US20140042143A1 - Sheathed welding wire - Google Patents
Sheathed welding wire Download PDFInfo
- Publication number
- US20140042143A1 US20140042143A1 US14/060,377 US201314060377A US2014042143A1 US 20140042143 A1 US20140042143 A1 US 20140042143A1 US 201314060377 A US201314060377 A US 201314060377A US 2014042143 A1 US2014042143 A1 US 2014042143A1
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- United States
- Prior art keywords
- wire
- metal
- sheath
- welding wire
- core
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3053—Fe as the principal constituent
- B23K35/308—Fe as the principal constituent with Cr as next major constituent
Definitions
- the invention relates generally to the field of welding systems and more particularly to sheathed welding wires that improve welding performance.
- Welding systems generally make use of electrodes configured to pass an arc between a torch and a work piece, thereby heating the work piece to create a weld, and in certain welding systems melting the electrode to add metal to the weld.
- a number of forms of welding are known and are generally used in the art.
- MIG metal inert gas
- the wire electrode is advanced through a welding torch and is generally consumed by the heat of the arc.
- the wire electrode may also be known as a “filler material” that becomes part of the weld.
- the electrode may be provided in a variety of materials and forms, including solid wire electrodes and metal-core wire electrodes.
- Metal-core wire electrodes generally include tubular shaped metal sheath about their exterior and a metal powder core including various powdered materials.
- desirable electrodes may include solid wire electrodes or metal-core wire electrodes that comprise similar compositions to a work piece when they are melted into the weld location.
- the core of the wire and the sheath material surrounding the core may combine to define an overall composition when the wire is melted.
- the electrode may include properties that affect the quality of the weld. For example, an electrode may dictate the width of the arc, the heat of the weld, the depth of the weld, and the like. The electrode may also affect the ease of welding. For example, a given electrode may be susceptible to sticking of electrode to the work piece during welding and, thus, increase the difficulty of welding.
- aspects of the welding operation may be less than optimal.
- certain applications may require specific wire metallurgy.
- One example is in the manufacture of vehicle exhaust systems, in which solid series 300 stainless steel welding wire is commonly used.
- 300 series wire has a tendency to micro-arc or stick during current transfer from the welding torch contact tip to the wire. Such micro-arcing causes contact tip wear and failure, as well as burn back.
- the wire may freeze momentarily, creating process stability problems.
- a welding wire comprises a metal core and a metal sheath encapsulating the core.
- the metal sheath comprises a ferritic steel.
- the combination of the metal sheath and the metal core comprises an overall alloy content of a 300 series stainless steel.
- a welding wire comprises a metal core and a metal sheath encapsulating the core.
- the metal sheath comprises between about 16 and about 18% of chromium by weight and up to about 0.75% of nickel by weight.
- An alloyed combination of the metal sheath composition and the metal core comprise comprises between about 23 and 25% of chromium by weight and between about 12 and 14% of nickel by weight.
- a welding wire is also provided that has a series 400 stainless steel sheath, and a core that, in combination with the sheath, provides the wire with an overall composition of a series 300 stainless steel.
- the present invention also provides a method of manufacturing a welding wire.
- a metal sheath comprising up to about 6 % of nickel by weight is first cupped, and a metal core material is disposed on the metal sheath.
- the combination of the metal sheath and the core provides an overall alloy content of a 300 series stainless steel.
- the metal sheath is then closed about the metal core material to form a wire, which may then be reduced a diameter of the wire and baked.
- FIG. 1 illustrates an exemplary welding system in which the wire electrode of the present invention may be employed
- FIG. 2 illustrates an exemplary welding wire electrode of the system in FIG. 1 in accordance with aspects of the present technique
- FIG. 3 illustrates a cross section taken across line 3 - 3 of the exemplary welding wire of FIG. 2 in accordance one aspects of the present technique
- FIG. 4 is a flowchart illustrating a method to manufacture the welding wire of FIGS. 2 and 3 in accordance with one aspect of the present technique.
- the electrode 12 includes a metal-core welding wire that is comprised of an outer sheath material and a core material.
- the welding wire may include a metal sheath that encapsulates a metal core material.
- the metal sheath may comprise a ferritic steel and the metal core material may comprise alloying elements such that the combination of the metal sheath and the metal core material create a series 300 series stainless steel.
- the compositions of the metal sheath and the metal powder core combine to form a series 300 series stainless steel filler material that is deposited into the weld.
- embodiments of the electrode 12 may create better arc-stability, better contact tip life due to reduced micro-arcing, reduced burn-through and produce smoother welds.
- the MIG welding system 10 includes a power source 18 , a shielding gas source 20 , a wire feeder 22 , electrode source 24 and a welding gun 26 .
- the power source 18 may supply power to the electrode 12 via a power conduit 28 and the welding gun 26 .
- a current may be provided to the electrode 12 within the welding gun 26 .
- an operator may control the location and operation of the electrode 12 by positioning the electrode 12 and triggering the starting and stopping of the current flow.
