Understanding metal-cored wire

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  By Steve Barhorst 
 
  May 8, 2007
 
  Article
 
  Arc Welding
 
  Join Discussion

If you're like most welders, you probably have heard of metal-cored wire and how it may offer
quality improvements and time savings. But, like many, you might not know enough about
metal-cored wire to understand whether it is the right fit for your application.

It's true. For the right applications, metal-cored wire can significantly reduce weld cycle times,
provide high deposition rates, and increase travel speeds. Metal-cored wires can also reduce
silicon deposits, overcome mill scale, and bridge poor fit-up. Still, transitioning to metal-cored
wire requires investing some time and money in research and testing. It is not a decision to be
made lightly, but the benefits of the wire may be the answer to optimizing your welding
processes.

What's Cored Wire?

Introduced in 1973, metal-cored wire is a hollow metal tube filled with a blend of metal, mineral,
and chemical powders. The majority of the powder core is iron, with varying amounts of other
materials added to the core to produce certain effects, such as reduced oxidation or higher
impact strengths. Other elements also are added to achieve various weld qualities, but the
combinations are proprietary among filler metal manufacturers.

The American Welding Society (AWS) classifies metal-cored wires by tensile strength, gas
requirements, and weld deposit chemistry according to impact strengths. Consider this example:
E70C-6M H4. Erefers to electrode; 70refers to tensile strength (here, 70,000 PSI); Cindicates it
is a composite wire (not solid); 6indicates that the weld deposit chemistry offers impact
strengths down to -20 degrees (the other option, 3, would indicate that it offers impact strengths
down to 0 degrees). Finally, the Mrefers to the wire's mixed gas requirements, and H4 indicates
the maximum amount of hydrogen per 100 grams in a weld deposit (in this case, 4 grams).
Metal-cored wire is available in diameters from 0.035 inch to 3/32 in. and is suitable for nearly
all types of steel, including mild, low-alloy, and stainless. It is not, however, recommended for
welding sheet metal.

Metal-cored wire can be used for single- or multiple-pass welding and is best-suited for flat,
horizontal or vertical-down welds. With pulsed power sources, metal-cored wire can be used in
all positions, but it is slower. As a rule, industries best-suited to using metal-cored wire include
automotive exhaust and chassis manufacturing, agricultural and heavy equipment
manufacturing, railcar fabrication, and the food and chemical industry. It is not recommended for
applications that require a significant amount of out-of-position welding.

Metal-cored wire is applied with a spray transfer process, which propels tiny droplets of filler
metal into the weld puddle, and typically requires a 75/25 argon/CO2 or richer argon shielding
gas mixture. Unlike solid wire, the outer sheath of the metal-cored wire is responsible for
conducting nearly all of the welding current to the workpiece.As a result, metal-cored wire
produces a conical-shaped arc, which generally creates a wider weld bead profile and a less
turbulent arc—factors that help prevent burn-through on thinner-gauge material.

What's the Bottom Line?

Despite its benefits, integrating metal-cored wire into a welding operation isn't as easy as simply
switching wire spools. Instead, learning if metal-cored wire offers benefits for your application
should involve time trials to compare the current process against the potential for improvement
with metal-cored wire. Testing shielding gas mixtures and current settings within these trials
also is necessary to find the optimal combination to use with the proposed metal-cored wire.
With the correct welding parameters and gas mixtures on the appropriate application, metal-
cored wire can offer deep penetration, good gap bridging, fast travel speeds, high contaminant
toleration, little spatter and slag, and little to no silicon deposits—all benefits that can help offset
metal-cored wire's higher per-unit cost.

Although metal-cored wires cost more than solid wire, for example, in the right applications,
those costs can be recouped in reduced labor and gas expenses, which combined can
comprise up to 85 percent of an operation's total weld cost.

So, how is that possible? Consider that in many applications, metal-cored wire offers high travel
speeds and deposition rates. It also can produce a deep-penetration profile than, resulting in
strong welds on thick material. Translation for the right application: fast, high quality welds with
less downtime and higher productivity.

What's Next?
If you find that your productivity levels or rework levels aren't acceptable, consider consulting
your local welding distributor or a reputable filler-metal manufacturer to discuss whether metal-
cored wire might help. Representatives from these companies can help you assess your current
welding processes and determine whether metal-cored wire will make a difference in both the
quality and cost of your welding operation.
 Gas-shielded cored wires find their niche
Suitable applications for flux-cored and metal-cored electrodes
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  By Dwight Myers 
 
  June 15, 2001
 
  Article
 
  Consumables
 
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Object

Gas-shielded flux-cored arc welding (FCAW) and metal-cored arc welding (MCAW) are growing
in popularity for many applications. To determine if these wires should be used, shop managers
should understand how formulations of cored wires do or do not fit their quality requirements for
certain applications.

Gas-shielded flux-cored wire applications often include an external shielding gas and have a
slag system that helps to clean and protect the molten weld puddle, not unlike that of a shielded
metal arc, or stick, welding (SMAW) electrode. The slag also acts as a shelf and aids out-of-
position welding.

Metal-cored wires also require an external shielding gas but, unlike flux-cored wires, do not
have a slag covering the weld deposit.

Metal-cored wires generally have arc characteristics and weld deposits similar to a solid gas
metal arc, or MIG, welding (GMAW) wire.Cored wires, whether flux-cored or metal-cored, are
fabricated wires. They usually are produced from a thin, flat ribbon of steel that is formed into a
U shape, filled with the flux and alloy formulation, and then closed into a tube with the flux and
alloy on the inside. Because they are fabricated, the wires can be adapted to meet many
welding requirements.

The core ingredients of fabricated cored wires can be formulated specifically to give them the
most suitable combination of mechanical properties, weldability, and productivity for the task at
hand. The fabrication process accounts for the increased electrode cost compared to solid
GMAW wire.

Deposition efficiency is the measure of how much wire actually becomes deposited weld metal.
Solid GMAW wires generally exhibit 95 to 98 percent efficiency, metal-cored wires exhibit 92 to
95 percent efficiency, and flux-cored wires exhibit 85 to 89 percent efficiency. Although the
deposition efficiencies of gas-shielded flux-cored and metal-cored wires are lower than those for
solid GMAW wires, their higher deposition rates, or the amount of weld metal deposited per
hour, as well as their contribution to weld quality help offset the higher costs in applications that
lend themselves to cored wire.

This article presents some of the welding applications and benefits for which cored wires can be
a good choice for the fabricator.

All-position Flux-cored Wires

All-position versatility is one of the greatest benefits offered by flux-cored wires. Over the years,
developments in the flux-cored wire process have allowed these wires to be used for welding in
all positions (including vertical and overhead) while maintaining the good mechanical properties
and high productivity allowed by the high deposition rates in all positions.

