Systems and methods for the manufacture of a solid wire using additive manufacturing techniques are disclosed. In one embodiment, a fine powdery material is sintered or melted or soldered or metallurgically bonded onto a metal strip substrate in a compacted solid form or a near-net shape (e.g., a near-net solid wire shape) before being turned into a final product through forming or drawing dies.

A tubular welding electrode for arc welding that has improved crack resistance comprises a steel sheath disposed around a granular powder flux fill core. The granular powder flux fill core comprises magnesium oxide and a sulfur source such as iron sulfide.

In various embodiments, metallic wires are fabricated by combining one or more powders of substantially spherical metal particles with one or more powders of non-spherical particles within one or more optional metallic tubes. The metal elements within the powders (and the one or more tubes, if present) collectively define a high entropy alloy of five or more metallic elements or a multi-principal element alloy of four or more metallic elements.

A wire for welding different types of materials and a method of manufacturing the same that enable suppressing the occurrence of non-uniform filling with flux while reducing the flux filling rate are provided. A conductive core wire material and a metal outer skin material are made of aluminum or aluminum alloy. A flux paste is applied to the surface of the conductive core wire material to form a coated conductive core wire material including a coating layer, or a flux paste is applied to the inner surface of the metal outer skin material to form a coated metal outer skin material including a coating layer. A tubular metal outer skin material is formed. The conductive core wire is disposed inside to form a wire for drawing. The flux is disposed as distributed over the longitudinal and circumferential directions of the wire after a solvent in the coating layer is removed.

The disclosure relates generally to welding and, more specifically, to tubular welding wires for arc welding processes, such as Gas Metal Arc Welding (GMAW), Flux Core Arc Welding (FCAW), and Submerged Arc Welding (SAW). The tubular welding wire includes a metal sheath surrounding a granular core. The metal sheath includes greater than approximately 0.6% manganese by weight and greater than approximately 0.05% silicon by weight. Further, the metal sheath has a thickness of between approximately 0.008 inches and approximately 0.02 inches.

A bonding member that includes a base material that has a spiral shape when viewing a cross section thereof orthogonal to a longitudinal direction thereof, and contains a low melting point metal; and a coating film in a gap between opposed surfaces of the base material when the base material is in the spiral shape. The coating film contains metal particles of a high melting point metal that forms an intermetallic compound having a melting point higher than that of the low melting point metal by reaction of the high melting point metal with a melt of the low melting point metal. The low melting point metal is, for example, Sn or a Sn alloy. The high melting point metal is, for example, a CuNi alloy, a CuMn alloy, a CuCr alloy, or a CuAl alloy.

Systems and methods for low-manganese welding alloys are disclosed. An example arc welding consumable that forms a weld deposit on a steel workpiece during an arc welding operation, wherein the welding consumable comprises: less than 0.4 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, wherein the grain control agents comprise greater than 0.06 wt % and less than 0.6 wt % of the welding consumable, wherein the weld deposit comprises 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, that is at least 22%, and a Charpy V-notch toughness greater than or equal to 20 ft-lbs at 20 F., and wherein the welding consumable provides a manganese fume generation rate less than 0.01 grams per minute during the arc welding operation.

An electrode in which the metallurgical structure of the active surface includes incoherent chromium precipitates, more than 90% of which have a surface of projection of less than 1 m.sup.2, the incoherent chromium precipitates having a size at least between 10 and 50 nm. The electrode further has a fibrous structure that is visible in a cross-section of the active surface of the electrode following surfacing and chemical etching. The fibrous structure includes a plurality of radial fibers having a thickness of less than 1 mm and of a substantially central fiberless region that has a diameter of less than 3 mm. The electrical conductivity of the electrode is greater than 85% IUPAC. The method for obtaining the electrode in a continuous casting process as well as to a use of the electrode in a resistive spot welding process.

A weld wire of the present invention comprises a steel sheath encapsulating a fluxed core having a combination of fluxing compounds and alloying elements. The fluxing compounds comprise up to 2% Wt of fluoride compounds and up to 49% Wt of oxide compounds. The alloying elements comprise Mn, Ni, Co, Ti and up to about 0.98% Wt of C. The amount of Co is sufficient to produce a ferrite-bainite weld metal morphology of a resulting weld. A yield strength of the resulting weld was measured from about 95 ksi to about 111 ksi.

This disclosure relates generally to Gas Metal Arc Welding (GMAW) and, more specifically, to Metal-cored Arc Welding (MCAW) of mill scaled steel workpieces. A metal-cored welding wire, including a sheath and a core, capable of welding mill scaled workpieces without prior descaling is disclosed. The metal-cored welding wire has a sulfur source that occupies between approximately 0.04% and approximately 0.18% of the weight of the metal-cored welding wire, and has a cellulose source that occupies between approximately 0.09% and approximately 0.54% of the weight of the metal-cored welding wire.