- the power source 18 typically will supply a constant voltage that helps to maintain a stable arc length as the distance from the electrode 12 to a work piece 30 is changed.
- wire feeder 22 advances wire electrode 12 from the electrode source 24 .
- the electrode source 24 may include a spool that unwinds as the wire feeder 22 draws the wire electrode 12 and feeds it through the electrode conduit 32 and through the contact tip 34 of the welding gun 26 .
- the electrode 12 may be protected by a liner that helps to prevent bucking and maintains an uninterrupted feed of wire.
- the electrode may be advanced through the gun when operator pulls a trigger on the welding gun 26 or provides another signal to advance the electrode.
- the welding arc is created as current flows from the tip of the electrode 12 to the work piece 30 and returns to the power source 18 . Therefore, the work piece 30 is generally grounded to the power source 18 to provide a return path. For example, as depicted, a work clamp 36 and cable 38 complete the electrical path between the work piece 30 and the power source 18 .
- Some forms of arc welding may include a shielding gas to protect the weld area from atmospheric gases such as nitrogen and oxygen. Left unprotected, these gases can cause fusion defects, porosity and weld metal embrittlement.
- the shielding gas may be provided to the gun 26 from a shielding gas source 20 via the gas supply conduit 40 .
- the gas is automatically supplied during the welding operation and automatically shut-off when the operation is interrupted. The flow of gas may be triggered by the same switch that initiates the feed of the wire electrode.
- the system 10 may include a control circuit 42 that coordinates functions of the system 10 .
- the control circuit 42 may be in communication with the power source 18 , the wire feeder 22 and/or the shielding gas source 20 to coordinate the operation of components of the system 10 .
- the current, wire speed and gas may all stop and start in conjunction during welding.
- the arc created between the electrode 12 and the work piece 30 melts the electrode 12 to provide a filler material to the weld location.
- the electrode 12 is continuously fed to the weld location and consumed during the welding process.
- the electrode 12 becomes part of the material used to create the weld, and the electrode materials may strongly influence the mechanical properties of the weld.
- manufacturers of exhaust systems may use a solid wire made of series 309 stainless steel material on series 304 stainless steel manifolds, mufflers, and so forth.
- the electrode 12 may affect the ease of welding. For example, some electrodes may have a tendency to stick to the work piece 30 and, thus, create vibration during welding, or even interrupt the steady flow of wire to the torch. It has been found that 300 series stainless steel wires pose particular difficulties in welding, believed due to the presence of specific alloying materials in specific percent ranges at the surface of the wire. That is, the very composition of the 300 series stainless steel, desirable in the weld, renders the welding wire difficult to use. To accommodate such applications, the present technique provides an electrode wire specifically designed to offer a composite metallurgy but in a jacket or sheath that prevents or reduces the adverse effects of the 300 series stainless steel composition at the surface of the electrode wire.
- an electrode 12 that has an overall composition of a series 300 stainless steel may include a ferritic steel metal sheath 14 .
- the core of the electrode wire includes alloying materials that result, in combination with the ferritic steel sheath 14 , in the overall composition meeting series 300 stainless steel specifications.
- an electrode 12 including a ferritic steel sheath has been shown to reduce or eliminate micro-arcing due to the absence or reduction of nickel in the ferritic steel metal sheath 14 .
- the ferritic stainless steel metal sheath 14 may improve wetting of the weld location and, thus, reduces the angle of the weld pool bead to the work piece 30 . The reduced angle is believed to reduce burn through and create better gap filling.
- the BCC crystal structure of ferritic steels may provide desirable electrical properties.
- Ferritic stainless steels are highly corrosion resistant. They contain between 10.5% and 27% chromium and very little nickel. Most compositions include molybdenum, aluminum or titanium. A ferritic stainless steel may include type 400 series stainless steels. Accordingly, the composition of the metal sheath 14 may include various 400 series stainless steels configured to accommodate numerous applications. In one embodiment, the metal sheath 14 may comprise a nickel content that is below about 6% by weight.
- the metal sheath 14 may comprise a series 430 stainless steel (UNS S43000) that comprises between about 16 and 18% chromium, up to about 0.12% carbon, up to about 1% manganese, up to about 1% silicon, up to about 0.04% phosphorus, up to about 0.03% sulfur, and up to about 0.75% nickel, all percentages being by weight.
- UNS S43000 series 430 stainless steel
- the metal sheath 14 may also be formed from other series 400 stainless steel metals.
- the metal sheath may be formed from series 409, or series 439 stainless steel.
- the series 409 stainless steel (UNS S40900) may comprise between about 10.5% and 11.75% chromium, up to about 0.08% carbon, up to about 1% manganese, up to about 1% silicon, up to about 0.045% phosphorus, up to about 0.03% sulfur, and up to about 0.5% nickel, all percentages again being by weight.
- the series 439 stainless steel (UNS S43035) may comprise between about 17% and 19% chromium, up to about 0.07% carbon, and up to about 0.5% nickel, for example.
