Metal Cored Welding Wire
Metal cored wires combine the high deposition rates of flux cored wires with the high efficiencies of solid wires to improve productivity.
Increases in travel speed of 25-40% are not unrealistic when converting from solid wire to a quality metal cored wire, whilst retaining weld integrity and appearance.
One of the biggest benefits of metal cored wires is the ability to reduce pre- and post-weld activities. Due to the flux components, they can weld through mill scale, dirt and debris, and have a greater tolerance of cold steels. With very little or no spatter, little clean up is needed - particularly good when doing multipass welding.
Metal cored wires are more tolerant of porosity-causing issues, such as moisture pick-up, or surface contaminates.
The best metal cored wires are easy to use with better penetration, which results in less weld defects due to operator technique.
MIG 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 on typical basic and synergic power sources, and keep the advantage over solid wires while welding with controlled waveforms (pulse, SpeedArc, SpeedUp, Power Wave, or similar programs).
Particular care needs to be taken when changing to fully synergic machines with the ability to run wires faster and harder, as solid wires are often then pushed outside the manufacturer's specifications and weld integrity is not maintained.
Finally, yes, metal cored wires do cost more on a per kg basis than solid or flux cored wires. However, in almost all applications, labour accounts for approximately 85% of the total cost of the welding work and the significant productivity increase gained by switching to metal-cored wire will out-weigh the increase in the filler metal cost.
In addition, a high quality metal-cored wire like KOBE MX-A70C6LF or NIPPON SM-3A runs much cleaner and smoother than solid wire - which means lower fume levels, less wear and tear on tips, liners, drive rollers, etc, leading to savings in other consumable costs as well.
Metal cored wires are not all equal in performance so it really does pay to trial before using.
Kobelco Welding (KW) and Nippon (NSSW) metal cored wires are the best quality available in the NZ market, call us to arrange a demonstration.
Faster, more efficient, better quality welding will decrease the largest cost component of your work – Labour.