A microporous tubular welding electrode having a length and a circumference may comprise a granular flux fill core extending substantially along the length of the electrode and a sheath extending substantially along the length of the electrode and substantially surrounding and substantially encasing the granular flux fill core. The sheath may comprise a plurality of pores distributed around the circumference and along the length of the microporous tubular welding electrode. The microporous tubular welding electrode may be formed by first creating a plurality of pores in a strip of material (such as a steel or aluminum alloy) using a process such as laser drilling or chemical etching. Second, the strip may be formed into a tubular welding wire electrode containing a core of a granular powder flux material.

Provided is a flux-cored wire with excellent welding workability, AW performance, and SR performance that can use both 100% CO.sub.2 gas and ArCO.sub.2 mixed gas as the shield gas in an initial layer welding for a structure body, particularly, a pipeline. The flux-cored wire with a flux filled into a steel outer sheath, includes, relative to the total mass of the wire: Mn: 1.5 to 3.1% by mass; Ni: 0.2% or more by mass and less than 1.00% by mass; at least one kind of Si, a Si alloy, and a Si oxide: 0.3 to 1.0% by mass in terms of Si; Ti: 0.05 to 0.29% by mass; C: 0.06 to 0.30% by mass; at least one kind of B, a B alloy, and a B oxide: 0.0030 to 0.0090% by mass in terms of B; and Fe: 91 to 97% by mass.

The present disclosure provides a thermal spray system and method that utilizes an exothermic reaction. The exothermic reaction creates substantial heat and provides increased diffusion and bonding between different components of the wire alloy during coating and solidifying. The disclosed exothermic reaction creates greater diffusion of boron and carbon within the coating, increases bond strength between different components and/or solidified droplets or splats of the coating, and increases bonding strength between the coating and the substrate. The resulting coating provides greater homogeneity of the coating chemistry and fewer micro-cracks. The exothermic reaction may be created by a particular alloy composition (such as powdered elements within a cored wire) that creates and maintains a higher droplet temperature. The exothermic reaction may be created by the use of an oxidizer and a fuel, such as iron oxide and aluminum, as well as other reactive elements causing an exothermic reaction.

This seamless wire containing welding flux is formed by filling a steel sheath with flux, the amount of Fe in the flux per total mass of the wire being 2-15 mass %, and the flux filling ratio being 10-30 mass %. When the amount (mass %) of Fe in the flux per total mass of the wire is X and the flux filling ratio (mass %) is Y, expression (1) is satisfied. By means of this seamless wire containing welding flux, variation in the flux cross-sectional area relative to the wire cross-sectional area, which is caused by a reverse airflow generated during a diameter reduction step, is reduced, and wire breakage during the diameter reduction step is prevented.

Y>2X+19(1)

The present disclosure relates to a method for producing a tubular welding electrode comprising the steps of providing a strip of copper-coated steel material having a length and first and second surfaces, wherein at least the first surface of the strip is at least substantially coated with 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 copper-coated steel material that substantially encases the granular powder flux, thus forming a tubular welding electrode.

This disclosure relates generally to welding and, more specifically, to electrodes for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW) of zinc-coated workpieces. In an embodiment, a welding consumable for welding a zinc-coated steel workpiece includes a zinc (Zn) content between approximately 0.01 wt % and approximately 4 wt %, based on the weight of the welding consumable. It is presently recognized that intentionally including Zn in welding wires for welding galvanized workpieces unexpectedly and counterintuitively alleviates spatter and porosity problems that are caused by the Zn coating of the galvanized workpieces.

Provided is a flux-cored wire for gas-shielded arc welding that contains, per wire total mass, specific amounts of C, Mn, TiO.sub.2 and specific amounts or less of P and S, and contains, in the flux, a specific amount of Ni per wire total mass. The Ni has a ratio (1/2) of 0.50-1.00 when 1 (mass %) is the content per wire total mass of particles having a size of 106 m or less and 2 (mass %) is the content per wire total mass of particles having a size exceeding 106 m.

A method of forming an additively manufactured aluminum part includes establishing an arc between a metal-cored aluminum wire and the additively manufactured aluminum part, wherein the metal-cored aluminum wire includes a metallic sheath and a granular core disposed within the metallic sheath. The method includes melting a portion of the metal-cored aluminum wire using the heat of the arc to form molten droplets. The method includes transferring the molten droplets to the additively manufactured aluminum part under an inert gas flow, and solidifying the molten droplets under the inert gas flow to form deposits of the additively manufactured aluminum part.

A self-shielded flux cored arc welding electrode is disclosed including a ferrous metal sheath and a core within the sheath enclosing core ingredients comprise a composition window of aluminum, manganese and rare earth metals in wires of about 2.0-3.0 wt. % [Al], 1.0-2.0 wt. % [Mn] and 0.001-0.11 wt. % rare earth metals or 0.001-0.5% rare earth metal oxides, such as, but not limited to, La, Ce, etc. Resulting welds include 0.7-1.0 wt. % [Al] and 1.1-1.5 wt. % [Mn]. 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.

A welding device for automatically welding a workpiece by a welding robot using a welding wire includes a welding control device that controls operation and welding work of the welding robot. The welding control device includes a sensing unit configured to detect a position of the workpiece, a root gap calculating unit configured to determine a root gap, and a storage unit including wire melting information as a database of a proper welding current corresponding to a feeding rate for each of the welding wire. A lamination pattern and a welding condition are provided in accordance with the root gap determined by the root gap calculating unit and the wire melting information so that an amount of heat input is equal to or less than a predetermined amount of heat input.