Welding is restricted primarily by the amount of weld metal that can be deposited and handled
when making a good-quality weld. The temperature of the weld pool, the fluidity of the weld
metal, and slag play important roles in allowing out-of-position welding.

Not all flux-cored wires will perform out of position. American Welding Society (AWS) A5.20
E70T-X wires are designed for flat and horizontal welding only. Flux-cored wires that are
designed for all-position welding (classified as E71T-X by AWS) include arc stabilizers and slag
systems that are formulated to support the weld pools in out-of-position welding with a faster-
freezing slag.

The outer metallic sheaths of a flux-cored wire conduct the electrical current for welding.
Because of the fabricated, composite nature of cored wires, their current-carrying density is
greater, which improves the deposition rates at lower current levels by depositing more metal
per inch of wire at equal wire feed speeds when compared to other welding processes.

All-position flux-cored wires include arc stabilizers and slag systems that are formulated to
support the weld pools, resulting in fast-freezing slag. The conducting part of cored wires is
small, which results in high current density and helps to improve their net deposition rates.

The productivity and manageability of this process make FCAW suitable for a variety of
positioned and all-positional applications. These include building dock assembly, pipe welding,
shipbuilding, and welding of other structures and fabrications that cannot be done in the flat
position.

Because flux-cored wires have a slag covering the weld, postweld removal of the slag is
necessary. However, the slag generally is easy to remove and, in some cases, almost self-
releasing.
In addition, the decision to use gas-shielded flux-cored wires depends on the availability of
shielding gas at the fabrication site. When welding is performed on a remote site and the
appropriate shielding gas is not accessible, a self-shielded flux-cored wire, which generates its
own shielding gas from the core ingredients, may be a better choice.

Welding with gas-shielded flux-cored and metal-cored wires creates a wide, deep-penetrating
arc. The resulting penetration and smooth tie-in of welds help to decrease the occurrence of
defects caused by lack of penetration and lack of sidewall fusion sometimes found in
applications using solid GMAW wires at low current settings.

The weld pool created by flux-cored and metal-cored wires generally is calm and flat, which
creates a consistent weld and smooth wash or wet-in on both legs of a fillet or both sides of a
weld.

Because fusion defects generally are minimal with flux-cored and metal-cored wire welding,
industries such as offshore fabrication, railcar, shipbuilding, and heavy machinery and earth-
moving equipment fabrication are using this process.

Metal-cored Wires
In an effort to achieve higher deposition rates and higher deposition efficiencies to lower the
cost per pound of welding material deposited, filler metal manufacturers working with industrial
fabricators developed metal-cored wires. These wires combine the high deposition rates of flux-
cored wires with the high deposition efficiencies of solid-wire GMAW.

The composition of the filler for fabricated metal-cored wires is predominantly metallic powders,
which are responsible for the high deposition rates. Like flux-cored wires, metal-cored wires can
be produced with specific alloy compositions for a wider electrode selection for specific
application requirements while allowing the purchase of smaller heats compared to the full melt
of a solid GMAW wire.

The fabricated nature of metal-cored wires (produced similarly to flux-cored wires), along with
their high deposition rates, high deposition efficiencies, high duty cycles, and low slag and
spatter, makes them suitable for high-production welding, including automatic and robotic
applications. In essence, metal-cored wires are able to exhibit up to a 30 percent increase in
travel speed over a solid GMAW wire to keep up with the continuous, high travel speeds
required for automatic or robotic welding while maintaining bead appearance, penetration, and
weld integrity.

Compared to flux-cored wires, metal-cored wires contain smaller amounts of arc stabilizers and
little or no slag-forming ingredients. The resulting weld deposit of a metal-cored wire is very
similar to that of a solid GMAW wire, with only a few easily removed silicon islands on the weld
surface. This allows metal-cored wires, like their solid GMAW wire counterparts, to be used
commonly for multipass welding because they can achieve productive high speeds, and
deslagging after every welding pass is not necessary.

The automotive industry was one of the first to use robotics; today, one of the most widespread
uses of metal-cored wires in robotic welding is for the exhaust systems of new cars. Metal-cored
wires were adapted to the changes in the alloyed steels developed to increase the life of
exhaust systems. Their ability to bridge gaps makes metal-cored wires a suitable choice when
precise part fit-up is not possible.

One-sided Welding with Ceramic Backing

Flux- and metal-cored wires are particularly suitable for one-sided welding on open butt joints.
Open butt joint welding requires a high skill level to achieve sufficient penetration with back-
bead reinforcement and burn-through prevention. With cored wires and ceramic backing,
however, the welder can choose a wire and match it with backing materials selected for
optimum results in all welding positions while maintaining a high productivity level.

Because the cored-wire process is one of the easiest welding processes to master, the welder
can achieve high productivity with one-sided welding. One-sided welding with cored wires and
ceramic backing also will reduce the amount of preweld setup and postweld machining because
back-gouging or grinding is not required.

Low-fume Cored-wire Welding

Cored wires typically generate more fumes than other continuous welding processes because
the cored wires deposit more weld metal per minute.

In recent years, manufacturers have introduced cored wires that produce less welding fume and
spatter. Cored wires have been formulated for use with high-argon gas mixtures previously used
only for solid-wire GMAW. This use of special low-fume cored wires with a deposition chemistry
balance for the use of higher-argon shielding gas mixtures tends to lower the fume and spatter
levels commonly associated with flux-cored wires.

These products are suitable for use in situations in which operator and industrial hygiene
concerns make low-fume production a priority. The higher cost of these products can be
weighed against the cost-effectiveness of achieving a low-fume environment through other
means—such as electrical precipitators and mechanical fume extraction systems —to
determine the most economical approach to lowering fume generation on the shop floor.

Conclusion
Through a thorough understanding of MCAW and FCAW, welders doing various types of
welding have been able to identify niches in which cored wires can contribute to higher
productivity and quality improvements. The differences in flux formulations among different
cored-wire products permit flexibility in meeting specific performance needs and end-result
requirements.

Not all applications are suitable for cored wires, but end users should be aware of the basic
economics of welding to determine the actual cost per pound of deposited weld metal (rather
than cost per pound of product) to choose the best wire for a particular application.

