Solid Vs. Flux Cored vs. Metal Cored Wire

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I received this email from ESAB. I found it interesting and thought it would help others.There is no one-size-fits-allwelding solution, and many variables will affect your decision to use solid,flux cored or metal cored wire. All three wires can work with a range ofshielding gases depending on the application and desired performance.For shielding gases, argonand carbon dioxide blends are the most common. The more argon in the blend, themore expensive it is. On the plus side, a high-argon blend achieves bettermechanical performance, generates less fumes, and typically appeals more to operators.Carbon dioxide, a lessexpensive gas, will provide the broadest penetration profile, provide the bestcleaning action but slightly lower mechanical test results, and generate morewelding fume.For a solid wire, the classification andshielding gas will have the most significant impact on performance. In mostapplications, base materials have a light layer of mill scale, light rust, orpickling oil which, if not removed before welding, can affect weldingperformance.In this case, it is ideal touse an ER70S-6 wire with a 90% argon/10% carbon dioxide blend shielding gas.The electrode's deoxidizers combined with the 10% carbon dioxide should provideadequate cleaning action and produce a weld with a good appearance,penetration, and smooth toe transitions.When working on materialsless than 3/16-inch thick down to thin sheet metal (24 gauge), solid wire willproduce a clean looking weld. If you are welding on higher-strength steels, besure you match the appropriate filler metal to the lowest-strength basematerial for that specific application.Metal cored wires are another option for flat or horizontal weld applications.These wires run very similar to solid wires except they do not run in theshort-circuiting mode and cannot be welded vertical-up or overhead unless youhave a machine capable of pulsed welding.Also, because of the highercurrent density of the wire, the melt-off rate is greater and results in poorperformance in vertical-down welding positions. You would likely need to haveanother process for those applications.Flux cored wires, on the other hand, can provide a one-wire solution but are notalways the most economical. These wires can be used in a wide range ofapplications, but they produce lower deposition efficiencies and generate morefumes.However, flux cored wiretypically has the ability to handle the welding of dirtier materials that mayhave higher levels of rust, mill scale or oil. When compared to solid wire, flux cored wire also increasespenetration on the sidewalls and offers the advantage of better depositionrates due to larger wire diameters commonly utilized.Other key considerations whenit comes to choosing solid wire versus a metal cored wire versus a flux coredwire? Speed and efficiency.Metal-cored and flux coredwires, for instance, have a higher current density compared to solid wire ofthe same diameter. This means you can increase the wire feed speed (WFS) forthe metal cored or flux cored wire, while maintaining the same amperage as thesolid wire. Compared to solid wire, metalcored wires allow for faster travel speeds and deposition rates at similarvoltage and amperage since they both have efficiencies in the 92 to 99% range.However, cored wires have more manufacturing steps involved to produce them,which adds to the cost.Flux cored wires typicallyhave an efficiency of around 86% because of the non-weld metal slag that has tobe removed after each weld pass. The deposition rate will be lower forequivalent wire diameters based on its efficiency and the time it takes for theoperator to remove slag.Overall, evaluate the totalpicture when deciding which wire to use. Look at cost savings, depositionrates, deposition efficiencies, duty cycles, travel speeds, slag volume, andspatter to make an informed choice that maximizes productivity and performance.Lincoln 330MPXLincoln Power Mig 256Lincoln LN-25X Wire FeederMagnum PRO 250LX GT Spool GunLincoln AC/DC 225¼ Ton of Torches OFC-A OFG-AAir Carbon Arc Gouging CAC-AEverlast 62i Plasma CutterIngersoll Rand T-30 14hpInstagram: #Freebird Welds
Reply:Back late 1970's fluxcore with gas was advised replacement submerged arc.Fluxcore with no gas was advised replacemen for stick and higher speed. My experience with both they very fast compared to other types of welding (MIG, STICK and TIG)Dave

Originally Posted by Freebirdwelds

I received this email from ESAB. I found it interesting and thought it would help others.There is no one-size-fits-allwelding solution, and many variables will affect your decision to use solid,flux cored or metal cored wire. All three wires can work with a range ofshielding gases depending on the application and desired performance.For shielding gases, argonand carbon dioxide blends are the most common. The more argon in the blend, themore expensive it is. On the plus side, a high-argon blend achieves bettermechanical performance, generates less fumes, and typically appeals more to operators.Carbon dioxide, a lessexpensive gas, will provide the broadest penetration profile, provide the bestcleaning action but slightly lower mechanical test results, and generate morewelding fume.For a solid wire, the classification andshielding gas will have the most significant impact on performance. In mostapplications, base materials have a light layer of mill scale, light rust, orpickling oil which, if not removed before welding, can affect weldingperformance.In this case, it is ideal touse an ER70S-6 wire with a 90% argon/10% carbon dioxide blend shielding gas.The electrode's deoxidizers combined with the 10% carbon dioxide should provideadequate cleaning action and produce a weld with a good appearance,penetration, and smooth toe transitions.When working on materialsless than 3/16-inch thick down to thin sheet metal (24 gauge), solid wire willproduce a clean looking weld. If you are welding on higher-strength steels, besure you match the appropriate filler metal to the lowest-strength basematerial for that specific application.Metal cored wires are another option for flat or horizontal weld applications.These wires run very similar to solid wires except they do not run in theshort-circuiting mode and cannot be welded vertical-up or overhead unless youhave a machine capable of pulsed welding.Also, because of the highercurrent density of the wire, the melt-off rate is greater and results in poorperformance in vertical-down welding positions. You would likely need to haveanother process for those applications.Flux cored wires, on the other hand, can provide a one-wire solution but are notalways the most economical. These wires can be used in a wide range ofapplications, but they produce lower deposition efficiencies and generate morefumes.However, flux cored wiretypically has the ability to handle the welding of dirtier materials that mayhave higher levels of rust, mill scale or oil. When compared to solid wire, flux cored wire also increasespenetration on the sidewalls and offers the advantage of better depositionrates due to larger wire diameters commonly utilized.Other key considerations whenit comes to choosing solid wire versus a metal cored wire versus a flux coredwire? Speed and efficiency.Metal-cored and flux coredwires, for instance, have a higher current density compared to solid wire ofthe same diameter. This means you can increase the wire feed speed (WFS) forthe metal cored or flux cored wire, while maintaining the same amperage as thesolid wire. Compared to solid wire, metalcored wires allow for faster travel speeds and deposition rates at similarvoltage and amperage since they both have efficiencies in the 92 to 99% range.However, cored wires have more manufacturing steps involved to produce them,which adds to the cost.Flux cored wires typicallyhave an efficiency of around 86% because of the non-weld metal slag that has tobe removed after each weld pass. The deposition rate will be lower forequivalent wire diameters based on its efficiency and the time it takes for theoperator to remove slag.Overall, evaluate the totalpicture when deciding which wire to use. Look at cost savings, depositionrates, deposition efficiencies, duty cycles, travel speeds, slag volume, andspatter to make an informed choice that maximizes productivity and performance.