and cannot be welded vertical-up or overhead unless you have a machine capable of pulsed welding.
Also, because of the higher current density of the
wire, the melt-off rate is greater and results in poor
performance in vertical-down welding positions. You
would likely need to have another process for those
Flux-cored wires can provide a one-wire solution
but may not be the most economical for your situation. These wires can be used in most applications,
but they produce lower deposition efficiencies and
generate more fumes, which may not be desirable
based on your shop’s ventilation system.
Now let’s compare speed and efficiency. Choosing a solid wire versus a metal-cored wire versus a
flux-cored wire, can have a significant impact on
speed and efficiency. Metal-cored and flux-cored
wires have a higher current density compared to
solid wire of the same diameter. This means you can
increase the wire feed speed (WFS) for the metal-cored or flux-cored wire while maintaining the same
heat input as the solid wire.
Compared to solid wire, metal-cored wires allow
for faster travel speeds and higher deposition rates
at similar voltage and amperage since they both
have efficiencies in the 92 to 99 percent range.
However, cored wires have more manufacturing
steps involved to produce them, which adds to the
cost, so the payback may not be there depending
upon your situation.
Flux-cored wires typically have an efficiency of
around 86 percent because of the nonweld metal
slag that has to be removed after each weld pass.
The deposition rate will be lower based on its efficiency and the time it takes for the operator to
remove slag. For this reason, flux-core wires are not
typically used in robotic applications.
To answer your original question, there may not
be one wire or process solution for your shop. If a
majority of the steel is relatively clean, then staying
with your current GMAW process is probably your
best bet. If you are not already doing so, using two
wire diameters may provide you the best optimization of applications.
wanted a positioner
to fabricate boats.
Capacity: 35,000 pounds
75 ft. long by 14 ft.
wide with 92" of
Tolerance: Less than one
inch of center deflection
• Labor per boat cut
from 6,000 hours to
• Improved ergonomics
• Higher PROFITS
ChesapeakeAd_Fab062017.indd 1 6/27/2017 3:09:07PM