OUTERSHIELD® WIRES
Outershield products are the group of welding consumables developed and produced by Lincoln Electric to be used with the
Flux Cored Arc Welding Process (FCAW). This semi-automatic welding process is similar to gas metal arc welding (GMAW)
and requires a power source and wire feeder, complete with welding gun and shielding gas supply. FCAW tubular cored
wires are mostly used instead of a solid wire and MMA electrodes  because of higher productivity and quality of welds.
Depending on the type and composition of the fill or core of the cored wires four main groups can be distinguished each of
which are designed for specific applications:
Rutile type (regular or micro-alloyed) for smooth arc characteristics, excellent weldability, easy slag release and smooth
bead appearance. CMn type wires are used for all position welding in general constructions and ship building, e.g.
Outershield 71M-H for CO2 shielding gas and Outershield 71E-H for argon/CO2 mix gas. With additions of 1-1,5% Ni,
Outershield 81Ni-H, 81 K2-H, 550-H and 690-H are recommended for applications where high yield strength and toughness
is required.
Basic type for high restraint constructions with excellent mechanical properties for applications in high strength fine-grained
steels, e.g. Outershield T55-H.
Metal Cored type for high deposition rates as for example fillets in the down hand welding position in the spray arc. Such
type of wire may be also applied for positional welding or root passing in the short arc mode. This wire produces very little
spatter and no slag, like the most well-known products on the market Outershield MC 710-H and MC 715-H. The welding
process is described as MAG welding with metal cored electrode and is marked as 138 according the ISO standards.
The principle of metal cored wire welding is given in the picture below. Similar to MAG welding torch position and angles can
be applied (however rutile flux cored will require different techniques).

Fig. 1. MAG welding with metal cored electrode (138). No slag removal required.

Almost the same welding techniques may be applied however metal cored wires will deliver easier to operate and more
forgiving arc, more regular bead appearance and lower number of welding defects. There is no need (in EU) to perform
additional certification for MAG welders hence their welding qualifications are also valid for welding with metal cored wire
(ISO 9606 Part 1, it was published in November 2013 and replaces EN287 Part 1 which will be withdrawn in October).

Range of qualification a - b
Wire used on the the test piece Solid (S) Metal Cored (M) Flux-cored (B) Flux-Cored (R, P, V, W, Y, Z)
Solid (S) x x - -
Metal Cored (M) x x - -
Flux-cored (B) - - x x
Flux-Cored (R, P, V, W, Y, Z) - - - x
a - Abbreviations : see 4.3.2
b - The type of core used in the qualification test of welders for root run welding without backing (ss nb) is the type of core qualified for root run
production
Key : x indicates those filler materials for which the welder is qualified / -  indicates those filler materials for which the welder is not qualified

 Fig. 2 Reprint from 287-1 : Welding qualification for MAG (135) covers also MAG welding with metal cored wire
(138)

OUTERSHIELD® METAL CORED WIRES

Metal cored electrodes are produced in such way that very low hydrogen content in the deposited weld metal (HDM < 1,5
ml/100 g) is obtained. It reduces the risk of hydrogen induced cracking to a minimum.

Fig 3. Hydrogen content in the weld metal of Outershield MC710-H and MC715-H as a function of time after unpacking. Storage in wo
conditions.

Typical applications cover all types of welds which can be made with:
Spray arc in dowhand position, short arc mode in all positions including root passing
Pulse modes in all positions

Outershield metal cored wires have gained their popularity because of particular advantages:

 High melt-off and deposition rates resulting from “tubular” nature of electrode (higher current density are obtained
than for MAG)
 High resistance against lack of penetration or cold laps, which are especially typical disadvantages of MAG
process while welding thicker plates
 Wider and more regular penetration profile
 Fig 4. Macro section of the a4 weld, PB/2F position. Outershield MC 710 – H 1,6 mm.

Fig. 5. Fillet weld after mechanical testing: Outershield MC710-H (left); solid wire SG2 (right)

Wider range of applicable electrode diameters: 1,4 mm is suitable for semiautomatic welding, 1,6mm as the most productive
electrode diameter for mechanized or robotic applications

Better than MAG tolerance against porosity caused by contaminations (rust, rests of paints, primers, oils, tec.), the benefit
comes from deoxidizers which are added to the flux

Well visible and easy to operate arc provides better tolerance against changing weld preparation and welding gap

Smooth and low spatter welding

Successful applications in robotic welding due to the absence of slag and high travel speeds achievable

 
Fig. 6. Fillet weld, robotic welding with 1,2 mm Outershield 710-H. Welding mode: Rapid Arc, 24V, 280 A, TS-2,7
m/min, shielding gas Ar/CO2 90/10.

The most popular applications are filling and capping passes in PA/1G and PC/2G positions as well as fillets in PB/2F
position. Iron and iron alloys metallic powders are the main flux components, so they are resistant again moisture pick-up.
The flux contains small addition of deoxidizers, that’s why metal cored wires gain resistance against porosity while welding
contaminated steel.

Fig. 7. Fillet weld on primed steel: Outershield MC710-H 1,2 mm

Argon blends are the most popular shielding gases (Ar/CO2 80/20, Ar/CO2 90/10, three components gas blends), however
specific types of wires are designed to work with CO2 as well (Outershield MC 710C-H). The slag forming is minimal so the
welds are very similar to that of solid wires with very little number of silicate islands. 
The most popular applications of Outershield® metal cored wires are:
- Steel fabrications,
- Heavy machinery,
- Shipbuilding,  
- Automotive industry and robotic welding,
- Offshore constructions.

CATALOGUE INFORMATION

Lincoln Electric range of metal cored wires includes

  

PRODUCTIVITY OF OUTERSHIELD® METAL CORED WIRES

Current density is the main factor determining melt-of rate, deposition rate (kg/h),  penetration and resistance against cold
laps. Schematic illustration of electrode cross section helps to understand mentioned above unbeatable advantages of metal
cored wires. These benefits come from high current density, which is expressed by the ratio of current flow and cross
section area of metallic tube. Welding current flows through the tube because of its lower electrical resistance (resistance of
steel is lower than of metallic flux).

Fig.8. Cross section: schematic illustration of metal cored and solid wires.

The same current flows through a smaller cross sections comparing to MAG welding with solid wire, that’s why FCW always
delivers higher current densities at similar wire feed speed. Because of that lower welding currents can be applied to
achieve the same productivity (comparing to MAG welding with solid wires).  
Proper electrode diameter is critical to obtain the best process productivity. Metal cored 1,2 mm wires deliver best deposition
rate at lower currents; they are also widely applied for thin sheet material welding and work well on smaller power sources.
For 1,4 mm and 1,6mm electrodes it is recommended  to use power sources and with higher Amps (>280-300A) to obtain
maximum process efficiency, however they’ll pose better tolerance against burn through than 1,2mm while welding at lower
currents.

Deposition rate curves for 1,2mm, 1.4mm and 1,6 mm metal cored wires are presented at Fig. 5 (blue line represents typical
deposition rate of 1,2 mm solid wire).
 Fig. 9. Deposition rates of 1,2; 1,4 and 1,6 mm metal cored wires (MC 700, MC 710, MC 715)

 In semiautomatic welding metal cored 1,4mm wires delivers good operability and provide deposition rate which in
unbeatable for 1,2 solid wire. 1,6 mm will  work the best for mechanized or robotic welding, but this is very popular electrode
diameter for heavy plate semiautomatic welding also.
Proper electrode diameter choice is a primary productivity factor. Clear example is given in Appendix 1, where total welding
cost for a5 fillet after welding with different electrode diameters is presented. Comparing to solid wires - metal cored wires
will always deliver better quality, productivity and will help to reduce the total cost of welding.