- the present technique relies upon combining a series 400 stainless steel sheath 14 with a powder core 16 to provide an overall composition of a series 300 stainless steel.
- the metal powder core 16 may comprise a core composition, as well as number of alloying elements to produce an electrode with an overall composition of a 300 series stainless steel when the electrode 12 is melted.
- the material of the metal powder core 16 may comprise iron. Additional alloying elements may include chromium, nickel, carbon, molybdenum, manganese, silicon, phosphorous, sulfur, copper and the like. The relative amounts of iron and alloying elements may be varied, along with the composition of the sheath 14 to provide an overall composition of the welding wire electrode 12 . For example, as more of one element is added to the metal sheath 14 , the amount of the elements in the metal powder core 16 may be reduced.
- the metal powder core 16 is not limited to materials in powder form, but may include any form of material that provides the desired overall composition.
- a series 300 overall composition may include between about 6% and 40% nickel and between about 10% and about 35% chromium.
- the overall composition may meet the specifications of a series 309 stainless steel.
- the series 309 stainless steel (UNS S30980) may comprise between about 23% and 25% chromium, up to about 0.12% carbon, up to about 0.75% molybdenum, between about 1% and 2.5% manganese, between about 0.3% and 0.65% silicon, up to about 0.03% phosphorus, about 0.03% sulfur, up to 0.75% copper, and between about 12% and 14% nickel, all by weight.
- the overall composition of the electrode 12 may include other series 300 stainless steels.
- embodiments may include overall compositions of series 309LSi, 308, 316 or 317 stainless steels.
- the series 309LSi stainless steel (UNS S30988) may comprise between about 23% and about 25% chromium, up to about 0.03% carbon, up to about 0.75% molybdenum, between about 1% and 2.5% manganese, between about 0.65% and 1% silicon, up to about 0.03% phosphorus, about 0.03% sulfur, up to 0.75% copper, and between about 12% and 14% nickel, all by weight.
- the overall composition may comprise between about 19% and about 21% chromium, up to about 0.08% carbon, up to about 2% manganese, up to about 1% silicon, up to about 0.045% phosphorus, about 0.03% sulfur, and between about 10% and 12% nickel, all by weight.
- the overall composition may comprise between about 16% and about 18% chromium, up to about 0.08% carbon, between about 2% and 3% molybdenum, up to about 2% manganese, up to about 0.75% silicon, up to about 0.045% phosphorus, about 0.03% sulfur, up to about 0.1% nitrogen, and between about 10% and 14% nickel, all by weight.
- the overall composition may comprise between about 18% and about 20% chromium (Cr), up to about 0.08% carbon, between about 3% and 4% molybdenum, up to about 2% manganese, up to about 0.75% silicon, up to about 0.045% phosphorus, about 0.03% sulfur, up to about 0.1% nitrogen, and between about 11% and 15% nickel, all by weight.
- a metal core wire electrode 12 comprising a ferritic steel sheath 14 and an overall composition of a series 300 stainless steel.
- a step in producing the metal-core wire electrode 12 may include cupping a metal sheath strip as shown at block 42 .
- a continuous strip of metal sheath material may be provided and manipulated to form a cup-shaped trough.
- an embodiment may include providing a generally continuous flat strip of series 400 metal and rolling the edges of the strip to form a trough shaped strip of metal sheath material.
- the method may include a step of depositing the metal powder core as depicted at block 44 .
- An embodiment may include a device depositing a composition of the metal powder core 16 into the trough of the cupped-shaped strip of the metal sheath material.
- a mechanism may deposit a continuous stream of the metal powder core 16 , including iron and other alloying elements, into the progressively cupped trough.
- the metal core composition will rest within the trough of the metal sheath material as the sheath is progressively closed around it.
- the metal sheath 12 may be closed to encapsulate the metal powder core 16 , as summarized at block 46 .
- the length of metal sheath 12 with the deposited metal powder core 16 may be advanced through one or more progressive rolling stations that roll the cupped metal sheath 14 into a tubular enclosure about the metal powder core 16 .
- the pressure of the rolling may form a seam along the length of the sheath 14 .
- a substantially round wire is formed including the metal sheath 14 about the powder metal core 16 .
- the diameter of the wire electrode 12 may be manipulated (e.g., reduced) to a desired dimensions, as depicted at block 48 .
- the closed metal sheath 14 and core 16 may be advanced through an additional rolling station configured to reduce the diameter to provide an appropriate round wire shape.
- a moderate size wire may include about 0.0625 inches in outer diameter, and a small wire may include a diameter of about 0.035 to 0.045 inches. In one embodiment, a larger wire may comprise a diameter of about 0.0983 inches. It is also worth noting that the rolling technique may also complete the seam formed at the edges of the metal sheath 14 .
- the wire may be baked, as depicted at block 50 . Baking the wire may remove moisture from the wire and consolidate the core materials.
- the reduced diameter wire may be baked at 600° F.-700° F. to promote the removal of moisture through the seam of the metal sheath 14 .
