Myth #2: Gas-shielded flux-cored wires are not suitable for outdoor applications. This in turn reduces weld failures and rework, and lowers overall production costs. At current loads and wire diameters that cause a typical solid wire to become too fluid and run out of the joint, the slag system and arc cone of a gas-shielded flux-cored wire under the same conditions allows it to remain in the joint and achieve better tie-in to the side walls. The benefits of gas-shielded flux-cored wire over solid wire are further amplified in vertical up applications. A 1.4 mm wire can deposit 4.9kg of wire per hour, for a 71 percent increase in productivity or 8.1kg of wire more per day than with a 1.2 solid wire. Given that labour accounts for roughly 80 percent of a welding operation’s costs, the potential for increased profitability becomes very substantial.įurther, a 1.4 mm gas-shielded flux-cored E71T-1C H8 wire can often be used in applications where 1.2 solid wire is being used. If a welding operator averages four hours of arc time per day, that equals 4.8kg more wire deposited per day or a productivity improvement of over 41 percent with the flux cored wire. A comparable 1.2 diameter ER70S-6 solid wire can deposit up to 2.8kg/h of wire at the same amperage. This increases deposition rates and allows welding operators to use larger diameter wires than would be possible with solid wire.įor example, a 1.2 gas-shielded flux-cored wire in the AWS class E71T-1C H8 can deposit 4kg/h of wire in the flat position. The slag system of flux cored wires allows them to be welded at higher amperages than solid wire without the weld puddle becoming too fluid. Although gas-shielded flux cored wire costs more than solid wire, the productivity gains possible with it can significantly outweigh the marginal increase in cost. As it stands, however, filler metal is only a minor cost in the overall welding operation. Truth: If filler metal were the only expense in a welding operation, this statement would be true. Myth #1: Gas-shielded flux-cored wire is more expensive than solid wire. Below, we identify and “bust” four common myths about this often misunderstood filler metal. Armed with this information we hope you will be able to make informed choices when selecting welding wires and take notice the of the benefits when using flux cored wire on your next job. Unfortunately, the myths surrounding this type of wire often obscure the benefits and prevent companies from considering it as a viable option for their welding operations. Still, there are very good reasons for using gas-shielded flux cored wire. On the other, you have to contend with the portability and location limitations of using an external shielding gas. On the one hand, you have to deal with the headaches of chipping slag. The myths surrounding Flux Cored wire often obscure the substantial benefits it offers.Īt first glance, gas-shielded flux cored welding might seem like the most troublesome filler metal to use.
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