SUMMARY

Gas metal arc welding with metal cored wires will always deliver easier to operate and more forgiving arc, regular bead
appearance, lower number of welding defects, better tolerance against surface contaminations and weld preparation. The
benefits come from tubular nature of the electrode and flux components. There is no need to perform additional certification
for MAG welders. Metal cored electrodes work well in spray or short arc area on typical CV power sources (Powertec, CV,
DC, Flextec, Speedtec) and keep the advantage over solid wires while welding with controlled waveforms (pulse, precision
pulse, RapidArc, RapidX on Speedtec SP and Power Wave). Proper electrode diameter choice helps to obtain the best
productivity and quality of welds with reduced total welding costs. 
Lincoln Electric’s offer of Outershield® metal cored wires covers almost all types  of base materials applied in steel
fabrications, heavy machinery, shipbuilding, automotive industry and robotic welding, offshore constructions.

 Appendix 1. Welding cost calculation for 1,2 1,4 and 1,6 mm metal cored wires
Conditions used for calculation:
- Weld size a5, overwelding -  20%
- Length of the weld: 10 m
- Shielding gas Ar/CO2 80/20
  

Appendix 2. Recommended starting parameters for 1,2 mm metal cored wires

  

Quantitative and Qualitative analisys of 10 mm steel plate welding with 135, 136, 138 methods in PB position delivered during the Seminar
on Steel Construction, Lincoln Electric Poland, 24-26th of November 2010 by Waldemar Radomski, Academy of Mining and Metallurgy,
Cracow, Poland.

Advantages and Disadvantages of Metal Cored Wires

190
In today’s world, fabricators have a wide range of choices in deciding the best welding process and
consumable to use in a particular application. Many different considerations are necessary including
welder skill, equipment, availability of the consumable, environmental issues and the economics of
the process. What is the best method to accomplish the task of joining two pieces of steel? One
rapidly growing process is being seen in the use of metal cored wires. Higher duty cycles, faster
travel speeds; low fumes and better cost effectiveness are some of the primary reasons. By
exploring the advantages and disadvantages of the metal cored wires, you can best determine
whether this is a process that you should employ to increase productivity and ultimately your
profitability.

Background
Since the day the carbon arc process to join two pieces of metal was discovered, we have been
looking for ways to improve upon the process. At the turn of the century, Oscar Kjellberg developed
the first coated electrode. In the 1930’s the first inert gas welding process (GTAW) was used as well
as the first submerged arc welding (SAW). The main goal in every advancement was to improve first
the integrity of the weld and second to improve upon the process itself, to make it faster, more
efficient, and more cost effective through higher productivity. In 1948 the solid wire process was
developed and this expanded the usage of continuous solid wire applications that were not readily
adaptable to the SAW process: i.e. vertical and overhead welding.

Manufacturers and fabricators who depended a great deal on the welding process for their finished
products were not totally satisfied with these improvements. They wanted more. In the 1950’s there
were many innovative designs for continuous welding that would give the end user higher deposition
rates. Unfortunately, most had flaws and were not commercially viable. It was not until around 1957
that the flux cored wire process as we know it today was first introduced to the market. The first flux
cored wires were large diameter, 1/8” (3.2 mm) and 5/32” (4.0 mm) diameters. In those days, the
3/32” (2.4 mm) diameter was a “small diameter” flux cored wire. Flux cored wires provided better
metal penetration, smoother arc transfers, lower spatter levels and were overall easier to use than
solid MIG wires, but they were limited to flat and horizontal positions and the equipment to use them
was heavy and cumbersome. As flux cored wires developed, smaller diameters began to emerge
onto the welding scene, which led to the ability to weld in all positions. Advancements in equipment
also made welding with flux cored wires more comfortable for the welder. Now for the first time high
deposition rates were obtainable in the vertical and overhead positions. Acid (rutile) slag systems
gave high welder appeal, good mechanical properties and lent themselves to many applications
formally welded with the MIG or SAW process.

However, flux cored wire manufacturers and fabricators did not stop their developments and quest
for a continuous process that was faster, better and more economical. They needed to overcome
one last hurdle, to achieve both high deposition rates or the amount of weld metal deposited per
hour and high deposition efficiencies, how much of the welding consumable actually becomes part of
the weld deposit. Could we reach the high productivity level of flux cored wires, but maintains the
high deposition efficiencies of the solid MIG wire process? The answer came in the form of a
fabricated composite cored wire known as the metal cored wire.

Metal cored wires are classified under the American Welding Society specification with solid MIG
wires (AWS A 5.18-93 for mild steel, AWS A5.28-98 for low alloy and AWS A5.9-93 for stainless
steel). Metal cored wires will carry the same basic classification for strength level and chemical
composition as solid MIG wire, but are denoted by a “C” for composite wire. For example, a 70 KSI
metal cored wire having a chemical composition and mechanical properties similar to an E70S-6
solid wire would be classified as an E70C-6 composite wire. Considered to have some
characteristics similar to flux cored wires and other characteristics similar to solid wire, metal cored
wires do share a similar construction to flux cored wires and performance similar to solid MIG wires.

The outer metallic sheath of a cored wire conducts the electrical current for welding. Because of the
fabricated, composite nature of cored wires, their current carrying density is greater, which improves
deposition rates at equal current levels when compared to solid MIG wires.

The internal components of a metal cored wire are composed chiefly of the alloys, manganese,
silicon, and in some cases, nickel, chromium and molybdenum as well as very small amounts of arc
stabilizers such as sodium and potassium, with the balance being iron powder. Metal cored wires
give the benefit of being able to have alloy compositions formulated for specific applications in
smaller batches than the normal large heats of solid wire. Many alloy compositions employing
chromium, nickel and molybdenum are now available including austenitic and ferritic stainless steel
alloys. Metal cored wires have little to no slag forming ingredients in the internal fill of the wire. Just
like solid MIG wire, welds made with a metal cored wire will only have small silicon islands from the
deoxidized products that appear on the surface of the weld. This allows for multiple pass welding
without deslagging.

So, how do metal cored wires fit into a particular welding application? When is a metal cored wire
the correct choice? What are the factors that need to be considered in choosing a metal cored wire?
Do metal cored wires really offer that much benefit over flux cored wires or solid MIG wires? When
making a major process change in the welding of an application, it is normal to ask a lot of
questions. The whole process can become a bit overwhelming to the point that no decision is made.
In order to prevent that from happening, the remainder of this paper will look at both the advantages
and possible disadvantages of using metal cored wires.