- the wire electrode 12 may be continuously advanced through an oven during the manufacture process to provide even heating across the wire electrode 12 .
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Abstract
Provided is a welding wire and method for manufacturing a welding wire providing for quality welds on 300 series stainless steel and similar materials. A metal powder core is encapsulated in a metal sheath. The metal sheath composition comprising up to about 6% nickel, by weight, and may correspond to a series 400 stainless steel. A combination of the metal sheath and the metal powder core provides an overall alloy content of a series 300 stainless steel.
Description
- The invention relates generally to the field of welding systems and more particularly to sheathed welding wires that improve welding performance.
- Welding systems generally make use of electrodes configured to pass an arc between a torch and a work piece, thereby heating the work piece to create a weld, and in certain welding systems melting the electrode to add metal to the weld. A number of forms of welding are known and are generally used in the art. In many systems, such as metal inert gas (MIG) systems, the wire electrode is advanced through a welding torch and is generally consumed by the heat of the arc. In such operations, the wire electrode may also be known as a “filler material” that becomes part of the weld. The electrode may be provided in a variety of materials and forms, including solid wire electrodes and metal-core wire electrodes. Metal-core wire electrodes generally include tubular shaped metal sheath about their exterior and a metal powder core including various powdered materials.
- The selection of the type of electrode for a particular welding operation may be based on several factors, including, the composition of the metals being welded, the joint design and the material surface conditions. In general, it is desirable that the weld electrode have mechanical properties similar to those of the base material and no discontinuities, such as porosity. Thus, desirable electrodes may include solid wire electrodes or metal-core wire electrodes that comprise similar compositions to a work piece when they are melted into the weld location. In other words, in a metal-core wire, the core of the wire and the sheath material surrounding the core may combine to define an overall composition when the wire is melted.
- Further, the electrode may include properties that affect the quality of the weld. For example, an electrode may dictate the width of the arc, the heat of the weld, the depth of the weld, and the like. The electrode may also affect the ease of welding. For example, a given electrode may be susceptible to sticking of electrode to the work piece during welding and, thus, increase the difficulty of welding.
- In addition, depending upon the particular metallurgy of the welding wire, aspects of the welding operation may be less than optimal. For example, certain applications may require specific wire metallurgy. One example is in the manufacture of vehicle exhaust systems, in which solid series 300 stainless steel welding wire is commonly used. However, due to energy density issues, diameter and wetting/viscosity, incidences of burn through can be high. Also, 300 series wire has a tendency to micro-arc or stick during current transfer from the welding torch contact tip to the wire. Such micro-arcing causes contact tip wear and failure, as well as burn back. Moreover, the wire may freeze momentarily, creating process stability problems.
- Accordingly, there is need for a welding wire that is compatible with welding applications and that comprises properties that provide for a quality weld.
- The invention provides a welding wire electrode designed to respond to such needs. In accordance with one aspect of the present invention, a welding wire comprises a metal core and a metal sheath encapsulating the core. The metal sheath comprises a ferritic steel. The combination of the metal sheath and the metal core comprises an overall alloy content of a 300 series stainless steel.
- In accordance with another aspect of the present invention, a welding wire comprises a metal core and a metal sheath encapsulating the core. The metal sheath comprises between about 16 and about 18% of chromium by weight and up to about 0.75% of nickel by weight. An alloyed combination of the metal sheath composition and the metal core comprise comprises between about 23 and 25% of chromium by weight and between about 12 and 14% of nickel by weight.
- A welding wire is also provided that has a series 400 stainless steel sheath, and a core that, in combination with the sheath, provides the wire with an overall composition of a series 300 stainless steel.
- The present invention also provides a method of manufacturing a welding wire. A metal sheath comprising up to about 6% of nickel by weight is first cupped, and a metal core material is disposed on the metal sheath. The combination of the metal sheath and the core provides an overall alloy content of a 300 series stainless steel. The metal sheath is then closed about the metal core material to form a wire, which may then be reduced a diameter of the wire and baked.
