Abstract: Provided is a welding wire and method for manufacturing a welding wire providing for quality welds on 300 series stainless steel and similar materials. A metal powder core is encapsulated in a metal sheath. The metal sheath composition comprising up to about 6% nickel, by weight, and may correspond to a series 400 stainless steel. A combination of the metal sheath and the metal powder core provides an overall alloy content of a series 300 stainless steel.

Abstract: A self-adjusting liner assembly for a welding torch includes an elongated tubular main body having forward and rearward ends. An elongated tubular retainer including a shoulder is mountable in the main body. An elongated tubular piston including a shoulder cooperates with the retainer in a telescoping relationship in the main body. A resilient member is disposed in the main body and envelops a portion of the retainer and the piston. The resilient member urges the shoulders away from each other and the tubular piston toward the forward end of the main body.

Abstract: A method for imparting wear- and corrosion-resistance to a metal component comprising overlaying the component with a ductile Co-based alloy comprising between about 0.12 wt % and about 0.7 wt % C, between about 20 wt % and about 30 wt % Cr, between about 10 wt % and about 15 wt % Mo, between about 1 wt % and about 4 wt % Ni, and balance of Co, without forming cracks during the alloy's solidification.

Abstract: Cored wires having a core comprising agglomerates of superfine particles and/or nanoparticles for thermal spray or overlay weld applications and methods of making the same are provided. Methods of coating a substrate by thermal spraying such as electric arc spraying with such cored wires are also provided. In an embodiment, a cored wire comprises a metallic sheath at least partially surrounding a core comprising agglomerates of superfine particles, nanoparticles, or a combination comprising at least one of the foregoing particles.

Abstract: A welding electrode comprising a metal core and a flux coating at least partially coated on an outer surface of said metal core, and also including a end coating material which at least partially inhibits porosity of a weld bead formed during the welding operation.

Abstract: A non-copper-plated solid wire for CO2 gas shielded arc welding. The non-copper-plated solid wire for CO2 gas shielded arc welding with excellent feedability ensures a reduced amount of generated spatters when welded at a relatively low current area, resulting from controlling the ten point average roughness (Rz) of the wire surface to 0.10 to 9.00 ?m and the Vickers micro-hardness of the wire surface (Hv(1g)) to 125 to 310. Therefore, the welding operation can be carried out with a high efficiency to produce a weld of good quality.

Abstract: Disclosed is a solid wire for arc welding, including: a flat portion of a wire surface with no copper plating, wherein micro Vickers hardness (Hv) of the flat portion is in the range of 115 to 310 and arithmetical average roughness (Ra) of the flat portion is in the range of 0.01 to 0.30·m. The solid wire is based on a new concept different from a conventional solid wire. The solid wire for arc welding has excellent feedability without copper plating, thereby improving weld workability. Consumption of energy during manufacture of the solid wire can be reduced because the solid wire is manufactured without copper plating, and a weld work environment can be improved because copper fumes are not generated.

Abstract: A welding wire comprising a flux core having a core composition alloyed with a combination of alloying elements is described. The alloying elements comprise Cr and N, wherein the flux core comprises between 10% and 50% of the total weight of the weld wire. A metal sheath encapsulates the flux core, wherein the metal sheath comprises between about 90% and 50% of the total weight of the welding wire and wherein the welding wire can be used in a welding process without destabilizing a welding arc. One of the applications of the wire and welding process of the present invention is hard surfacing of the steel mill rolls, which are hollow cylinders usually on continuous casters. As an example, the rolls welded by the wire and method of the present invention can have a diameter of about 12 inches or less. Additionally, a welding apparatus comprising a welding gun with a device for feeding an electrode into the welding gun is described.

Abstract: Disclosed is a wire for arc welding of high feedability having a hardness deviation of less than 18 between a central portion and a surface of a cross section of the wire, and a hardness deviation of less than 15 between each interval of 200 mm in a longitudinal direction when measured by an Hv1 hardness tester. The hardness deviation of the wire is adjustable through control of the area, in which the wire is in contact with dies. The present invention is characterized by adjusting the hardness deviation of the wire by adjusting the contact area ratio defined by the following formula.

