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  • Deposition Rate by Wire Type

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    Alex Gigena
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    A Deposition Rate by Wire Type common question in the field is which wire type will provide the best deposition rate. In one of our earlier posts “Calculating Deposition Rate for Solid Wires” we discussed deposition rates strictly for solid wires. Here we will talk about deposition rates across wire types – mainly solid wire, metalcored wire and fluxcored wire.

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    A Deposition Rate by Wire Type common question in the field is which wire type will provide the best deposition rate. In one of our earlier posts “Calculating Deposition Rate for Solid Wires” we discussed deposition rates strictly for solid wires. Here we will talk about deposition rates across wire types – mainly solid wire, metalcored wire and fluxcored wire.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    17 views2 pages

    Deposition Rate by Wire Type

    Uploaded by

    Alex Gigena
    A Deposition Rate by Wire Type common question in the field is which wire type will provide the best deposition rate. In one of our earlier posts “Calculating Deposition Rate for Solid Wires” we discussed deposition rates strictly for solid wires. Here we will talk about deposition rates across wire types – mainly solid wire, metalcored wire and fluxcored wire.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    Deposition Rate by Wire Type

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    A commonquestioninthefieldiswhichwiretypewillprovidethebestdepositionrate.
    InoneofourearlierpostsCalculatingDepositionRateforSolidWireswediscussed
    depositionratesstrictlyforsolidwires.Herewewilltalkaboutdepositionratesacrosswire
    typesmainlysolidwire,metalcoredwireandfluxcoredwire.

    Weseedifferentfabricatorsbuildingthesameproductandeachusesadifferenttypeof
    wire.Theyallclaimthattheyuseaparticularwirebecauseitprovidesthebestdeposition
    rateandthushigherproductivity.Strangelyenough,theymayallbecorrect.

    Thetruthofthematteristhattheanswertowhichwiretypeprovidesthehighestdeposition
    rateisnotbasedonthewireitselfbutratherontheapplicationandontheuser.Ifwelook
    strictlyatdepositionrateofaspecificdiameterataspecificwirefeedspeedthensolidwire
    wouldbethewinnereverytimeastheimagebelowshows.

    Comparisonofdepositionratesatdifferentwirefeedspeedsanddiamterforthethreewiretypes

    However,ifwearetryingtoachievethehighestdepositionratetheapplicationandwelder
    skillcomeintoplay.
    Herearethreeexamplesofwhytheapplicationisthedeterminantfactor:

    1. SheetMetalLapJointstoachievethehighestdepositionratesolidwireisthe
    probablewinner.Alotofmanufacturerswilluseasmalldiametermigwireforthis
    application.Thisisbecauseoncethewirereachesitssaturationpoint(maximum
    currentdensity)itwillnotpenetratefurther,andanyincreaseinWFSisstrictlyan
    increaseindepositionrate.Fluxcoredwireswillpenetratemorethanasolidwireat
    thesameamperageandwilltypicallyblowthroughthinmaterialbeforeitreachesits
    saturationpoint.

    2. VerticalUpHeavyFabWeldsWhenweldingoutofpositionnothingwillachievea
    higherdepositionratethanfluxcoredwire.Thisisbecausetheslagsystemwillcarry
    alargerpuddle.Theslagactsasashelfthatcarriesthepuddleandpreventsitfrom
    spilling.Pulseproceduresareabletoincreaseoutofpositiondepositionratesfor
    solidandmetalcoredwires,butnowherenearwhatwegetoutoffluxcoredwires.

    3. FlatGroveWeldsonMaterialwithHeavyMillScaleMetalcoredwireisthewinner
    here.Itsabilitytodealwithmillscaleandprovidesmoothnessatthetoesallows
    metalcoredwirestoshineinthisapplication.Solidwirewillprobablyrequireyouto
    slowdowntoinsuretherearenowelddiscontinuitiescausedbythemillscale.Flux
    coredwiresarebestonmillscale,butwiththeirlowerefficiencies(lossofmaterialin
    theformofslag)willresultinlowerdepositionrates.

    Aswithmanythingsinweldingapplicationsthereareexceptions,butingeneralthisiswhat
    ourobservationsinthefieldsupport.

    Whatisyourchoiceofwiretype?

    Categories:Theory and Education,Welding Costs Comments (0)

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