Abstract: The disclosed technology relates generally to welding, and more particularly to consumable electrodes based on aluminum and methods of welding using the same. In one aspect, a consumable welding electrode comprises a base metal composition comprising at least 70% by weight of aluminum and a fluidity-enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660° C. The fluidity-enhancing metal is present in form and a hypoeutectic concentration of 0.05-0.5 weight % such that a solidification temperature range of a molten weld metal formed by melting the consumable welding electrode is less than 65° C.

Abstract: The disclosed technology generally relates welding electrodes, and more particularly to consumable welding electrodes having functional coatings. In one aspect, a welding electrode comprises a core wire having a base metal composition and two or more coatings covering at least a portion of the core wire. The two or more coatings comprise an electrically conductive coating including one or more electrically conducting elements or compounds in addition to or other than copper (Cu). The two or more coatings additionally comprises an additional functional coating including one or more additional elements or compounds adapted to reduce friction of the welding electrode, stabilize an arc formed from the welding electrode, modify a microstructure of a weld metal formed from the welding electrode and/or modify a surface tension of a molten droplet formed from the welding electrode.

Abstract: The disclosed technology generally relates welding electrodes, and more particularly to consumable welding electrodes having functional coatings. In one aspect, a welding electrode comprises a core wire having a base metal composition and two or more coatings covering at least a portion of the core wire. The two or more coatings comprise an electrically conductive coating including one or more electrically conducting elements or compounds in addition to or other than copper (Cu). The two or more coatings additionally comprises an additional functional coating including one or more additional elements or compounds adapted to modify a surface tension of a molten droplet formed from the welding electrode. In another aspect, a method of manufacturing a welding electrode comprises providing the core wire having the base metal composition and forming the two or more coating layers.

Abstract: The disclosed technology relates generally to welding, and more particularly to consumable electrodes based on aluminum. In one aspect, a consumable welding electrode comprises a base metal composition comprising magnesium (Mg) and at least 70% by weight of aluminum (Al), and a smut-suppressing metal. A standard free energy change (?G°) of formation of a smut-suppressing oxide by oxidation of the smut-suppressing metal under equilibrium conditions at a temperature of 1600K or higher is more negative than a ?G° of formation of MgO by oxidation of Mg, such that the smut-suppressing metal is configured to form the smut-suppressing oxide that is thermodynamically more favored over MgO on a surface of a weld metal formed from the consumable welding electrode. The smut-suppressing metal is present in an amount of 0.05-0.50% by weight of the consumable welding electrode.

Abstract: The disclosed technology relates generally to welding, and more particularly to consumable electrodes based on aluminum and methods of welding using the same. In one aspect, a consumable welding electrode comprises a base metal composition comprising at least 70% by weight of aluminum and a fluidity-enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660° C. The fluidity-enhancing metal is present in form and a hypoeutectic concentration of 0.05-0.5 weight % such that a solidification temperature range of a molten weld metal formed by melting the consumable welding electrode is less than 65° C.

Abstract: The disclosed technology generally relates welding wires, and more particularly to coated welding wires. A consumable welding wire comprises a base wire comprising a steel composition and a coating comprising an iron surrounding the base wire, wherein the iron oxide has an oxygen to iron (O/Fe) ratio such that an outer surface of the welding wire has a dark gray to black color.