- These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
-
FIG. 1 illustrates an exemplary welding system in which the wire electrode of the present invention may be employed; -
FIG. 2 illustrates an exemplary welding wire electrode of the system inFIG. 1 in accordance with aspects of the present technique; -
FIG. 3 illustrates a cross section taken across line 3-3 of the exemplary welding wire ofFIG. 2 in accordance one aspects of the present technique; and -
FIG. 4 is a flowchart illustrating a method to manufacture the welding wire ofFIGS. 2 and 3 in accordance with one aspect of the present technique. - Referring now to
FIG. 1 ,welding system 10 is illustrated that employselectrode 12 in accordance with one embodiment of the present technique. As discussed in greater detail below, theelectrode 12 includes a metal-core welding wire that is comprised of an outer sheath material and a core material. For example, as described in greater detail below, the welding wire may include a metal sheath that encapsulates a metal core material. As will be discussed in greater detail below, in one embodiment, the metal sheath may comprise a ferritic steel and the metal core material may comprise alloying elements such that the combination of the metal sheath and the metal core material create a series 300 series stainless steel. In other words, when theelectrode 12 is melted, the compositions of the metal sheath and the metal powder core combine to form a series 300 series stainless steel filler material that is deposited into the weld. As will be discussed below, embodiments of theelectrode 12 may create better arc-stability, better contact tip life due to reduced micro-arcing, reduced burn-through and produce smoother welds. - As depicted, the
MIG welding system 10 includes apower source 18, ashielding gas source 20, a wire feeder 22,electrode source 24 and awelding gun 26. In the illustrated embodiment, thepower source 18 may supply power to theelectrode 12 via apower conduit 28 and thewelding gun 26. For example, a current may be provided to theelectrode 12 within thewelding gun 26. In such awelding system 10, an operator may control the location and operation of theelectrode 12 by positioning theelectrode 12 and triggering the starting and stopping of the current flow. In gas metal arc welding, thepower source 18 typically will supply a constant voltage that helps to maintain a stable arc length as the distance from theelectrode 12 to awork piece 30 is changed. - During a welding operation, wire feeder 22
advances wire electrode 12 from theelectrode source 24. For example, as depicted, theelectrode source 24 may include a spool that unwinds as the wire feeder 22 draws thewire electrode 12 and feeds it through theelectrode conduit 32 and through thecontact tip 34 of thewelding gun 26. On the path to thecontact tip 34, theelectrode 12 may be protected by a liner that helps to prevent bucking and maintains an uninterrupted feed of wire. The electrode may be advanced through the gun when operator pulls a trigger on thewelding gun 26 or provides another signal to advance the electrode. - The welding arc is created as current flows from the tip of the
electrode 12 to thework piece 30 and returns to thepower source 18. Therefore, thework piece 30 is generally grounded to thepower source 18 to provide a return path. For example, as depicted, awork clamp 36 andcable 38 complete the electrical path between thework piece 30 and thepower source 18. - Some forms of arc welding may include a shielding gas to protect the weld area from atmospheric gases such as nitrogen and oxygen. Left unprotected, these gases can cause fusion defects, porosity and weld metal embrittlement. As depicted in
FIG. 1 , the shielding gas may be provided to thegun 26 from ashielding gas source 20 via thegas supply conduit 40. In some applications, the gas is automatically supplied during the welding operation and automatically shut-off when the operation is interrupted. The flow of gas may be triggered by the same switch that initiates the feed of the wire electrode. - Further, the
system 10 may include acontrol circuit 42 that coordinates functions of thesystem 10. For example, thecontrol circuit 42 may be in communication with thepower source 18, the wire feeder 22 and/or the shieldinggas source 20 to coordinate the operation of components of thesystem 10. Thus, the current, wire speed and gas may all stop and start in conjunction during welding. - As mentioned previously, during welding the arc created between the
electrode 12 and thework piece 30 melts theelectrode 12 to provide a filler material to the weld location. In a typical application, theelectrode 12 is continuously fed to the weld location and consumed during the welding process. Thus, theelectrode 12 becomes part of the material used to create the weld, and the electrode materials may strongly influence the mechanical properties of the weld. Accordingly, it is generally desired that the composition of theelectrode 12 be compatible with the composition of thework piece 30. For example, manufacturers of exhaust systems may use a solid wire made of series 309 stainless steel material on series 304 stainless steel manifolds, mufflers, and so forth. - Further, the
electrode 12 may affect the ease of welding. For example, some electrodes may have a tendency to stick to thework piece 30 and, thus, create vibration during welding, or even interrupt the steady flow of wire to the torch. It has been found that 300 series stainless steel wires pose particular difficulties in welding, believed due to the presence of specific alloying materials in specific percent ranges at the surface of the wire. That is, the very composition of the 300 series stainless steel, desirable in the weld, renders the welding wire difficult to use. To accommodate such applications, the present technique provides an electrode wire specifically designed to offer a composite metallurgy but in a jacket or sheath that prevents or reduces the adverse effects of the 300 series stainless steel composition at the surface of the electrode wire. - As illustrated in