Abstract: The present invention is a weld wire comprising a sheath encapsulating a metal core made of powdered metal, wherein a fill percentage of the metal core is no less than approximately 12%. The metal core comprises a core composition alloyed with an alloying element or an combination of elements comprising Cr, Mo, V, W, Hf and Nb or combinations thereof, wherein a total weight percentage of the alloying element or the combination of elements in the core composition does not exceed approximately 1%. In a particular embodiment, the alloying element is Mo in the amounts selected from the range of about 0 to about 0.5 percent by weight and the fill percentage of the metal core is selected from the range of about 12% to about 30%. In a particular embodiment of the invention, the total percentage of the combination of elements is selected from the range of about 0.4% to about 0.8%.

Abstract: The invention an arc welding solid wire whose surface comprises copper plated film, wherein the elastic limit ratio (elastic limit/tensile strength) of the wire finally produced is controlled in the range between 50 and 88% by installing three to eight elastic limit ratio control vertical rollers and three to eight elastic limit ratio control transverse rollers which have a ratio D/d equal to 40 to 60, following coil control vertical and transverse rollers after final drawing.

Abstract: The art has experienced difficulty obtaining “sound” welds with high-nickel welds above the second pass. Particular problems are tension anomalies and sub-optimal interweld pass fusion at higher order passes of the weld wire, along with undesirably high heat levels transferred to the workpiece. The inventors have discovered that ductile iron-to-ductile iron welds can be reliably formed at mission-critical junctures by compensating for the brittle nature of the heat affected zone through enhancing ductility of the weld itself. The present invention provides in continuing part for a highly durable weld without soundness problems such as tension anomalies, multilayer fusion imperfections, or pinholes; and a method of forming such a weld. The weld is created using high nickel weld wire (filler metal or consumable electrode, or both) welded in a pure inert gas (or mixture of pure inert gasses and even reducing gasses).

Abstract: The present invention relates to high efficiency welding electrodes, and more particularly, to an improvement in section structure of a wire rod for a fusion welding in which the section of the wire rod has a polygonal shape or is formed with a multiple of grooves in the longitudinal direction of the wire rod. Thereby, the sectional area of the wire rod becomes decreased and the surface area of the wire rod becomes increased. Therefore, a welding efficiency is highly improved.

Abstract: Disclosed is a solid wire for arc welding, including: a flat portion of a wire surface with no copper plating, wherein micro Vickers hardness (Hv) of the flat portion is in the range of 115 to 310 and arithmetical average roughness (Ra) of the flat portion is in the range of 0.01 to 0.30·m. The solid wire is based on a new concept different from a conventional solid wire. The solid wire for arc welding has excellent feedability without copper plating, thereby improving weld workability. Consumption of energy during manufacture of the solid wire can be reduced because the solid wire is manufactured without copper plating, and a weld work environment can be improved because copper fumes are not generated.

Abstract: A copper-free wire having worked faces meaning faces drawn with dies and unworked faces continued in the circumferential direction on a wire surface, the copper-free wire has LD/LT ranging from 0.51 to 0.84 and LY ranging from 10 to 40 &mgr;m when measurement lines are drawn at every 5 &mgr;m in a width direction of a measurement area (10,000 &mgr;m2=100 &mgr;m×100 &mgr;m) on the wire surface about 4 wire faces, in which each of the measurement straight lines having a length in the circumferential direction includes at least two worked faces and unworked faces, respectively, in the measurement area, and its starting point and termination point which are all positioned on contact points of the worked faces and the unworked faces.

Abstract: A plating-free solid wire for arc welding has pits opening on its circumference, and wider inside than at each opening, and/or pits having a portion non-irradiated with an externally incoming light. A sulfide and a polyisobutene-containing oil are present in the pits and/or on the wire surface, the latter being present in an amount of 0.1-2 g/10 kg of wire. Twenty or more pits are present in total per and along wire circumference. The effective pit length ratio is 0.5% inclusive-50% exclusive. 0.1-2 g of the oil is present per 10 kg of wire. 0.01-0.5 g/10 kg of 0.1-10-&mgr;m-particle-dia MoS2 is present in “bottleneck-like and/or cave-like pits”, on the wire surface or immediately under the wire surface. A 2-10 mass ppm/total wire mass of K compound in K is present in the pits and/or on the wire surface. These ensure good feedability and lubricating properties, and less spatters.

Abstract: A non-copper-plated solid wire for CO2 gas shielded arc welding. The non-copper-plated solid wire for CO2 gas shielded arc welding with excellent feedability ensures a reduced amount of generated spatters when welded at a relatively low current area, resulting from controlling the ten point average roughness (Rz) of the wire surface to 0.10 to 9.00 &mgr;m and the Vickers micro-hardness of the wire surface (Hv(1 g)) to 125 to 310. Therefore, the welding operation can be carried out with a high efficiency to produce a weld of good quality.

