A welding or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

A plurality of welding torches, which are disposed in a welding device and are made movable in three-dimensional directions, are provided with welding wires that differ in composition and diameter from each other. When welding is performed in the horizontal direction, an arc is generated by at least two of the welding torches to form a bead while the welding wires are being fed. When welding is performed in the vertical direction, the arc is generated by any one welding torch of the two welding torches to form a bead while the welding wire is being fed. Thus, a steel sheet to which an anti-corrosion material has been applied can be welded continuously with high quality and high-efficiency in a horizontal orientation and vertical orientation.

Utilizing a hydrogen compound source as an arc stabilizer is counter-intuitive to standard formulation design practices which often strive to limit or eliminate hydrogen from the welding arc and weld pool. The present disclosure is directed to a tubular metal-cored welding electrode that comprises a metallic sheath disposed around a granular metal core in which the granular metal core comprises an alginate arc stabilizer (as a hydrogen compound source) configured to release hydrogen near a surface of a workpiece during welding. The tubular metal-cored welding electrode may further comprise primary de-oxidizers such as manganese and silicon. In certain embodiments, the amount of manganese in the tubular metal-cored welding electrode may be minimized or eliminated. The tubular metal-cored welding electrode may also comprise nickel or titanium.

The disclosed technology generally relates to welding, and more particularly to a consumable electrode wire for metal arc welding, and a method and a system for metal arc welding using the consumable electrode wire. In one aspect, a consumable welding wire configured to serve as an electrode during metal arc welding comprises one or more alkaline earth metal elements at a concentration between 0.005% and 10% on the basis of a total weight of the welding wire.

A welding system includes a welding power source configured to provide pulsed electropositive direct current (DCEP), a gas supply system configured to provide a shielding gas flow that is at least 90% argon (Ar), a welding wire feeder configured to provide tubular welding wire. The DCEP, the tubular welding wire, and the shielding gas flow are combined to form a weld deposit on a zinc-coated workpiece, wherein less than approximately 10 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

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.

A welding wire is disclosed including a ferrous metal welding material and a flux material including flux ingredients. The flux ingredients include, in weight percent based on the total weight of the welding wire: no greater than 1.91 aluminum, no greater than 1.02 manganese, less than 1.50 magnesium, and no greater than 0.02 rare earth metal oxide, where the rare earth metal oxide comprises at least 99 wt % cerium oxide based upon total weight of rare earth metal oxide. Resulting welds have a maximum diffusible hydrogen content of 5 mL/100 g or less. Resulting welds also have a Charpy V-notch toughness at 40 F. of at least 100 ft-lbs (135.6 Joules).

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.

It discloses a high-efficient energy-saving and surfacing layer well-forming self-shielded flux-cored welding wire. A low-carbon steel strip is used as an outer cover, and a flux core comprises the following components in percentage by mass: 42-60% high carbon ferrochrome with a particle size of 80 meshes, 10-18% ferrosilicon, 16-25% ferroboron, 2-8% rare earth silicon, 2-8% graphite, 1-4% aluminum magnesium alloy, 2-5% manganese powder and the balance of iron powder, wherein the graphite, the aluminum magnesium alloy and the manganese powder are all added with two particle sizes including 60 meshes and 200 meshes, and the weight of the flux core powder accounts for 49-53% of the total weight of the welding wire.

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.