FIGS. 2 and 3 , in an embodiment of the present technique, anelectrode 12 that has an overall composition of a series 300 stainless steel may include a ferriticsteel metal sheath 14. The core of the electrode wire includes alloying materials that result, in combination with theferritic steel sheath 14, in the overall composition meeting series 300 stainless steel specifications. Through use of the composite wire of the invention, anelectrode 12 including a ferritic steel sheath has been shown to reduce or eliminate micro-arcing due to the absence or reduction of nickel in the ferriticsteel metal sheath 14. In addition, the ferritic stainlesssteel metal sheath 14 may improve wetting of the weld location and, thus, reduces the angle of the weld pool bead to thework piece 30. The reduced angle is believed to reduce burn through and create better gap filling. Further, the BCC crystal structure of ferritic steels may provide desirable electrical properties. - Ferritic stainless steels are highly corrosion resistant. They contain between 10.5% and 27% chromium and very little nickel. Most compositions include molybdenum, aluminum or titanium. A ferritic stainless steel may include type 400 series stainless steels. Accordingly, the composition of the
metal sheath 14 may include various 400 series stainless steels configured to accommodate numerous applications. In one embodiment, themetal sheath 14 may comprise a nickel content that is below about 6% by weight. For example, themetal sheath 14 may comprise a series 430 stainless steel (UNS S43000) that comprises between about 16 and 18% chromium, up to about 0.12% carbon, up to about 1% manganese, up to about 1% silicon, up to about 0.04% phosphorus, up to about 0.03% sulfur, and up to about 0.75% nickel, all percentages being by weight. - The
metal sheath 14 may also be formed from other series 400 stainless steel metals. For example, the metal sheath may be formed from series 409, or series 439 stainless steel. The series 409 stainless steel (UNS S40900) may comprise between about 10.5% and 11.75% chromium, up to about 0.08% carbon, up to about 1% manganese, up to about 1% silicon, up to about 0.045% phosphorus, up to about 0.03% sulfur, and up to about 0.5% nickel, all percentages again being by weight. The series 439 stainless steel (UNS S43035) may comprise between about 17% and 19% chromium, up to about 0.07% carbon, and up to about 0.5% nickel, for example. - The present technique relies upon combining a series 400
stainless steel sheath 14 with apowder core 16 to provide an overall composition of a series 300 stainless steel. For example, themetal powder core 16 may comprise a core composition, as well as number of alloying elements to produce an electrode with an overall composition of a 300 series stainless steel when theelectrode 12 is melted. Generally, the material of themetal powder core 16 may comprise iron. Additional alloying elements may include chromium, nickel, carbon, molybdenum, manganese, silicon, phosphorous, sulfur, copper and the like. The relative amounts of iron and alloying elements may be varied, along with the composition of thesheath 14 to provide an overall composition of thewelding wire electrode 12. For example, as more of one element is added to themetal sheath 14, the amount of the elements in themetal powder core 16 may be reduced. Themetal powder core 16 is not limited to materials in powder form, but may include any form of material that provides the desired overall composition. - As a general characteristic, a series 300 overall composition may include between about 6% and 40% nickel and between about 10% and about 35% chromium. In one embodiment, the overall composition may meet the specifications of a series 309 stainless steel. The series 309 stainless steel (UNS S30980) may comprise between about 23% and 25% chromium, up to about 0.12% carbon, up to about 0.75% molybdenum, between about 1% and 2.5% manganese, between about 0.3% and 0.65% silicon, up to about 0.03% phosphorus, about 0.03% sulfur, up to 0.75% copper, and between about 12% and 14% nickel, all by weight.
- In other embodiments, the overall composition of the
electrode 12 may include other series 300 stainless steels. For example, embodiments may include overall compositions of series 309LSi, 308, 316 or 317 stainless steels. The series 309LSi stainless steel (UNS S30988) may comprise between about 23% and about 25% chromium, up to about 0.03% carbon, up to about 0.75% molybdenum, between about 1% and 2.5% manganese, between about 0.65% and 1% silicon, up to about 0.03% phosphorus, about 0.03% sulfur, up to 0.75% copper, and between about 12% and 14% nickel, all by weight. - In an embodiment of a series 308 stainless steel (UNS S30800) the overall composition may comprise between about 19% and about 21% chromium, up to about 0.08% carbon, up to about 2% manganese, up to about 1% silicon, up to about 0.045% phosphorus, about 0.03% sulfur, and between about 10% and 12% nickel, all by weight.
- In an embodiment of a series 316 stainless steel (UNS S31600) the overall composition may comprise between about 16% and about 18% chromium, up to about 0.08% carbon, between about 2% and 3% molybdenum, up to about 2% manganese, up to about 0.75% silicon, up to about 0.045% phosphorus, about 0.03% sulfur, up to about 0.1% nitrogen, and between about 10% and 14% nickel, all by weight.
- In an embodiment of a series 317 stainless steel (UNS S31700) the overall composition may comprise between about 18% and about 20% chromium (Cr), up to about 0.08% carbon, between about 3% and 4% molybdenum, up to about 2% manganese, up to about 0.75% silicon, up to about 0.045% phosphorus, about 0.03% sulfur, up to about 0.1% nitrogen, and between about 11% and 15% nickel, all by weight.