High Deposition Efficiency

Whenever a weld is made, a percentage of the welding consumable is lost to slag, spatter and fume.
Deposition efficiency relates to the amount of a consumable that becomes deposited weld metal.
The higher the deposition efficiency of a consumable, the lower the amount of that consumable is
wasted by not becoming part of the deposited weld metal. Because of the characteristics of a flux-
cored wire, slag covering the molten weld puddle, they are efficient in the range of 84-89%
depending upon the diameter and slag volume of the particular wire design. Solid MIG wires are
highly efficient based on virtually non-existent slag. Solid MIG wires will typically exhibit efficiencies
in the range of 95-98% depending upon the mode of the transfer used. Deposition Efficiency A true
“spray” transfer under high Argon shielding gas mixtures will yield the highest deposition efficiency.
Metal cored wires with their arc characteristics being similar to solid MIG wires and very low spatter
level as well as low slag volume, also exhibit deposition efficiencies in the 92-98% range with the
selection of spray transfer mode and high Argon shielding gas mixtures. When solid wires are used
in the “short arc” transfer mode or with higher CO2 content shielding gas, some deposition efficiency
will be lost due to the increased spatter level. This is also true with flux cored and metal cored wires.
Changes in transfer mode and shielding gas will have an effect on the deposition efficiency. In some
high-speed applications, solid MIG wires are used at lower voltages to avoid a large spray column.
Using a solid MIG wire at voltages that produce a high spray column could produce undercut,
underfill and can prevent the high travel speeds required for productivity. This practice produces a
higher level of fine spatter, which decreases the deposition efficiency of the wire. When the same
practice is used with metal cored wires, the level of fine spatter is greatly reduced. Along with
obtaining a better deposition efficiency, maintenance costs for tooling and equipment can be lower.

Deposition Rates
Deposition Rate ComparisonThe deposition rate of a welding consumable is the measurement of
how much weld metal is deposited within a given time period. Deposition rates along with deposition
efficiency are the leading determinants of the cost effectiveness of a consumable. Generally
expressed as pounds per hour (Kg./hr) flux cored and metal cored wires have some of the highest
deposition rates of all of the welding consumables. Flux cored and metal cored wires are capable of
having deposition rates as high as 12-14 pounds per hour (5.4-6.4 Kg/hr) for a 0.045” (1.2mm)
diameter wire. This compares to a solid MIG wire in the same diameter of 8-10 pounds per hour
(3.6-4.5 Kg/hr). The high deposition rates coupled with high deposition efficiencies and low slag
volume will allow the metal cored wire to be used at higher travel speeds resulting in increased
productivity. A general rule of thumb that has been used is that when a deposition rate of 9 pounds
per hour or greater is achieved with a metal cored wire versus a solid MIG wire, the economics of
the weld will show a cost savings in favor of the metal cored wire.

High Duty Cycles, High Travel Speeds

Any continuous welding process will inherently have a higher duty cycle, or the amount of
continuous arc time. This makes sense. Deposition Travel SpeedThe SMAW process of stick
electrodes requires the welder to stop in short intervals of the weld to de-slag and change
electrodes. The duty cycle for SMAW electrodes is considered to be in the range of 20%. This
translates to only 12 minutes of welding every hour an arc is generated. With a continuous process
such as cored wire or solid MIG wire, the duty cycle increases to as much as 50% of the time or 30
minutes per hour for arc generation. This is one factor that makes the use of automated or robotic
welding so attractive, the ability to use a continuous process. Along with the increase in duty cycle
comes the benefit of faster travel speeds. Automated welding is only limited to the supply of parts to
the weld station and the travel speed of the process. Solid MIG and flux cored wires can contribute
to the higher duty cycles, but only metal cored wires have the capability of combining high duty
cycles with high travel speeds to exploit these factors without sacrificing bead appearance,
penetration and weld integrity. Increases in travel speed of 35-40% are not unrealistic when
converting from a solid MIG wire to a metal cored wire. Increased duty cycles and higher travel
speed can significantly reduce the cost of welding. Fabricators who for the first time use a metal
cored wire in an automatic application are often surprised at the ability to increase in travel speed
while maintaining weld integrity and bead appearance.

Low Slag Volume, Low Spatter Levels

Coupled with increase duty cycle of a consumable is the decrease in removing slag from the weld.
This is one of the biggest advantages solid MIG wires have over flux cored wires. Because of the
compositional characteristics of the metal cored wires, they also have a very low slag volume like
solid MIG wires. The advantage of metal cored wires comes in decreased spatter levels that need to
be cleaned from the parent material prior to finishing. In many cases, the small silicon islands formed
on the weld are easily removed. Metal cored wires tuned to the proper welding parameters and
using high Argon mixes for shielding gas will also have a decrease the amount of spatter.

This is especially an advantage to continuous operations where the part moves from an
assembly/welding operation directly into a cleaning and painting operation. Cleaning of weld spatter
from a fabricated piece can cost significantly in post weld clean up. One particular application in
which this was very evident was in a mobile crane manufacturer who went from a basic slag flux
cored wire to a metal cored wire and saved an average of 12-14 man hours per unit in post weld
cleaning prior to painting. Metal cored wires have the advantage of having arc stabilizers in both the
internal components as well as applied to the surface of the wire. The arc stabilizers enhance the arc
characteristics as well as minimize the spatter levels.
Economics
The real payback for any change in process or welding consumable comes with the economics of
the change. How can we do it better, but at a less cost per unit. A common mistake is to try to obtain
the incumbent filler metal at a lower price. Because the actual cost of the filler metal for welding is a
small percentage of the total, maximum savings are not achieved. When breaking down the actual
cost per pound for a deposited weld, the cost of the filler metal only contributes approximately 15%
of the total cost. Other factors such as labor and overhead, equipment, electrical cost, deposition
efficiency and deposition rates of the filler metal can have a much larger impact. Bottom line with a
filler metal is that it is not how much it costs per pound that counts, but how much it costs per pound
to use. An analogy to this would be in purchasing paint. Take one brand that costs $10 per gallon
versus another brand that cost $20 per gallon. If the lower priced paint takes additional coats for
coverage and does not cover the same square footage per gallon, any savings in the purchasing
price is lost. The same can be true of choosing the correct filler metal to maximize the cost per
pound of deposited weld metal.

Consider an actual application using 0.052’ (1.4 mm) E70S-6 MIG wire welded under pulse
conditions at 425 inches per minute wire feed speed, 24.5 volts and travel speed of 70 inches per
minute. This was converted to metal cored wire welded and at the same wire feed speed, voltage
and travel speed. Because of the benefits of the metal cored wire, the travel speed could be
increased to 85 inches per minute, or a 20% increase. Not only was the travel speed increased,
increasing the through put, the number of necessary repairs diminished as did the amount of time to
make repairs by 10%. Because the line time cost was calculated in dollars per minute, a huge saving
in real dollars was realized from even small advances in productivity improvement. The cost per
pound for the metal cored wire was more than the cost per pound for the solid MIG wire, but the
realized savings more than offset any additional cost for the metal cored wire.

