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: 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: 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 invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). In one embodiment, a tubular welding wire includes a sheath and a core. The tubular welding wire is configured to form a weld deposit on a structural steel workpiece, wherein the weld deposit includes less than approximately 2.5% manganese by weight.

Abstract: The present systems and methods relate generally to the field of welding systems, and particularly to flux-cored arc welding systems with self-shielded electrodes (FCAW-S). In an embodiment, a tubular welding wire includes a core and a sheath disposed around the core. Further, the tubular welding wire includes greater than approximately 2.4% glassy slag promoter by weight.

Abstract: The invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). In one embodiment, a tubular welding wire includes a sheath and a core. The tubular welding wire includes less than approximately 0.4% manganese metal or alloy by weight, and the tubular welding wire is configured to form a weld deposit having less than approximately 0.5% manganese by weight.

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: 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: The invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). In one embodiment, a tubular welding wire includes a sheath and a core. Further, the core includes a carbon source and an agglomerate having a Group I or Group II compound, silicon dioxide, and titanium dioxide. Additionally, the carbon source and the agglomerate together comprise less than 10% of the core by weight.