- Further, various methods may be employed to manufacture a metal
core wire electrode 12 comprising aferritic steel sheath 14 and an overall composition of a series 300 stainless steel. For example, a method for manufacturing a metal core wire is depicted inFIG. 4 . A step in producing the metal-core wire electrode 12 may include cupping a metal sheath strip as shown atblock 42. In one embodiment, a continuous strip of metal sheath material may be provided and manipulated to form a cup-shaped trough. For example, an embodiment may include providing a generally continuous flat strip of series 400 metal and rolling the edges of the strip to form a trough shaped strip of metal sheath material. - Next, the method may include a step of depositing the metal powder core as depicted at
block 44. An embodiment may include a device depositing a composition of themetal powder core 16 into the trough of the cupped-shaped strip of the metal sheath material. For example, as a generally continuous length of thecupped metal sheath 12 passes a deposition station, a mechanism may deposit a continuous stream of themetal powder core 16, including iron and other alloying elements, into the progressively cupped trough. Thus, the metal core composition will rest within the trough of the metal sheath material as the sheath is progressively closed around it. - With a bead of
metal powder core 16 deposited along the length of thecupped metal sheath 12, themetal sheath 12 may be closed to encapsulate themetal powder core 16, as summarized atblock 46. In one embodiment, the length ofmetal sheath 12 with the depositedmetal powder core 16 may be advanced through one or more progressive rolling stations that roll thecupped metal sheath 14 into a tubular enclosure about themetal powder core 16. As themetal sheath 12 is rolled about the powder core, the pressure of the rolling may form a seam along the length of thesheath 14. Thus, a substantially round wire is formed including themetal sheath 14 about thepowder metal core 16. - Subsequent to closing the metal sheath about the metal powder core (block 46), the diameter of the
wire electrode 12 may be manipulated (e.g., reduced) to a desired dimensions, as depicted atblock 48. In one embodiment, theclosed metal sheath 14 andcore 16 may be advanced through an additional rolling station configured to reduce the diameter to provide an appropriate round wire shape. A moderate size wire may include about 0.0625 inches in outer diameter, and a small wire may include a diameter of about 0.035 to 0.045 inches. In one embodiment, a larger wire may comprise a diameter of about 0.0983 inches. It is also worth noting that the rolling technique may also complete the seam formed at the edges of themetal sheath 14. - Finally, the wire may be baked, as depicted at
block 50. Baking the wire may remove moisture from the wire and consolidate the core materials. For example, the reduced diameter wire may be baked at 600° F.-700° F. to promote the removal of moisture through the seam of themetal sheath 14. In one embodiment, thewire electrode 12 may be continuously advanced through an oven during the manufacture process to provide even heating across thewire electrode 12. - While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
Claims (21)
1-25. (canceled)
26. A welding wire, comprising:
a metal sheath comprising a 430 stainless steel; and
a core encapsulated by the sheath, an alloyed combination of the metal sheath and the core comprising a 309 stainless steel.
27. The welding wire of claim 26 , wherein the sheath comprises between about 16 and 18% chromium and up to about 0.75% nickel, all by weight.
28. The welding wire of claim 26 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight.
29. The welding wire of claim 26 , wherein the alloyed combination comprises less than about 0.12% carbon.
30. The welding wire of claim 26 , wherein the alloyed combination comprises between about 0.65 and 1% silicon, by weight.
31. The welding wire of claim 26 , comprising an outer diameter equal to or less than approximately 0.0625 inches.
32. The welding wire of claim 26 , comprising an outer diameter of between approximately 0.035 inches and 0.045 inches.
33. A welding wire, comprising:
a metal sheath comprising a 439 stainless steel; and
a core encapsulated by the sheath, an alloyed combination of the metal sheath and the core comprising a 309 stainless steel.
34. The welding wire of claim 33 , wherein the sheath comprises between about 17 and 19% chromium and up to about 0.5% nickel, all by weight.
35. The welding wire of claim 33 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight.
36. The welding wire of claim 33 , wherein the alloyed combination comprises less than about 0.12% carbon.
37. The welding wire of claim 33 , wherein the alloyed combination comprises between about 0.65 and 1% silicon, by weight.
38. The welding wire of claim 33 , comprising an outer diameter equal to or less than approximately 0.0625 inches.
39. A method of manufacturing a welding wire, comprising:
cupping a metal sheath strip comprising a 430 or 439 stainless steel;
disposing a metal core material on the metal sheath, a combination of the metal sheath and the metal core material comprising an overall alloy content of series 309 stainless steel;
closing the metal sheath about the metal core material to form a wire;
reducing a diameter of the wire; and
baking the wire.
40. The method of claim 39 , wherein the sheath comprises between about 16 and 18% chromium and up to about 0.75% nickel, all by weight.
41. The method of claim 40 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight.
42. The method of claim 39 , wherein the sheath comprises between about 17 and 19% chromium and up to about 0.5% nickel, all by weight.
