Abstract: Utilizing a hydrogen compound source as an arc stabilizer is counter-intuitive to standard formulation design practices which often strive to limit or eliminate hydrogen from the welding arc and weld pool. The present disclosure is directed to a tubular metal-cored welding electrode that comprises a metallic sheath disposed around a granular metal core in which the granular metal core comprises an alginate arc stabilizer (as a hydrogen compound source) configured to release hydrogen near a surface of a workpiece during welding. The tubular metal-cored welding electrode may further comprise primary de-oxidizers such as manganese and silicon. In certain embodiments, the amount of manganese in the tubular metal-cored welding electrode may be minimized or eliminated. The tubular metal-cored welding electrode may also comprise nickel or titanium.

Abstract: A welding system includes a welding power source configured to provide pulsed electropositive direct current (DCEP), a gas supply system configured to provide a shielding gas flow that is at least 90% argon (Ar), a welding wire feeder configured to provide tubular welding wire. The DCEP, the tubular welding wire, and the shielding gas flow are combined to form a weld deposit on a zinc-coated workpiece, wherein less than approximately 10 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

Abstract: The disclosure relates generally to welding and, more specifically, to tubular welding wires for arc welding processes, such as Gas Metal Arc Welding (GMAW), Flux Core Arc Welding (FCAW), and Submerged Arc Welding (SAW). The tubular welding wire includes a metal sheath surrounding a granular core. The metal sheath includes greater than approximately 0.6% manganese by weight and greater than approximately 0.05% silicon by weight. Further, the metal sheath has a thickness of between approximately 0.008 inches and approximately 0.02 inches.

Abstract: Systems and methods for low-manganese welding alloys are disclosed. An example arc welding consumable that forms a weld deposit on a steel workpiece during an arc welding operation, wherein the welding consumable comprises: less than 0.4 wt % manganese; strengthening agents selected from the group consisting of nickel, cobalt, copper, carbon, molybdenum, chromium, vanadium, silicon, and boron; and grain control agents selected from the group consisting of niobium, tantalum, titanium, zirconium, and boron, wherein the grain control agents comprise greater than 0.06 wt % and less than 0.6 wt % of the welding consumable, wherein the weld deposit comprises a tensile strength greater than or equal to 70 ksi, a yield strength greater than or equal to 58 ksi, a ductility, as measured by percent elongation, that is at least 22%, and a Charpy V-notch toughness greater than or equal to 20 ft-lbs at ?20° F., and wherein the welding consumable provides a manganese fume generation rate less than 0.

Abstract: A welding system includes a welding power source configured to provide pulsed electropositive direct current (DCEP), a gas supply system configured to provide a shielding gas flow that is at least 90% argon (Ar), a welding wire feeder configured to provide tubular welding wire. The DCEP, the tubular welding wire, and the shielding gas flow are combined to form a weld deposit on a zinc-coated workpiece, wherein less than approximately 10 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

Abstract: This disclosure relates generally to Gas Metal Arc Welding (GMAW) and, more specifically, to Metal-cored Arc Welding (MCAW) of mill scaled steel workpieces. A metal-cored welding wire, including a sheath and a core, capable of welding mill scaled workpieces without prior descaling is disclosed. The metal-cored welding wire has a sulfur source that occupies between approximately 0.04% and approximately 0.18% of the weight of the metal-cored welding wire, and has a cellulose source that occupies between approximately 0.09% and approximately 0.54% of the weight of the metal-cored welding wire.

Abstract: The present disclosure relates to a method for producing a tubular welding electrode comprising the steps of providing a strip of metal material having a length and first and second surfaces, wherein at least the first surface of the strip is at least substantially coated with nickel or a nickel alloy and then copper or a copper alloy, forming the strip into a “U” shape along the length, filling the “U” shape of the strip with a granular powder flux, and mechanically closing the “U” shape to form a sheath of nickel- and copper-coated metal material that substantially encases the granular powder flux, thus forming a tubular welding electrode. In certain embodiments, the metal material may be steel. In certain other embodiments, the metal material may be nickel or a nickel alloy, which may be at least substantially coated with copper or a copper alloy.

Abstract: A microporous tubular welding electrode having a length and a circumference may comprise a granular flux fill core extending substantially along the length of the electrode and a sheath extending substantially along the length of the electrode and substantially surrounding and substantially encasing the granular flux fill core. The sheath may comprise a plurality of pores distributed around the circumference and along the length of the microporous tubular welding electrode. The microporous tubular welding electrode may be formed by first creating a plurality of pores in a strip of material (such as a steel or aluminum alloy) using a process such as laser drilling or chemical etching. Second, the strip may be formed into a tubular welding wire electrode containing a core of a granular powder flux material.

Abstract: The present disclosure relates to a method for producing a tubular welding electrode comprising the steps of providing a strip of copper-coated steel material having a length and first and second surfaces, wherein at least the first surface of the strip is at least substantially coated with a copper alloy, forming the strip into a “U” shape along the length, filling the “U” shape of the strip with a granular powder flux, and mechanically closing the “U” shape to form a sheath of copper-coated steel material that substantially encases the granular powder flux, thus forming a tubular welding electrode.

Abstract: This disclosure relates generally to welding and, more specifically, to electrodes for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW) of zinc-coated workpieces. In an embodiment, a welding consumable for welding a zinc-coated steel workpiece includes a zinc (Zn) content between approximately 0.01 wt % and approximately 4 wt %, based on the weight of the welding consumable. It is presently recognized that intentionally including Zn in welding wires for welding galvanized workpieces unexpectedly and counterintuitively alleviates spatter and porosity problems that are caused by the Zn coating of the galvanized workpieces.

