Every welding power source, component and filler metal has its unique benefits, as well as certain limitations. Metal-cored wires are no different. While certainly not a new technology, metal-cored wires have been gaining popularity in recent years, particularly in the manufacturing, fabricating and repair industries. Still, there seems to be some mystery surrounding this filler metal, with much less known about it among the general public compared to its counterparts, including solid wires. In many cases, there are some common misconceptions surrounding metal-cored wires, too.

To gain a better understanding of metal-cored wires, it helps to consider the technology behind these filler metals and the applications for which they are best suited. Additionally, it is important to know the general characteristics of metal-cored wires, along with the ways they can bring potential improvements in the welding operation.

When used with the right applications, metal-cored wire can help minimize costs, improve quality and increase productivity in the welding operation. Like any filler metal, metal-cored wire has unique characteristics, benefits, limitations and applications where the wire is best suited. Knowing when and how to use this wire can help companies achieve the best success with the product.

This article discusses the most appropriate applications for metal-cored wire, some of the characteristics to consider when choosing this filler metal and tips for welding successfully with metal-cored wire.

Reducing the opportunity for moisture pickup — in the filler metal and deposited weld metal — is important in any welding operation, but especially in industries with more critical applications.

Controlling moisture helps minimize the risk of hydrogen-induced cracking in these demanding, high-strength applications, and with it costly repairs or potentially catastrophic weld failures.

Seamless wires can help in moisture-control efforts. These filler metals also offer excellent impact toughness, even at lower temperatures, and low hydrogen properties to further mitigate cracking risks.

Weld failures can occur in any number of ways and are often caused by simple oversights in the welding operation. In many cases, those oversights can result from lack of proper training about the techniques required for welding on a particular material or joint style. Regardless of the reason, the result is the same. Issues like hot and cold cracking toweld defects like lack of sidewall fusion, slag inclusions or cold lap result can occur, causing delays in production and downtime for rework of parts. Both problems adversely affect the welding operation’s overall productivity and profitability. When a part is rejected for a weld failure, a company incurs the time, labor and cost of identifying and rectifying the problem. Not only that, but the company also runs a greater risk of compromising safety should a weld fail in a particularly critical application.

There are, however, precautions welding operators can take to protect against weld failures. Such provisions can help mitigate unnecessary costs, support greater productivity and help the welding operation remain more competitive.

Following are six key ways to prevent weld failures.

Stainless steel is not a specific material, but a common term for a group of corrosion-resistant steel types. Stainless steels are steels which normally have a chromium content of at least 10.5%.

Welding of stainless steel requires knowledge about the material as well as welding methods and products to maintain the material’s stainless properties.