Introduction
Have you ever welded? If you have, then you are probably aware of the wonderful world of welding wire. Welding wire is the one the most essential item needed in the welding process. This little beauty or sometimes not so pretty component is the prime point at where the two base metals are joined together.
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When a welder places their welding gun over their item and applies the heat, the wire is being melted by the heat of the welder. The wire droplets then fall into the weld pool, and melt to create a weld. It is very important to note that choosing the correct or incorrect wire can have a major jesting on the quality of weld. So, why don’t we get knee deep in welding wire. What are the different types of wire? What are all the sizes you can get? What can you do with it when it comes to welding?
Types of Welding Wire
What type of filler metal should I use? Well, that primarily depends on what type of filler and shielding gas is being used. However, in general, you’ll most likely have a filler metal that is the same “family” as your base metal. So, if you’re putting mild steel on mild steel then your wire will most likely be E70 wire.
Solid wire is exactly what it sounds like. Inside the wire is filler metal that, when heated, creates the bond between the base metals. You will need a gas shielding system for this process because the solid wire is unable to have any shielding materials inside of it.
The main difference between flux cored arc welding and MIG welding, is the way the electrode is shielded from the air. Flux cored arc welding just like the name implies, has a hollow wire with flux in the center, similar to wire used in the wire feed section of a MIG welder. Just like MIG welding, a machine is used. For the gas-shielded wire, you’ll often see the letters “AWS” on it.
Metal-cored wire contains metal fillers that mix with either flux or metal powders to create the weld. This type of welding wire is not only easy to use, but those who prefer it to their solid wire counterparts boast less spatter and easier post-weld cleanup, if that even matters to you.
Sizes of Welding Wire
Now onto what sizes of welding wire is going to best suit you on your next project.Your welding wire size for your welder will depend on the voltage, amperage, type of welder and what you are welding. There are many different sizes, with the most common sizes ranging from. 035 to. 045. The larger the wire the more heat and power you are going to require to run it. So if you don’t have 220v. machine you may be limited to the wire you can use. Also you need to consider wire feed rate which is due to voltage and amperage as well. An amperage typically less than 220 Amps is suitable for wire diameters of 0.035” – 0.068” fin thickness of 1/4 – ½”; for wire diameter of 0.45” – 1/16” thickness of 1/2 – 3/4”; for diameters of 0.072” – 5/64” thickness of 3/4” and above.
Applications of Welding Wire
The applications of welding wire are literally endless.How about inside the automotive industry, have you ever looked inside your cars or trucks frame work before it gets painted to the beautiful vehicle that gets to see daylight? Welding wire. Shipbuilding? Welding wire. You also have a pool of options in the medical system, the aerospace industry and even in a remarkable project like a roller coaster. Do you know how many meters or miles of metal it takes to create a roller coaster? Lot of wire is consumed in the process.
Choosing The Right Welding Wire
The information you need to know about welding wire is what they are. You have to look at three things: AWS classification, wire size thickness and shielding gasses. You have to look at those three things, as well as the project itself such as if you are welding mild steel or stainless steel or else with consideration of project expense and availability.
In conclusion, welding wire is all about knowing how to bond two pieces of metal, whether you’re using the same material and welding process or whether you’re stretching the limits a bit. The application along with the right alloy and metal thickness, with the right shielding gas all should match.