In another application, a 0.040”diameter (1.0mm) ER409Cb solid MIG wire was welded under pulse
conditions at 180 amps, 20 volts and 19.6 inches per minute travel speed for a thin wall tube.
Conversion to an 0.045” (1.2 mm) EC409Cb metal cored wire welded under pulse conditions at 190
amps, 21 volts and 27.5 inches per minute travel feed speed. Not only did the travel speeds
increase, but an additional advantage was seen in the ability of the metal cored wire to bridge gaps
due to poor fit up. This also contributes to a lower defect rate and the need to rework parts off line.
The results are on the average a 40% increase in production, lower consumable cost per pound of
weld metal and lower maintenance cost.

Disadvantages to Metal Cored Wires

So far this paper has been weighted to show the advantages of converting solid MIG wires or flux
cored wires to a metal cored wire, but there are disadvantages as well. To gain the fullest potential
benefit from using a metal cored wire, an automated or robotic set up is required. Expecting the
maximum potential increase in travel speed to be met and consistently maintained in a hand held
operation is expecting a lot from a welder. Automated systems are consistent and do not tire nor do
they need breaks. As long as a continual supply of parts are supplied, an automated system keeps
on working. If a current application is being handled only by hand held welding stations, a capital
investment would need to be made in an automated system. Repetitiveness of an application is
necessary to minimize set up and jig costs. Experience in programming a robot is necessary due to
an increase in weld puddle fluidity. Such would be the case in welding a small diameter tube where
the positioning of the torch to the part is more sensitive with a metal cored wire. The cost of the
automated system has to be taken into account also as well as the ability to provide a reasonable
payback on the investment.

In order to obtain a spray transfer, which is the best mode to provide excellent wetting in of the bead
and to minimize spatter, high Argon gas mixtures are required. Although high percentages of Argon
in the shielding gas reduce fumes generation these types of shielding gases also generate more
heat and higher amounts of radiant light. Water-cooled welding guns as well as protection from not
only the arc, but also reflected light are essential for a safe work place. This is another reason
automated systems help in maximizing the benefits of metal cored wires. They are not as
susceptible as a welder to the effects of the additional heat and radiant light generated.

To gain all position capability with a metal cored wire, like the solid MIG wires, either a short arc
transfer mode or pulse mode is required. Short arc would be eliminated due to the significant drop in
deposition rate, deposition efficiency and increase in spatter. Most pulse machines do not contain a
program specifically for metal cored wires. Although not absolutely necessary, the development of a
synergic curve and pulse parameters does enhance the performance of a metal cored wire. If
existing equipment is not able to pulse or does not have a pulse program specifically for metal cored
wires and the desire to enhance the arc and operability is there, the equipment manufacturer will
have to make adjustments and program modification to the power source. Depending upon the
machine manufacturer, these adjustments may be able to be made to the current power sources.

A significant increase in productivity and through put in one station will be negated if the subsequent
stations down the line cannot handle the additional parts. It would not be an advantage to increase
productivity by 30-40% in a weld station if the station is only operated 50-60% of the time due to
parts backing up. Payback on the investment would be extended to the point of being unattractive to
most. When considering the increase in parts per hour that can be achieved from changing to the
higher productivity metal cored process, the stations down the line from the operation also need to
be considered as far as their capability of handling the increase from productivity gains.

Conclusion
The industry to a large extent still views metal cored wires as being somewhat Marketing smoke and
mirrors. It is sometimes very hard to understand how a product that has a higher cost per pound as a
filler metal will actually save money when evaluated as cost per pound deposited, or the true cost for
the welding application. It is not until actual results are obtained that the reality of what can be
achieved is believed. It is human nature to believe what is in front of our eyes rather than what
someone is promoting today. Trying metal cored wires in your application could result in significant
improvement in productivity. Evaluating the total picture should result in being able to identify
specific benefits over the consumables that may be currently being used. Among these benefits,
which translate into cost savings, are high deposition rates, high deposition efficiencies, high duty
cycles, high travel speeds, low slag volume and low spatter. In addition, the newer technology
offered by manufacturers would give the operators the added benefit of lower fume generation rate
for a safer, healthier weld environment. Metal cored wires can be a benefit regardless of whether
they are used in a hand held operation or in an automated weld station. From hand held to simple
automation to a full multi-process robot, metal cored wires can and do offer benefits over other
 choices in consumables.

About The Author

Dwight Myers is the Director of Marketing, Filler Metals for ESAB Welding and Cutting Products and
is responsible for the product management and global marketing of all North American produced
filler metal products for all welding processes. He has served in postions of Research and
Development, Product Management and Marketing in his 33 years with the company.

How metal-cored wires reduce hidden

welding costs
Spending a bit more on wire can make certain applications more
productive
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
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

  By Amanda D'Arcy 
 
  April 3, 2012
 
  Article
 
  Arc Welding
 
  Join Discussion

In the right applications, metal-cored wire may help companies eliminate hidden costs in the
welding operation.

When making decisions about the fabrication process, fabricators have begun to look not just at
the costs incurred in the weld cell, but also at the total cost of the welding operation—and rightly
so.

Pre- and postweld activities, product flow, inventory management, and the equipment itself all
affect quality, productivity, and profitability. The filler metal is important, too, as it can create
costs in many ways that may not be immediately apparent. These hidden costs can mean the
difference between maintaining a gainful, competitive welding operation and trying to keep up
with the rest of the industry.
Since the 1970s metal-cored wire has been an option for a range of applications, including
those involving mild and low-alloy steels. And in recent years metal-cored wire has undergone
significant advancements, partly because it is readily alloyed to match different materials.

Metal-cored Wire Basics

Metal-cored wire consists of a hollow metal sheath filled with metallic powders, alloys, and arc
stabilizers, each of which offers distinct benefits such as lowering oxidation, providing higher
impact strengths, and reducing silicon deposits in the final weld. This mechanical and chemical
structure causes the wire to operate differently than solid wires, which are solid throughout the
entire cross section. It also generates different arc and weld profile characteristics. At equivalent
amperage settings, metal-cored wires also carry higher current densities.

The American Welding Society classifies metal-cored wires by tensile strength, gas
requirements, and weld deposit chemistry according to impact strength. Consider E70C-6M H4.
The E refers to electrode and 70 refers to tensile strength (70,000 PSI). C indicates a composite
metal-cored wire (not a solid wire); -6 indicates that the weld deposit chemistry offers impact
strength—that is, Charpy impact test of 20 foot-pounds—down to -20 degrees F. (The other
option, -3, indicates that the wire offers 20 ft.-lbs. of impact strength down to 0 degrees F). The
M refers to the gas requirements (signifying a mixture of CO2 and argon; C signifies that the
wire calls for 100 percent CO2); and H4 indicates the maximum amount (in milliliters) of
hydrogen per 100 grams in a weld deposit (in this case, 4 ml).

