Cored Wire Process

Metal Cored Wire

Metal cored wires are classified under the same specifications by the American Welding Society (AWS) as solid MIG wires. They combine the best properties of both solid wires and flux cored wires. The basic composition of metal cored wire is a tubular electrode comprised of an outer metal sheath with a core of powdered materials. The metal sheath can be cobalt, nickel, iron, or stainless steel-based. The sheath conducts the electrical current during the welding and thermal spray processes. Metal cored wire’s internal powder composition consists of both elemental and alloyed powders such as nickel, cobalt, chromium, tungsten, molybdenum, and manganese to name a few. 

During the manufacturing process, a metal strip enters a mill, forming the outer metallic sheath to house the powder core. Using a specialized feeding process, the powder is fed into the sheath in a precise manner. The wire is rolled into a tubular shape and then drawn to a final size, ranging from .045″ to .125″ diameter. Typical processes that use these wires include Submerged Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), and Wire Arc Spray/Thermal Spray. 

Some of the advantages of using metal cored wires are that there are higher deposition rates, great sidewall fusion, reduced slag, reduced fumes and special alloys can be manufactured for specific applications. The product can be provided on spools, coils, or drums ranging from 25 to 500 pounds. Click to view our Thermal Spray and Industrial Hardfacing & Welding product lines.