants on the surfaces is not higher than 2.

Other methods proposed for increasing the surface roughness such as laser irradiation, shot blasting, and embossing by cemented carbide rolls with uneven surfaces are not practically applicable because of problems of high costs in equipment and operation.

The present invention is intended to provide a method for producing wires which have rough surfaces necessary to retain lubricants by modifying the process of reduction of diameter in sequence from raw wires to welding wires. Application of lubricants on the surfaces of wires produced by the present method permits satisfactory feeding of welding wires without lack of lubricants even in severe operation conditions.

The present method for production of welding wires through drawing of raw wires is characterized by comprising steps of dry hole die drawing with application of powder lubricants, roller dies drawing by such as cassette-type roller dies, and wet hole die drawing, at least in a part of a sequence of wire drawing processes. Furthermore a succeeding step of drawing by hole dies with application of lubrication oil may be conducted to make the wire to a product diameter.

In the present method the wires prior to the dry hole die drawing have surface roughness of preferably at least 0. Furthermore, the welding wires produced by the present invention are either sold wires or cored wires and have surface roughness Ra of preferably at least 0.

In the method for production of welding wires by drawing from raw wires to smaller diameters, the present invention differs from the conventional methods at least in a part at the later stage of drawing.

The raw wires for production of solid wires are hot-rolled wires of 10mm or so in diameter produced by wire rod mills. Besides, the raw wires for production of cored wires are tubes in which filler materials such as fluxes are filled by supplying from one end of long tubes of 10 mm or so in diameter with application of vibration, otherwise, tubes which are made by steel bands continuously bent by rolls into U shape, filled with filler materials, further formed into a cylindrical shape and welded at the seam.

Besides, in the present invention the cored wire is not limited to the closed-seam type, but also includes a open-seam type with folded-in seam. Although drawing into welding wires is sometimes executed continuously in a single stage, explanation will be made for the case of separate two-stage drawing of roughing and finishing. In manufacturing of solid wires, starting wire rods are pickled to remove oxide scale formed at high temperatures in hot rolling, lubrication films such as phosphate are formed on them, and transferred into roughing process.

In the roughing process wires are reduced in diameter by passing continuously through a series of hole dies under dry lubrication with lubricants containing mainly metal soap. In the roughing process some of the hole dies can be replaced by roller dies which pass the wire through a pair of free rotating rollers. Roller dies drawing permits a high reduction in a draft, while a large reduction in hole die drawing needs a high drawing force tending to lead in fracture of wires.

Because the drawn wires after roughing into as much as several times of the final diameter are work hardened, they are softened by annealing to facilitate the latter drawing process. Subsequently the surfaces are cleansed and plated with copper, then the wires are transferred to further drawing processes.

In the above process copper plating may not be applied for stainless steel wires and annealing may be omitted for some usage of welding wires. In the finishing process while wires are continuously drawn into the final diameter through a series of hole dies, drawing is performed usually under wet lubrication by immersing the hole dies in emulsion oil or spraying emulsion oil to the hole dies.

For prevention of buckling while feeding in welding operation, welding wires should have sufficient strength and rigidity; so work hardening during the finish drawing can give this property. In the above process for production of welding wires, roughing drawing is sometimes executed in multiple stages separated by intermediate annealing for softening.

The annealing may be executed as batch in a form of coil in furnaces or continuously by passing through a furnace. And another modification is a combination of continuous annealing and copper plating in a line. Details in processes can be different in accordance with production factories. In the above the production method of solid wires are mentioned. In the production of cored wires, since drawing just after filling of filler material may leads to nonuniform distribution of them, cold rolling before roughing drawing is executed by groove rolls to be dense enough for prevention of movement of the filler material.

The subsequent process is the same as the process for solid wires. Hereupon, the present invention comprises steps of dry hole die drawing with application of powder lubricants, subsequent roller dies drawing and subsequent wet hole die drawing, at least in apart of the sequence of the above mentioned wire drawing processes for production of welding wires, in place of conventional drawing solely by hole dies.

Through these processes, welding wires of good feeding performance can be produced by forming roughness enough for deposition of lubricants on the surfaces of welding wires. The finishing wire-drawing process of the present invention represents the processing after the dry hole die drawing in the sequence of wire drawing.

By operation of the above mentioned three types of drawing processes at least in a part of a sequence of the wire drawing processes in particular in the final process or just prior to the final process, the effects of the present invention can be attained. Therefore no particular specification is made for roughing process in the present invention, and also, any additional drawing process into the finishing process represents no departure from the present invention, although such necessity is not usually found.

