In various embodiments, additive manufacturing is utilized to fabricate three-dimensional metallic parts using metallic alloy wire as a feedstock material.

The invention relates to a method for producing a welding wire that includes the steps of providing a hollow wire, through at least part of which at least one cavity extends; producing the welding wire by introducing a welding material containing titanium aluminide or at least one nickel-based superalloy into the at least one cavity, the at least one cavity being evacuated or being filled with a protective gas before, during and/or after the introduction of the welding material, and the hollow wire being formed from nickel if the welding material contains the at least one nickel-based superalloy. Further aspects of the invention relate to a welding wire and to a component having at least one component region obtained by hardfacing using at least one such welding wire.

Provided is a flux-cored ring of a tubular brazing material enclosing flux that is formed into a ring by abutting both end portions in an extending direction of the tubular brazing material against each other. The flux-cored ring includes: in one of the both end portions of the brazing material, a pair of protruded portions protruding toward the other of the both end portions of the brazing material and opposed to each other in a direction orthogonal to the extending direction of the brazing material; and in the other of the both end portions of the brazing material, a pair of recessed portions fitting onto the protruded portions and opposed to each other in the direction orthogonal to the extending direction of the brazing material.

Systems and methods for low-manganese welding alloys are disclosed. An example arc welding consumable may comprise: between 0.4 and 1.0 wt% manganese; strengthening agents selected from the group consisting of nickel, cobalt, copper, carbon, molybdenum, chromium, vanadium, silicon, and boron; and grain control agents selected from the group consisting of niobium, tantalum, titanium, zirconium, and boron. The grain control agents may comprise greater than 0.06 wt% and less than 0.6 wt% of the welding consumable. The resulting weld deposit may comprise a tensile strength greater than or equal to 70 ksi, a yield strength greater than or equal to 58 ksi, a ductility (as measured by percent elongation) of at least 22%, and a Charpy V-notch toughness greater than or equal to 20 ft-lbs at -20° F. The welding consumable may provide a manganese fume generation rate less than 0.01 grams per minute during the arc welding operation.

The electrode for welding sheets of steel or aluminum, with a conductivity greater than or equal to 90% IACS and made of an alloy including, by weight based on the total weight of the alloy, chromium in a proportion higher than or equal to 0.1% and lower than 0.4%, between 0.02 and 0.04% of zirconium, lower than 0.015% of phosphorus, the remainder being copper and less than 0.1% of unavoidable impurities. The electrode structure advantageously includes incoherent chromium precipitates, more than 90% of which have a projected surface area of less than 1 μm.sup.2, the precipitates having a size of between 10 and 50 nm. The electrode has a fiber structure of radial fibers, each fiber having a thickness of less than 1 mm and a substantially central fibreless region that has a diameter of less than 5 mm. The invention also relates to a method for producing the electrode.

A flux-cored wire including a sheath and a flux that fills the sheath, wherein the flux includes a titanate and a nanoparticulate oxide selected from the group consisting of TiO.sub.2, SiO.sub.2, ZrO.sub.2, Y.sub.2O.sub.3, Al.sub.2O.sub.3, MoO.sub.3, CrO.sub.3, CeO.sub.2, La.sub.2O.sub.3 and mixtures thereof.

The present disclosure relates to a method for producing a tubular welding electrode comprising the steps of providing a strip of metal material having a length and first and second surfaces, wherein at least the first surface of the strip is at least substantially coated with nickel or a nickel alloy and then copper or a copper alloy, forming the strip into a “U” shape along the length, filling the “U” shape of the strip with a granular powder flux, and mechanically closing the “U” shape to form a sheath of nickel- and copper-coated metal material that substantially encases the granular powder flux, thus forming a tubular welding electrode. In certain embodiments, the metal material may be steel. In certain other embodiments, the metal material may be nickel or a nickel alloy, which may be at least substantially coated with copper or a copper alloy.

The invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). In one embodiment, a tubular welding wire for joining steel workpieces via arc welding includes a steel sheath disposed around a core. The core includes iron powder, iron titanium powder, silico-manganese powder, iron silicon powder, iron sulfide, graphite, rare earth compound, and a frit. The frit includes a Group I or Group II compound, silicon dioxide, and titanium dioxide. The graphite and the frit together comprise less than 10% of the core by weight.

The invention relates to a weld metal deposit having the following chemical composition: C: 0.08-0.10 wt % Mn: 1.30-2.00 wt % Si: 0.35-0.60 wt % Cr: 0.60-0.80 wt % Ni: 2.50-3.00 wt % Mo: 0.30-0.80 wt % V: 0.20-0.30 wt %
and optionally further components, in particular: Co: ≤0.02 wt % Ti: 0.01-0.02 wt % Al: ≤0.010 wt %,
Balance: iron as well as unavoidable impurities.

The invention relates generally to welding and, more specifically, to corrosion resistant weld deposits created during arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). A disclosed corrosion resistant weld deposit comprises nickel, chromium, and copper, and has a low porosity.