During the welding process, metal-cored wire carries the current through the outside metal
sheath, resulting in a broad, conical arc (see Figures 1 and 2) that creates a wide penetration
profile and is capable of bridging gaps in the weld joint. The conical-shaped arc also helps
create a wide weld bead profile that can help prevent melt-through on thin-gauge material. The
wire operates in the spray transfer mode, during which it creates very small droplets that deposit
in the weld puddle but generate little to no spatter.

Companies can use metal-cored wire for single or multipass welding in the flat, horizontal, and
vertical-down positions. Using a standard constant-voltage power source, welders also can use
the wires in the overhead position. Welding with metal-cored wire in the vertical-up position
tends to be slower than welding with other types of wires, and requires a power source with
pulsing capabilities because the weld puddle is quite fluid. In most cases, metal-cored wire uses
a high-argon shielding gas mixture (at least 75 percent argon is recommended, blended with a
balance of CO2) and is typically available in diameters from 0.035 to 5/64 inch.

Metal-cored wire has a high burnoff rate that provides fast travel speeds and high deposition
rates. For the right application, the wire also helps minimize defects such as porosity,
incomplete fusion, and undercut.

The Right Applications

Just like any welding technology, metal-cored wire is not a cure-all. It is suitable for certain
applications, such as heavy equipment manufacturing, railcar fabrication, and food and
petrochemical fabrication. The technology also works well for automotive exhaust fabrication
and wheel and chassis manufacturing. The wire excels in these applications largely because it
can be alloyed for almost every type of steel, from mild and stainless to low-alloy.
Metal-cored wire often can be used as an alternative to certain submerged-arc or gas-shielded,
flux-cored wire applications. It also can be used in many of the same applications that employ
solid wire. Other areas where metal-cored wire works well include work prone to burn-through,
piping, or other components on which poor fit-up occurs. Applications requiring aesthetic bead
appearances also may be good candidates.

Figure 1: Metal-cored wire produces a broad, cone-shaped arc capable of bridging gaps in the
weld joint.

Reducing Hidden Costs

Given its structure and broad penetration profile, metal-cored wire can weld aptly on thin
material without burning through and also provide good deposition rates on thick materials. This
means that one metal-cored wire diameter can weld various material thicknesses—especially
0.25 in. and thicker, which often makes it possible for fabricators to standardize on a single wire
diameter throughout the welding operation. This can help minimize inventory and the time
associated with managing it and reduce downtime for wire changeover.

The metal-cored wire lowers hidden costs in other ways. Because it contains added deoxidizers
it can weld through mill scale and rust, still with very little spatter. The broader arc also provides
some cleaning action. As a result, it helps eliminate activities like grinding, sandblasting, and
applying antispatter before welding.

It also reduces the need to degrease materials before welding. Not surprisingly, such preweld
activities often cause bottlenecks that adversely affect throughput, reducing an operation’s
overall productivity and profitability. This also adds to expenses for abrasives (grinding wheels
or sanding discs) and grinding equipment.

Such work may generate costs for additional labor and could lead to costly health and safety
problems. For example, grinding may cause more operator fatigue and repetitive-stress injuries
that could increase insurance costs. Preweld activities like antispatter application also can result
in downtime for cleanup, because antispatter solution is notoriously messy and frequently needs
to be cleaned off equipment and floors.

Because metal-cored wire can minimize defects such as undercut and incomplete fusion,
fabricators may be able to reduce reject rates, as well as rework in postweld areas. Fewer
postweld operations may increase part flow of completed parts to other stages of production,
such as painting or coating. In some cases, eliminating certain pre- or postweld functions allows
companies to reallocate labor elsewhere in the welding operation to produce more parts and
increase overall productivity.

In the welding cell, the fast travel speeds and high deposition rates that metal-cored wire
provides frequently increase productivity. Improvements are most often seen in robotic and
automatic welding, but measurable productivity gains also can occur in semiautomatic
applications.

The Big Picture

Metal-cored wire typically costs more than solid wire, but the benefits often offset the per-unit
price. In reality, any consumable comprises a relatively small portion of overall welding costs; in
fact, material and labor make up the lion’s share of welding expenditures. But in the right
application, an increase in filler metal costs may lead to greater savings elsewhere.

When considering metal-cored consumables, fabricators should thoroughly assess their existing
welding operations to ensure a conversion is justified. A good first step is to identify bottlenecks
in productivity caused by pre- or postweld activities, and calculate the costs for labor and
equipment associated with them.

Companies should analyze current part quality; the cost associated with weld defects like
undercut or incomplete fusion; the cost of rejected parts; and how these problems affect overall
production rates. If any or all of these are unnecessarily high or just higher than desired, further
investigation into metal-cored wires may be warranted. Such assessments set a good baseline
for improvement and can help fabricators gauge the potential for productivity and cost
improvements.
Figure 2: Metal-cored wire carries the current through the outside metal sheath to create a wide
penetration profile. The wire also operates in the spray transfer mode, during which it creates
very small droplets that deposit in the weld puddle but generate little to no spatter.

The flux-cored arc welding process (FCAW or FCA) is made possible by the
design of the electrode.
This inside-outside electrode consists of a metal sheath surrounding a core of
fluxing and alloying compounds.

The compounds contained in the electrode perform essentially the same

functions as the coating on a covered electrode, i.e., deoxidizers, slag formers,
arc stabilizers, alloying elements, and may provide shielding gas.

There are three reasons why flux-cored welding wires are developed to

supplement solid electrode wires of the same or similar analysis.
1. There is an economic advantage. Solid wires are drawn from steel billets
of the specified analyses. These billets are not readily available and are
expensive. A single billet might also provide more solid electrode wire than
needed. In the case of cored wires, the special alloying elements are
introduced in the core material to provide the proper deposit analysis.
2. The tubular wire production method provides the versatility of composition
and is not limited to the analysis of available steel billets.
3. Tubular electrode wires are easier for the flux core welder to use than solid
wires of the same deposit analysis, especially for welding pipe in the fixed
position.
Flux Cored Welding Basics Video

Flux-Cored Electrode Design

Flux-Cored Electrode Design

The sheath or steel portion of the flux-cored wire comprises 75 to 90 percent of
the weight of the electrode, and the core material represents 10 to 25 percent of
the weight of the electrode.

For a covered electrode, the steel represents 75 percent of the weight and the
flux 25 percent. This is shown in more detail below:

More flux is used on covered electrodes than in a flux-cored wire to do the same
job. This is because the covered electrode coating contains binders to keep the
coating intact and also contains agents to allow the coating to be extruded.

Self-Shielding Flux-Cored Electrodes

The self-shielding type flux-cored electrode wires include additional gas forming
elements in the core. These are necessary to prohibit the oxygen and nitrogen of
the air from contacting the metal transferring across the arc and the molten weld
puddle.

