Abstract: Apparatuses, systems, and methods for manufacturing grooved wire are provided. A set of rollers may form grooves on an outermost surface of a wire along an axial distance of the wire. The set of rollers may include a first roller and a second roller. The first and second roller may include groove-fabricating portions aligned circumferentially around a radial face of each of the rollers. The first roller and second roller, via the groove-fabricating portions, may form grooves on the outermost surface of the wire along the axial direction of the wire.

Abstract: An electrode (10) is presented including a sheath (14) formed of a ductile material, an outer coating (16) including a flux material, and a core (12) including at least one of flux material and alloying material. The ductile material may be an extrudable subset of elements of a desired superalloy material and the alloying material may include elements that complement the ductile material to form a desired superalloy material when the electrode is melted. The outer coating may be formed of a flexible bonding material or it may be segmented (18, 20) to facilitate bending the electrode onto a spool. Any hygroscopic material of the electrode may be included in the core to protect it from exposure to atmospheric moisture.

Abstract: A speedy method of welding in a tight space using a single pass is provided using a technique which involves the use of a particularly shaped, flux treated consumable insert to provide deep weld penetration by a GTAW machine which is compact and fits the narrow spaces found in applications such as feeder tube repair since it does not require an insert wire flux feed system and is thus capable of negotiating narrow spaces found in feeder tubes.

Abstract: A continuous welding electrode suitable for short circuit welding is provided. The electrode has a continuous metal core with a welding flux material coated on its entire outer surface and circumscribing gaps are formed at regular interval over its entire length to expose a portion of the metal core. The gaps are adaptable for applying the welding current to the electrode in the welding operation. The melting temperature of the welding flux material is about 0.8 to 0.9 times the melting temperature of the metal core; and the unit weight of the welding flux material coating is about 0.37 to 0.48 times the unit weight of the metal core.

Abstract: A continuous welding electrode suitable for short circuit welding is provided. The electrode has a continuous metal core with a welding flux material coated on its entire outer surface and circumscribing gaps are formed at regular interval over its entire length to expose a portion of the metal core. The gaps are adaptable for applying the welding current to the electrode in the welding operation. The melting temperature of the welding flux material is about 0.8 to 0.9 times the melting temperature of the metal core; and the unit weight of the welding flux material coating is about 0.37 to 0.48 times the unit weight of the metal core.

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: 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.