Metal core wire is a fairly new type of wire that some welders are using for specific projects. This is a tubular electrode and it has a core with a variety of powdered materials and a metal sheath.

When comparing solid wire and tubular wire it is easy to see why some welders use it for specific project. Part of the difference between the two is where the welding current resides. On solid wire the entire section will carry the welding current while with metal core wire the current is only concentrated on the sheet that is outside. The metal powders are granular so they are less conducive to the weld.

The welder will get a more bowl shaped arc when using tubular wire and it will create a finer melting of the metal and the weld pool will be less turbulent.

Why Welders Use Metal Core Wire

This type of wire is more cost effective than other wires because for ever pound of weld metal they save between $100 and $200. This wire has little splatter and there is no slag associated with it. Using burn-through a welder can bridge partial gaps between metals which cannot be done with other types of wire.

When purchasing metal core wire it will be a little more expensive but in other types of wires, filler metals make up at least 10% of the cost. With this wire the welder will have an increase in productivity which balances out with the cost of the wire.

Welders can also weld thinner materials at higher amperages when they need to without worrying about the metals burning through each other. Larger electrode diameters can be used since the metal core wire is made up of metal and granular powder.

Applications for Metal Core Wire

There are a variety of projects that are best done with metal core wire. Some of these include:

• When you have a project that you would normally use single wire with but the weld is more than 3 inches long and you will only make single pass over the metal.

• When you are in the horizontal or flat position and you are using spray transfer.

• When automatic welding is being used or where robotics will make a multiple pass through the metal.

Metal core wire will give a strong fusion especially when you want to bridge a gap or help to eliminate a cold lap.

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Tags: metal core wire, weld, Welders, welding