43. The method of claim 42 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight.
44. The method of claim 39 , wherein the alloyed combination comprises less than about 0.12% carbon.
45. The method of claim 39 , wherein baking the wire comprises baking at a temperature between about 600° F. and 700° F.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US14/060,377 US20140042143A1 (en) | 2007-04-30 | 2013-10-22 | Sheathed welding wire |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US11/796,913 US8563897B2 (en) | 2007-04-30 | 2007-04-30 | Sheathed welding wire |
US14/060,377 US20140042143A1 (en) | 2007-04-30 | 2013-10-22 | Sheathed welding wire |
Related Parent Applications (1)
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US11/796,913 Continuation US8563897B2 (en) | 2007-04-30 | 2007-04-30 | Sheathed welding wire |
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US20140042143A1 true US20140042143A1 (en) | 2014-02-13 |
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US11/796,913 Expired - Fee Related US8563897B2 (en) | 2007-04-30 | 2007-04-30 | Sheathed welding wire |
US14/060,377 Abandoned US20140042143A1 (en) | 2007-04-30 | 2013-10-22 | Sheathed welding wire |
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US11/796,913 Expired - Fee Related US8563897B2 (en) | 2007-04-30 | 2007-04-30 | Sheathed welding wire |
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WO (1) | WO2008134167A1 (en) |
Families Citing this family (20)
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US20110100970A1 (en) * | 2009-11-03 | 2011-05-05 | Lincoln Global, Inc. | Manufacture of cored welding electrodes |
TWI604912B (en) * | 2011-07-13 | 2017-11-11 | Illinois Tool Works | Cored welding wires, the method for making the same and its use |
US9180553B2 (en) * | 2011-09-29 | 2015-11-10 | Lincoln Global, Inc. | Electrode for GMAW hybrid laser arc welding |
US9029733B2 (en) * | 2012-04-13 | 2015-05-12 | Hobart Brothers Company | Systems and methods for tubular welding wire |
US10906135B2 (en) | 2012-05-24 | 2021-02-02 | Hobart Brothers Llc | Systems and methods for low-manganese welding wire |
US10898966B2 (en) * | 2012-05-24 | 2021-01-26 | Hobart Brothers Llc | Systems and methods for low-manganese welding wire |
US20140021188A1 (en) * | 2012-07-19 | 2014-01-23 | Lincoln Global, Inc. | Hot-wire consumable to provide weld with increased wear resistance |
US9272358B2 (en) * | 2012-07-19 | 2016-03-01 | Lincoln Global, Inc. | Hot-wire consumable to provide self-lubricating weld or clad |
KR101677317B1 (en) * | 2013-07-03 | 2016-11-17 | 주식회사 포스코 | Method for manufacturing electrical steel sheet laminated core for reducing core loss and increasing strength and laminated core produced by the same |
FR3008333B1 (en) * | 2013-07-10 | 2015-08-07 | Air Liquide Welding France | FERRITIC STAINLESS STEEL WELDING YARN |
DE112014004111T5 (en) * | 2013-09-05 | 2016-06-09 | Mahle Industries, Inc. | Wire alloy for plasma arc coating |
DE112013007705T5 (en) * | 2013-12-24 | 2016-09-29 | Posco | Welding material for heat-resistant steel |
US20150360322A1 (en) * | 2014-06-12 | 2015-12-17 | Siemens Energy, Inc. | Laser deposition of iron-based austenitic alloy with flux |
US10646965B2 (en) | 2015-08-11 | 2020-05-12 | Hobart Brothers Llc | Tubular welding wire with a thinner sheath for improved deposition rates |
US10427250B2 (en) * | 2015-09-03 | 2019-10-01 | Hobart Brothers Llc | Systems and methods for welding wires for welding zinc-coated workpieces |
JP6719217B2 (en) * | 2016-01-25 | 2020-07-08 | 株式会社神戸製鋼所 | Stainless steel flux cored wire |
TWI685391B (en) * | 2016-03-03 | 2020-02-21 | 美商史達克公司 | Three-dimensional parts and methods fabricating the same |
US10953464B2 (en) * | 2016-11-22 | 2021-03-23 | The Johns Hopkins University | Empowering additive manufacturing metals and alloys against localized three-dimensional corrosion |
US10799974B2 (en) | 2017-08-16 | 2020-10-13 | Lincoln Global, Inc. | Electrodes for forming austenitic and duplex steel weld metal |
US11701730B2 (en) | 2019-01-15 | 2023-07-18 | Postle Industries, Inc. | Nickel-containing stick electrode |
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FR2513920A1 (en) | 1981-10-02 | 1983-04-08 | Air Liquide | Oxygen-contg. helium rich protective welding atmos. - for welding stainless steel using core-filled welding wire |
US6042782A (en) * | 1996-09-13 | 2000-03-28 | Sumikin Welding Industries Ltd. | Welding material for stainless steels |
US7863538B2 (en) * | 2004-03-19 | 2011-01-04 | Hobart Brothers Company | Metal-core gas metal arc welding of ferrous steels with noble gas shielding |
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- 2007-04-30 US US11/796,913 patent/US8563897B2/en not_active Expired - Fee Related
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- 2008-03-28 WO PCT/US2008/058564 patent/WO2008134167A1/en active Application Filing
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2013
- 2013-10-22 US US14/060,377 patent/US20140042143A1/en not_active Abandoned
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US5378871A (en) * | 1989-08-25 | 1995-01-03 | Kabushiki Kaisha Kobe Seiko Sho | Flux containing wire for use in stainless steel welding |
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US8563897B2 (en) | 2013-10-22 |
WO2008134167A1 (en) | 2008-11-06 |
US20080264924A1 (en) | 2008-10-30 |
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