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.

Provided is a thermal spray wire as a thermal spray material for use in continuous arc wire thermal spraying machines, the thermal spray wire being for performing continuous and stable arc thermal spraying with sufficient electrical conductivity and at a stable voltage. The thermal spray wire includes a copper-plated coating having a thickness of from 0.3 to 1.2 μm on a surface of a rod made of stainless steel. Using the thermal spray wire allows for stable arc thermal spraying by a continuous arc thermal spraying machine including a wire feeding mechanism.

The disclosed technology generally relates welding electrodes, and more particularly to consumable welding electrodes having functional coatings. In one aspect, a welding electrode comprises a core wire having a base metal composition and two or more coatings covering at least a portion of the core wire. The two or more coatings comprise an electrically conductive coating including one or more electrically conducting elements or compounds in addition to or other than copper (Cu). The two or more coatings additionally comprises an additional functional coating including one or more additional elements or compounds adapted to modify a surface tension of a molten droplet formed from the welding electrode. In another aspect, a method of manufacturing a welding electrode comprises providing the core wire having the base metal composition and forming the two or more coating layers.

An arc welding solid wire includes: a steel material; and a copper plating layer formed on a surface of the steel material, in which an amount of Cu in the steel material and the copper plating layer is 0.05 mass % to 0.30 mass % with respect to a total mass of the wire, a surface of the wire is coated with 0.05 g to 0.20 g of oil with respect to 1 kg of the wire, and on a surface of the copper plating layer, an arithmetic average roughness Rac in a circumferential direction is 0.25 .Math.m to 1.00 .Math.m, and an arithmetic average roughness Ral in a longitudinal direction is 0.07 .Math.m to 0.50 .Math.m.

Welding wires may include a high alloy metal core comprising greater than about 10.5 percent by weight of the high alloy metal core of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, the layer comprising copper or a copper alloy. Welding methods may include applying an electrical current sufficient to convert a welding wire to a molten state to produce a molten weld material, the welding wire comprising: a high alloy metal core comprising greater than about 10.5% of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, the layer comprising copper or a copper alloy; and depositing the molten welding material onto a workpiece.

The present disclosure provides a device and method for manufacturing a coated welding rod. The device for manufacturing a coated welding rod includes a grabbing device, a heating device, and a flux storage device. The heating device is configured to heat a welding rod in the grabbing device. A flux in granular form is stored in the flux storage device, the grabbing device is configured to transport the heated welding rod into the flux storage device, and the heated welding rod is configured to heat the flux surrounding the welding rod into a viscous glassy state so that the flux in the viscous glassy state adheres to the surface of the welding rod. The heated welding rod enables the granular flux to be formed into a viscous glassy state so that the flux can be adhered directly to the surface of the welding rod.

A solder material for use in electronic assembly, the solder material comprising: solder layers; and a core layer comprising a core material, the core layer being sandwiched between the solder layers, wherein: the thermal conductivity of the core material is greater than the thermal conductivity of the solder.

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.

The disclosed technology generally relates welding electrodes, and more particularly to covered consumable welding electrodes. In an aspect, a consumable welding electrode comprises a core wire comprising a steel composition and a coating formed on the core wire. The coating comprises weld metal alloying elements comprising Fe, C, Mn, Si, Ni, Mo, V and Cr that are arranged such that an undiluted weld metal formed from the covered welding electrode has a combination of high tensile strength and high impact strength.

Various embodiments of a metal cored wires and methods are disclosed. In one embodiment of the present invention, a metal cored wire comprises a metal sheath and a metal-powder core material comprising manganese particles. The manganese particles are coated with a coating material to reduce the manganese fumes and exposure during welding.