Self-shielding electrodes also include extra deoxidizing and denigrating elements

to compensate for oxygen and nitrogen which may contact the molten metal.
Self-shielding electrodes are usually more voltage-sensitive and require electrical
stickout for smooth operation. The properties of the weld metal deposited by the
self-shielding wires are sometimes inferior to those produced by the externally
shielded electrode wires because of the extra amount of deoxidizers included.

It is possible for these elements to build up in multipass welds, lower the ductility,
and reduce the impact values of the deposit. Some codes prohibit the use of self-
shielding wires on steels with yield strength exceeding 42,000 psi (289,590 kPa).
Other codes prohibit the self-shielding wires from being used on dynamically
loaded structures.

Metal Transfer
Metal transfer from consumable electrodes across an arc has been classified into
three general modes. These are:

 Spray transfer
 Globular transfer
 Short circuiting transfer
The metal transfer of flux-cored electrodes resembles a fine globular transfer. On
cored electrodes in a carbon dioxide shielding atmosphere, the molten droplets
build up around the outer sheath of the electrode. The core material appears to
transfer independently to the surface of the weld puddle.

At low currents, the droplets tend to be larger than when the current density is
increased. Transfer is more frequent with smaller drops when the current is
increased. The larger droplets at the lower currents cause a certain amount of
splashing action when they enter the weld puddle. This action decreases with the
smaller droplet size.

This explains why there is less visible spatter, the arc appears smoother to the
welder, and the deposition efficiency is higher when the electrode is used at high
current rather than at the low end of its current range.

Mild Steel Electrodes

Carbon steel electrodes are classified by the American Welding Society
specification, “Carbon Steel Electrodes for Flux-cored-Arc Welding”. This
specification includes electrodes having no appreciable alloy content for welding
mild and low alloy steels.

The system for identifying flux-cored electrodes follows the same pattern as
electrodes for gas metal arc welding, but is specific for tubular electrodes. For
example, in E70T-1, the E indicates an electrode; 70 indicates the required
minimum as-welded tensile strength in thousands of pounds per square inch
(psi); T indicates tubular, fabricated, or flux-cored electrode; and 1 indicates the
chemistry of the deposited weld metal, gas type, and usability factor.

Classification Of Flux-Cored Electrodes

1. E60T-7 electrode classification. Electrodes of this classification are used
without externally applied gas shielding and may be used for single-and
multiple-pass applications in the flat and horizontal positions. Due to low
penetration and to other properties, the weld deposits have a low
sensitivity to cracking.
2. E60T-8 electrode classifications. Electrodes of this classification are
used without externally applied gas shielding and may be used for single-
and multiple-pass applications in the flat and horizontal positions. Due to
low penetration and to other properties, the weld deposits have a low
sensitivity to cracking.
3. E70T-1 electrode classification. Electrodes of this classification are
designed to be used with carbon dioxide shielding gas for single-and
multiple-pass welding in the flat position and for horizontal fillets. A quiet
arc, high-deposition rate, low spatter loss, flat-to-slightly convex bead
configuration, and easily controlled and removed slag are characteristics of
this class.
4. E70T-2 electrode classification. Electrodes of this classification are used
with carbon dioxide shielding gas and are designed primarily for single-
pass welding in the flat position and for horizontal fillets. However,
multiple-pass welds can be made when the weld beads are heavy and an
appreciable amount of mixture of the base and filler metals occurs.
5. E70T-3 electrode classification. Electrodes of this classification are used
without externally applied gas shielding and are intended primarily for
depositing single-pass, high-speed welds in the flat and horizontal
positions on light plate and gauge thickness base metals. They should not
be used on heavy sections or for multiple-pass applications.
6. E70T-4 electrode classification. Electrodes of this classification are used
without externally applied gas shielding and may be used for single-and
multiple-pass applications in the flat and horizontal positions. Due to low
penetration, and to other properties, the weld deposits have a low
sensitivity to cracking.
7. E70T-5 electrode classification. This classification covers electrodes
primarily designed for flat fillet or groove welds with or without externally
applied shielding gas. Welds made using-carbon dioxide shielding gas
have better quality than those made with no shielding gas. These
electrodes have a globular transfer, low penetration, slightly convex bead
configuration, and a thin easily removed slag.
8. E70T-6 electrode classification. Electrodes of this classification are
similar to those of the E70T-5 classification but are designed for use
without an externally applied shielding gas
9. E70T-G electrode classification. This classification includes those
composite electrodes that are not included in the preceding classes. They
may be used with or without gas shielding and may be used for multiple-
 pass work or may be limited to single-pass applications. The E70T-G
electrodes are not required to meet the chemical, radiographic, bend test,
or impact requirements; however, they are required to meet tension test
requirements. Welding current type is not specified.
The flux-cored electrode wires are considered to be low hydrogen since the
materials used in the core do not contain hydrogen. However, some of these
materials are hygroscopic and thus tend to absorb moisture when exposed to a
high-humidity atmosphere.

Electrode wires are packaged in special containers to prevent this. These

electrode wires must be stored in a dry room.

Stainless Steel Tubular Wires

Flux-cored tubular electrode wires are available which deposit stainless steel
weld metal corresponding to the A.I.S.I. compositions. These electrodes are
covered by the A.W.S specification, “Flux-Cored Corrosion Resisting Chromium
and Chromium-Nickel Steel Electrodes.” These electrodes are identified by the
prefix E followed by the standard A.I.S.I. code number. This is followed by the
letter T indicating a tubular electrode. Following this and a dash are four-possible
suffixes as follows:

 1 indicates the use of C02 (carbon dioxide) gas for shielding and DCEP.
 2 indicates the use of argon plus 2 percent oxygen for shielding and
DCEP.
 3 indicates no external gas shielding and DCEP.
 G indicates that gas shielding and polarity are not specified.
Tubular or flux-cored electrode wires are also used for surfacing and submerged
arc welding applications.

Deposition Rates And Weld Quality

The deposition rates for flux-cored electrodes are shown in figure 8-2 below.
These curves show deposition rates when welding with mild and low-alloy steel
using direct current electrode positive.

Two types of covered electrodes are shown for comparison. Deposition rates of
the smaller size flux-cored wires exceed that of the covered electrodes. The
metal utilization of the flux-cored electrode is higher. Flux-cored electrodes have
a much broader current range than covered electrodes, which increases the
flexibility of the process.
The quality of the deposited weld metal produced by the flux-cored arc welding
process depends primarily on the flux-cored electrode wire that is used. It can be
expected that the deposited weld metal will match or exceed the properties
shown for the electrode used. This assures the proper matching of base metal,
flux-cored electrode type and shielding gas.

Quality depends on the efficiency of the gas shielding envelope, on the joint
detail, on the cleanliness of the joint, and on the skill of the welder.

The quality level of weld metal deposited by the self-shielding type electrode
wires is usually lower than that produced by electrodes that utilize external gas
shielding.