Abstract: This disclosure relates generally to Gas Metal Arc Welding (GMAW) and, more specifically, to Metal-cored Arc Welding (MCAW) of mill scaled steel workpieces. A metal-cored welding wire, including a sheath and a core, capable of welding mill scaled workpieces without prior descaling is disclosed. The metal-cored welding wire has a sulfur source that occupies between approximately 0.04% and approximately 0.18% of the weight of the metal-cored welding wire, and has a cellulose source that occupies between approximately 0.09% and approximately 0.54% of the weight of the metal-cored welding wire.

Abstract: Systems, methods, and apparatus to heat welding wire for low hydrogen welding are disclosed. An example method includes drawing a supply material through a die to form a wire; and applying electrical current to a portion of the wire to reduce a hydrogen content of the wire.

Abstract: Systems and methods for low-manganese welding alloys are disclosed. An example arc welding consumable that forms a weld deposit on a steel workpiece during an arc welding operation, wherein the welding consumable comprises: less than 0.4 wt % manganese; strengthening agents selected from the group consisting of nickel, cobalt, copper, carbon, molybdenum, chromium, vanadium, silicon, and boron; and grain control agents selected from the group consisting of niobium, tantalum, titanium, zirconium, and boron, wherein the grain control agents comprise greater than 0.06 wt % and less than 0.6 wt % of the welding consumable, wherein the weld deposit comprises a tensile strength greater than or equal to 70 ksi, a yield strength greater than or equal to 58 ksi, a ductility, as measured by percent elongation, that is at least 22%, and a Charpy V-notch toughness greater than or equal to 20 ft-lbs at ?20° F., and wherein the welding consumable provides a manganese fume generation rate less than 0.

Abstract: The present disclosure relates generally to welding alloys and, more specifically, to welding consumables (e.g., welding wires and rods) for welding, such as Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), Shielded Metal Arc Welding (SMAW), and Flux Core Arc Welding (FCAW). In an embodiment, a welding alloy includes less than approximately 1 wt % manganese as well as one or more strengthening agents selected from the group: nickel, cobalt, copper, carbon, molybdenum, chromium, vanadium, silicon, and boron. Additionally, the welding alloy has a carbon equivalence (CE) value that is less than approximately 0.23, according to the Ito and Bessyo carbon equivalence equation. The welding alloy also includes one or more grain control agents selected from the group: niobium, tantalum, titanium, zirconium, and boron, wherein the welding alloy includes less than approximately 0.6 wt % grain control agents.

Abstract: The present disclosure relates generally to welding alloys and, more specifically, to welding consumables (e.g., welding wires and rods) for arc welding operations. In an embodiment, a welding consumable includes less than approximately 1 wt % manganese as well as one or more strengthening agents selected from the group: nickel, cobalt, copper, carbon, molybdenum, chromium, vanadium, silicon, and boron. The welding consumable also includes one or more grain control agents selected from the group: niobium, tantalum, titanium, zirconium, and boron, wherein the welding consumable includes less than approximately 0.6 wt % grain control agents. Additionally, the welding consumable has a carbon equivalence (CE) value that is less than approximately 0.23. The welding consumable is designed to provide a manganese fume generation rate that is less than approximately 0.01 grams per minute during a welding operation.

Abstract: This disclosure relates generally to welding, and more specifically, to submerged arc welding (SAW). In an embodiment, a welding system includes a gas supply system configured to provide a gas flow. The system also includes a wire supply system configured to provide welding wire, and a flux supply system configured to provide flux near a welding arc during submerged arc welding (SAW). The system further includes a welding torch assembly configured to receive the gas flow and the welding wire and to deliver the gas flow and the welding wire near the welding arc during SAW.

Abstract: This disclosure relates generally to welding, and more specifically, to submerged arc welding (SAW). In an embodiment, a welding system includes a gas supply system configured to provide a fluorine-containing gas flow. The system also includes a wire supply system configured to provide welding wire, and a flux supply system configured to provide flux near a welding arc during submerged arc welding (SAW). The system further includes a welding torch assembly configured to receive the fluorine-containing gas flow and the welding wire and to deliver the fluorine-containing gas flow and the welding wire near the welding arc during the SAW.

Abstract: Provided is a welding method and electrodes (wires) with aluminum as a primary deoxidizer and a basic flux system for joining a workpieces with weld metal of comparable strengths and enhanced toughness. For instance, provided is a welding wire, comprising an aluminum content configured to act as a primary deoxidizer, and an overall composition configured to produce a weld deposit comprising a basic slag over a weld bead, wherein the aluminum content is configured to kill the oxygen in the weld pool, and wherein the oxygen comprises oxygen provided by a shielding gas or produced by heating of welding filler materials. Further provided is a welding method comprising arc welding a workpiece using an electrode having aluminum as a primary deoxidizer under a gas shield to produce a bead of weld deposit and a basic slag over the weld bead.

Abstract: This disclosure relates generally to welding and, more specifically, to electrodes for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW) of zinc-coated workpieces. In an embodiment, a welding consumable for welding a zinc-coated steel workpiece includes a zinc (Zn) content between approximately 0.01 wt % and approximately 4 wt %, based on the weight of the welding consumable. It is presently recognized that intentionally including Zn in welding wires for welding galvanized workpieces unexpectedly and counterintuitively alleviates spatter and porosity problems that are caused by the Zn coating of the galvanized workpieces.

Abstract: The disclosure relates generally to welding and, more specifically, to tubular welding wires for arc welding processes, such as Gas Metal Arc Welding (GMAW), Flux Core Arc Welding (FCAW), and Submerged Arc Welding (SAW). The tubular welding wire includes a metal sheath surrounding a granular core. The metal sheath includes greater than approximately 0.6% manganese by weight and greater than approximately 0.05% silicon by weight. Further, the metal sheath has a thickness of between approximately 0.008 inches and approximately 0.02 inches.