The best welding wire; Rutile flux cored, Metal Cored or Solid welding wire?
Choosing the right welding wire is a crucial aspect of any welding project. Different types of welding wires have unique properties that make them suitable for specific applications. In this comprehensive blog, we compare three popular types of welding wire: Rutile flux cored welding wire, metal cored welding wire and solid welding wire. We discuss their advantages, disadvantages, and areas of application so that you can make an informed choice for your specific project.
Before we discuss the specific types of welding wire, it is important to understand what cored welding wire is. Cored welding wire consists of a metal casing filled with flux or metal powder. These wires can be used in various environments, with or without shielding gas, and are ideal for a wide range of applications. We distinguish between two different flux cored wires: seamless cored wires and folded cored wires.
Folded cored wires are produced by folding a metal strip and filling it with flux, after which it is tightly folded. The folded cored wires are not completely closed, allowing moisture to enter the filling. This moisture absorption can lead to porosities and cracks in the weld. Additionally, the mechanical properties are often lower than those of seamless cored wires.
Seamless cored wires are produced by filling a seamless tube with metal or rutile powder. The tube is then drawn to the desired diameter. Because the wire is completely closed, the chance of porosities and cracks due to moisture absorption is minimal. This is the reason Certilas has only CEWELD seamless cored wires in it’s productrange.
Metal cored Wire
GMAW (C)
Metal cored welding wire contains metal powder in the core, which contributes to the mechanical properties of the weld metal. This type of wire typically requires external gas shielding, such as CO₂ or a mixture of argon and CO₂.
"Metal cored welding wires offer high efficiency, resulting in more efficient welding and higher productivity," says Roel Litjens, Welding Technologist at Certilas. "Increased tensile strength and toughness are achieved thanks to the metal powder and other alloying elements in the core," adds Roel.
Metal cored welding wires create welds with minimal porosity, improving the durability and strength of the weld. This makes them particularly suitable for heavy and critical applications such as shipbuilding, offshore applications, and pressure vessels.
Rutile flux-cored Wire
FCAW
Rutile flux cored welding wire contains a core of rutile (titanium dioxide) and other minerals. This type of welding wire can be used with shielding gas but can also be used without gas shielding.
" Rutile flux cored wire is suitable for welding in various positions, especially vertical up," explains Roel Litjens. The arc is more stable and produces less spatter, resulting in a cleaner weld. The slag is easy to remove, saving time in cleaning the weld.
"Less spatter means less cleaning after welding, what is saving time and costs," adds Roel.
The high deposition rate increases welding productivity, providing an economic advantage. In general, rutile flux cored wire has lower tensile strength and toughness compared to metal cored welding wire, making it less suitable for critical applications requiring high strength and durability.
Solid Wire
GMAW
Solid welding wire is a completely solid wire without the addition of powder. This type of wire is used for MIG/MAG welding (Metal Inert Gas / Metal Active Gas) and requires shielding gas such as argon, CO₂, or a mixture thereof. Roel says: "Solid welding wires produce welds with good mechanical properties, but the chance of lack of fusions is higher."
In general, solid wires are cheaper than cored wires due to the simpler production process. Solid wire produces less welding fumes and vapors, promoting a healthier work environment. The use of clean materials is preferred to avoid imperfections such as porosities. "For positional welding, solid wires are less suitable than cored wires due to the lower efficiency compared to cored wires," says Roel. "This significantly increases production costs," he adds.
The choice between Flux cored welding wire, metal cored welding wire, and solid welding wire strongly depends on the specific requirements of the project, such as mechanical properties, weld quality, costs, and environmental factors. Choosing the right welding wire based on the specific demands of the project can significantly improve the efficiency, quality, and durability of the weld.
As Roel Litjens emphasizes: "Choosing the right welding wire is not only a financial decision but also a technical one." Often, savings are made on the choice of welding consumables, but this is only a small part of the total welding costs, as extensively discussed in our blog"Does seamless fluxcored wire results in higher quality and less welding cost in shipbuilding?":