Furthermore, as will be mentioned later, finish drawing through hole dies with a small reduction into a final diameter can be carried out by application of lubrication oil. The welding wires produced in accordance with the present invention are provided with a good feeding performance being coated with both of solid lubricants and lubrication oil. The purpose of the present invention is to provide welding wires which are coated these lubricants uniformly and stably on the surface of wires.

The solid lubricants to be used are one or two kinds of MoS 2 and WS 2. In the following description the solid lubricants and the lubrication oil to be applied on welding wire product are distinguished from the lubricants for drawing by describing as solid lubricants for feeding and lubrication oil for feeding respectively. Details of the present invention will be explained in the following.

In this example the starting material of wire 11 is coiled in a supply reel The starting wire is an intermediate product of solid wires or cored wires of about 2 to 5 mm in diameter with or without copper plating and is desired to have a surface roughness at least 0.

This means that some degree of roughness on the surface of starting material is desirable to effectively achieve the effects of the present invention for formation of the required roughness in the final products. These rough surfaces can be produced mostly by drawing through hole dies under dry lubrication at the last stage of roughing, or sometimes by drawing through roller dies with rough surfaces produced by shot blasting. Furthermore rough surfaces can be produced by chemical etching with controlling the conditions for pickling prior to the copper plating.

Besides, the roughness Ra represents an average of the absolute derivation values from the central of a measured roughness curve; Ra is used in the same manner in the standards of many nations as Japanese industrial standards JIS. The surface roughness described in the present invention represents values measured as roughness curves along a longitudinal direction of wires if not particularly mentioned otherwise. To begin with, dry hole die drawing as the first process of the present invention is performed through hole dies 13 by use of powder lubricants containing solid lubricants for feeding without use of liquid lubricants.

Powder lubricants are strongly inlayed on the surface of drawn wire by the drawing through the hole dies Therefore, the original surface roughness is kept and the powder lubricants are retained in the dents on the wire surfaces.

As the hole dies 13 for dry hole die drawing, use of rotary dies is favorable in order to maintain their holes exactly circular. In the subsequent roller dies drawing, cassette type roller dies 21, 22, 23 and 24 are employed in the example shown in FIG. As shown in the figure, small diameter rollers 41 to 50 having a groove with a profile to match the size of wire 51 to be drawn are arranged in each pair such as 41 and 42, 43 and 44, 45 and 46 to form a unit of roller dies.

These roller dies are arranged at a near position so that the rotating axes are set alternately to be oriented in perpendicular direction as shown in FIG. These pairs of roller dies are called a cassette-type roller dies since the units are compactly combined into a block as a whole. Drawing through the roller dies is executed without further use of lubricants and wires are reduced in diameter in sequence. Because the powder lubricants inlayed on the wire surfaces by the dry hole die drawing resist collapse of the dents, decrease in roughness is minimized.

In other words in contrast to the conventional hole die drawing which occurs much slip between wire surfaces and dies, the roller dies drawing retains much of the powder lubricants on the wire surfaces with little stripping off of them.

The wires reduced to a given diameter through the roller dies drawing are further drawn into a product size of 1 to 2 mm diameter by wet hole die drawing. The wet hole die drawing-equipment 14 is composed of multistage slip-type drawing machine with a multiple of hole dies 15 immersed in a bath containing lubricant oil. The speed of wet hole die drawing reaches as high as m per minute.

The wet drawing has effects for removal of excessive lubricants and stains and for making wire cross-section accurate circle.

Cryo-Shield L is an all-position flux cored wire adaptable to a variety of shop and field erection applications. Designed for cryogenic applications where good weld metal

Provide Feedback. ISO certified manufacturer of flux cored wire solder. Offered in different specifications. Features include even layer winding, low oxide shiny appearance and non-offensive odor. GHS compliant.

Flux-Cored Wire – The Future of Welding

Nagpur, Maharashtra. Pune, Maharashtra. Kamathipura, Mumbai , Dr. Mahimtura Marg, Kamathipura, Mumbai - , Dist. Mumbai, Maharashtra. Grant Road, Mumbai Shop No. Ahmedabad, Gujarat.

