Abstract: A method for making continuously a cored wire includes feeding a flat metal strip at a first speed during a run, and measuring automatically dimensions of the strip continuously during the run. The strip is formed into a channel open upwardly and sized to hold a quantity of at least one fill material, which is transported continuously during the run and delivered through a metering device at a delivery speed. The delivery speed is automatically adjusted during the run to ensure that the quantity of the at least one fill material deposited into the channel is in a desired core ratio range about the desired core ratio. The delivery speed adjustment is based on the first speed, the measured dimensions of the strip, and the volume of the at least one fill material determined to be in transport by the metering device.

Abstract: An apparatus and method for making cored wire filled with a powdery and/or granular fill material are disclosed. The present invention controls automatically the depositing of fill material used in cored wire manufacturing by accounting for a variety of process changes, such as, for example, variations in strip width, strip thickness, fill material flow, and fill material density. Such automatic monitoring and control uses detected strip measurements and detected fill material volumes to produce a high quality tubular welding wire (e.g., about±0.5% variation from a desired core ratio).