Abstract: A filler wire for laser-welding an aluminum alloy is described, which comprises a base material of Aluminum-Silicon based alloy and a flux of Aluminum-Potassium-Fluorine-based composition. The amount of the flux in the base material is greater than 0 (zero) wt. % and less than approximately 1.0 wt. %.

Abstract: A copper-free wire having worked faces meaning faces drawn with dies and unworked faces continued in the circumferential direction on a wire surface, the copper-free wire has LD/LT ranging from 0.51 to 0.84 and LY ranging from 10 to 40 &mgr;m when measurement lines are drawn at every 5 &mgr;m in a width direction of a measurement area (10,00 &mgr;m2=100 &mgr;m×100 &mgr;m) on the wire surface about 4 wire faces, in which each of the measurement straight lines having a length in the circumferential direction includes at least two worked faces and unworked faces, respectively, in the measurement area, and its starting point and termination point which are all positioned on contact points of the worked faces and the unworked faces.

Abstract: A flux cored wire for gas-shielded arc welding is disclosed. The flux cored wire is excellent in a zinc resistant primer performance and a low temperature impact toughness and comprises a flux filled in a mild steel sheath. The flux comprises: an oxide of TiO2+SiO2+Al2O3 in an amount of 2% to 10% by weight of the wire; at least one component in an amount of 0.1% to 1.0% by weight of the wire, the one component being selected from a metal fluoride group consisting of CaF2, NaF, K2SiF6, Na2SiF6 and KF, a metal titanium in an amount of 0.1% to 0.25 t % by weight of the wire; a metal boron in an amount of 0.002% to 0.008% by weight of the wire; and a subsidiary component in an amount of 5% to 20% by weight of the wire, the subsidiary component consisting of an iron component, a deoxidizer and an arc stabilizer.

Abstract: A welding wire for use in electric arc welding and method of making same, wherein the wire has an effective outer diameter and comprises a length of solid metal formed into a series of distinct segments each having a selected volume and having an indented and non-indented region with the cross sectional area of the solid metal at said non-indented region being greater than the cross sectional area of the solid metal at the indented region.

Abstract: A welding wire for use in electric arc welding and method of making same, wherein the wire has an effective outer diameter and comprises a length of solid metal formed into a series of distinct segments each having a selected volume and joined together by interconnecting bridging elements with the cross sectional area of the solid metal at said segments being greater than the cross sectional area of the solid metal at the bridging elements.

Abstract: Methods and apparatus for replacing an old wire threaded through a flyer winder with a new wire are provided. A first end of the old wire is connected to a first end of the new wire. The wires may be connected by twining, clamping, welding or the like. A second end of the old wire that extends from one of the winder's flyers is then connected to a collection device, and the old wire is collected until the new wire has been threaded through the flyer winder along the same path traveled by the old wire. The collection device may be an armature or similar structure having recesses for collecting the old wire during wire change-over or replacement. Preferably the collection device is configured so that conventional coil lead connection operations may be used to expedite wire change-over or replacement.

Abstract: A solid-solution strengthened superalloy weld composition, includes: about 10 to about 15 wt % Co; about 18 to about 22 wt % Cr; about 0.5 to about 1.3 wt % Al; about 3.5 to about 4.5 wt % Ta; about 1 to about 2 wt % Mo; about 13.5 to about 17.0 wt % W, up to about 0.08 wt % C; up to about 0.06 wt % Zr; up to about 0.015 wt % B; about 0.4 to about 1.2 wt % Mn; about 0.1 to about 0.3 wt % Si; and balance Ni.

Abstract: Disclosed is a wire for arc welding of high feedability having a hardness deviation of less than 18 between a central portion and a surface of a cross section of the wire, and a hardness deviation of less than 15 between each interval of 200 mm in a longitudinal direction when measured by an Hv1 hardness tester. The hardness deviation of the wire is adjustable through control of the area, in which the wire is in contact with dies. The present invention is characterized by adjusting the hardness deviation of the wire by adjusting the contact area ratio defined by the following formula.

Abstract: A welding wire for use in electric arc welding and method of making same, wherein the wire has an effective outer diameter and comprises a length of solid metal formed into a series of distinct segments each having a selected volume and having an indented and non-indented region with the cross sectional area of the solid metal at said non-indented region being greater than the cross sectional area of the solid metal at the indented region.