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Effective date : Disclosed is a method for manufacturing a flux cored wire for welding stainless steel of 0. The present invention relates to methods for manufacturing a flux cored wire FCW for welding stainless steel, more specifically, to methods for manufacturing a flux cored wire for welding stainless steel with a seam for not only for manual welding but also for semiautomatic welding and robotic welding. First of all, MIG welding is a welding process which uses an expensive shielding gas, e.

Kind code of ref document : A1.

Each test piece was stretched 10 times in the test. A method of manufacturing a flux-cored wire for stainless steel welding, the flux cored wire having a diameter of 0. The method of claim I, wherein the strip is filled in the U-shaped flux mixture containing the moisture is not more than ppm. The method of claim I, wherein the tubular wire from the final product to have almost the same diameter as the use of polycrystalline diamond wire die or roller die cartridge, polycrystalline diamond die using drawing process ends. A method for manufacturing flux cored wire for welding stainless steel having seam. CN CNC en. Methods for manufacturing flux cored wire for welding stainless steel and products thereof.

Flux Cored Wire Suppliers

As a pioneer, Ador Welding Ltd. Exceeding expectations is the cultural trademark of this company ably supported by state-of-the-art manufacturing plants. Today Fimer products are particularly oriented to the inverter with innovative solutions in each welding process.

This invention relates to a process for manufacturing flux-cored welding wire for low-hydrogen welding having superior resistance to cracking and primer-proof quality suited for use in the welding of high-tensile steels and other high-grade steels and steel structures subjected to large restraining forces. Dehydrogenation under heat has been applied on wires with small diameters of 2 to 4 mm for the following reasons: 1 There have been no efficient heating dehydrogenating process for large-diameter wires; and 2 Small-diameter wires can be easily formed into coils or loops that are required for shortening the overall length of bell or tunnel furnaces.

This article brings the specific and special merits of flux-cored wire in the method of production and application in Industries. FCAW Welding. Flux-cored wire is basically a tubular electrode. The conventional electrode has the core the wire and the flux is coated outside. In tubular electrode, flux becomes the core and tube becomes the holding system. The above concept makes the making of electrode easier and simulation techniques can be very easily adopted to make various types of electrodes to specific customer needs and specifications. The method of production is made simpler, easier to operate and get the desired quality of welding consumables. This is possible due to the best and relevant technology in flux preparation, flux filling, tube forming and wire drawing methods and with special protective coatings.

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Flux-Cored Welding: The Basics for Mild Steel

Social Media Terms of Use. Self-shielded Flux Cored Arc Welding FCAW has been a viable welding process for structural steel erection, heavy equipment repair, bridge construction and other similar applications for many years. Fortunately, with some know-how and a bit of practice, you can prevent some of the common problems associated with the process and gain the weld quality you need. Tip One: Avoid Wire Feeding Problems Wire feed stoppages and malfunctions are common problems on many job sites and they can cause a considerable amount of downtime. The two most prevalent type of wire feeding problems—burnback and birdnesting—tend to extinguish the arc prematurely, which in turn can lead to weld defects. To prevent birdnesting—a tangle of wire that halts the wire from being fed—during FCAW welding, always use knurled V- or U-groove drive rolls in your wire feeder. Compared to a GMAW solid welding wire which uses a smooth V-groove drive roll , FCAW wire is much softer due to its tubular design and if you use the incorrect drive roll, it can easily compress the wire. Prevent burnback, as shown here, by having the appropriate wire feed speed and MIG gun to work piece distance. Additionally, setting the correct drive roll tension can prevent the wire from flattening and becoming tangled.

Getting to Know Flux-cored Wires

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Welding wires

And answering those needs is all about knowing the customer very closely, and them knowing us. Along with the commitment to customization, the company has stayed consistent in many other ways through the years. The same family that started Taylor Machine Works is still at the helm today, with the third and fourth generations involved. The Taylor legacy also includes a commitment to innovation and improvement.


Manufacturer producer - flux cored wire. Refine your search Locate the companies on a map. KG supplies the highest-quality special wires for solving problems in the electronic, photovoltaic and light technology industries Contact this company.

EP0914899A1 - Method of production of welding wire - Google Patents

Supplier Location:. Supplier Types: Trade Assurance.

A Guide to MIG Welding Success

Self-shielded flux-cored welding can be an excellent process to use for welders of all skill levels who frequently need to weld outside or on dirty material. Self-shielded flux-cored welding is a wire welding process in which a continuous hollow wire electrode is fed through the welding gun into the weld joint. Instead, a flux compound contained within the wire reacts with the welding arc to form a gas that protects the weld pool.

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