Manufacture of flux cored wire

Manufacture of stainless steel flux cored wire

The manufacturing process control of flux cored wire is very strict. As the molten filler metal comes from the steel sheet and the components contained in the flux, the size and chemical components must be carefully checked before manufacturing to ensure the quality.

Due to the limited internal space of the welding material, the size of the flux particles becomes more important. The particles form a bird's nest like combination, and the elements of the flux are uneven.

Most of the flux cored wires are rolled into a U-shaped section section by section from a flat metal thin strip. The granular flux is filled in the U-shaped metal groove, and then the flux is tightly rolled into the tubular wire through the final sealing rolling step

The welding wire rolled into a tubular shape will become the final required wire diameter through a series of pulling actions, which can also make the filled flux uniformly fixed in the welding wire skin.

How to prevent some wires from forming hollow (without flux) due to poor control in the welding wire during manufacturing/production is the key to the production quality of flux cored wire. In addition, the wire surface shall be smooth, smooth and clean, otherwise it will affect the smoothness of wire feeding and the transmission of welding current. The welding wires are packaged in rolls or barrels to avoid entanglement or breakage of wires. Generally, the coiled wires are wrapped with plastic sleeves and placed with desiccant to avoid moisture. The wrapped materials are put into cardboard boxes for delivery.

When the skin material is thick, the section is mostly BUTT and the amount of flux is small. For most carbon steel and low alloy steel, the wire diameter of 2.8mm and below is of this shape. When high alloy such as stainless steel and the wire diameter is large, the wire material needs large space to contain flux and alloy elements. The section shape is usually overlapped or heart shaped (LAP and HEART SHAPED) joint.

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