Abstract: The invention relates generally to welding and, more specifically, to corrosion resistant weld deposits created during arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). A disclosed corrosion resistant weld deposit comprises nickel, chromium, and copper, and has a low porosity.

Abstract: Welding rods and associated cladded articles are described herein. Briefly, a welding rod comprises a hard particle component dispersed in a nickel-based alloy matrix or cobalt-based alloy matrix, the hard particle component comprising tungsten carbide particles having an average size of less than 45 ?m, and the nickel-based alloy matrix or the cobalt-based alloy matrix comprising at least one metal carbide forming element.

Abstract: A method for manufacturing an integrated member and an integrated member manufactured by the method which can improve the joining strength and reduce the manufacturing cost. A method for manufacturing an integrated member by welding a first member formed of aluminum alloy material and a second member formed of ferrous-based material characterized in that the first member contains a predetermined amount of silicon and has a thickness larger than that of the second member. The second member can be pressed against the first member along the thickness direction, and by electrically energizing the pressed-in portion during the pressing period, electric resistance welding can be used. The pressing-in amount is set to a value larger than the thickness of the second member and less than that of the first member. The overlapping margin of the first and second members is set to a value of 0.5 mm or more.

Abstract: A system includes a fume collection system that collects fumes from a welding operation, multiple data sources that detect operational data of the fume collection system and/or of the welding operation indicative of at least two of arc on time, operator factor, electrode feed speed, electrode size, and electrode type, an analysis system that analyzes the operational data and estimates fume data indicative of amount and content of the fumes, and a reporting system configured to populate at least one user viewable electronic report based upon the fume data.

Abstract: A method for manufacturing an integrated member and an integrated member manufactured by the method which can improve the joining strength and reduce the manufacturing cost. A method for manufacturing an integrated member by welding a first member formed of aluminum alloy material and a second member formed of ferrous-based material characterized in that the first member contains a predetermined amount of silicon and has a thickness larger than that of the second member. The second member can be pressed against the first member along the thickness direction, and by electrically energizing the pressed-in portion during the pressing period, electric resistance welding can be used. The pressing-in amount is set to a value larger than the thickness of the second member and less than that of the first member. The overlapping margin of the first and second members is set to a value of 0.5 mm or more.

Abstract: A lead-free solder wire includes a core wire with a first alloy and a shell coating layer with a second alloy. The first alloy may be composed of Bi—Ag, Bi—Cu, Bi—Ag—Cu, or Bi—Sb; and the second alloy may be composed of Sn, In Sn—Ag, Sn—Cu, Sn—Ag—Cu, Sn—Zn, Bi—Sn, Sn—In, Sn—Sb or Bi—In, such that the shell coating layer is applied to a surface of the core wire. In another implementation, the lead free solder wire may include a first wire with a first alloy and a second wire with a second alloy. The first alloy may be composed of Bi—Ag, Bi—Cu, Bi—Ag—Cu, or Bi—Sb; and the second alloy may be composed of Sn, Sn—Ag, Sn—Cu, Sn—Ag—Cu, Sn—Zn, Bi—Sn, Sn—In, Sn—Sb or Bi—In, such that the first alloy of the first wire and the second alloy of the second wire are braided together.

Abstract: An electrode for use in a welding process may comprise a finite length electrode core. The electrode core may be encapsulated at least partially within a coating comprising a flux material. One end of the electrode core may be tapered from a first diameter D to a second smaller diameter D1. The tapered end may further be covered with a coating that enhances the arc starting capabilities of the electrode.

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). A disclosed tubular welding wire has a sheath and a core, and the tubular welding wire includes an organic stabilizer component, a rare earth component, and a corrosion resistant component comprising one or more of: nickel, chromium, and copper.

Abstract: Methods for forming an aluminum weld on an aluminum work surface are disclosed. The methods include providing an aluminum metal-core wire having a sheath with an outer surface and a core composition within the sheath, applying a voltage to the aluminum metal-core wire in the vicinity of the aluminum work surface to generate an arc, and melting the wire and the work surface to form the weld. The sheath is formed with an inorganic lubricant on its outer surface and the core composition includes metal powders, metal alloy powders, or combinations thereof and less than about 5% of non-metallic components or non-metallic agents based on the weight of the wire.

Abstract: A solid wire is for gas-shielded arc welding, using a shielding gas, and for galvanized steel sheet welding. The solid wire comprises, to the mass of the whole of the solid wire, predetermined amount of C, Si, Mn, P, S, O, and Cr, with the balance consisting Fe and inevitable impurities. The solid wire satisfies “1.0?(percentage by mass of Si+that by mass of Mn)/{100(that by mass of S+that by mass of O}?4.0” and “0.50?percentage by mass of Mn/that by mass of Si?2.00”. The shielding gas is an Ar gas comprising 25 to 40% of CO2 gas. It is achieved to improve spatter-decreasing performance and pore-resisting performance (performance of restraining the generation of porosity defects, such as pits and blowholes).

Abstract: An electrode is disclosed for use in MIG/MAG welding. The electrode comprises an elongated electrode body within which is embedded a metallic filament. In some embodiments, the filament is copper, and is offset from the center of the electrode body. A method is disclosed for forming an electrode. The method may include removing oxidation from a surface of an electrode body, forming the electrode body to a desired size and geometry, removing lubricants from the surface of the electrode body, forming an elongated channel in a surface of the electrode body, depositing a filament in the elongated channel, and forming the electrode body over the filament. Other embodiments are disclosed and claimed.

Abstract: A shielded metal arc welding electrode for depositing a high strength weld metal bead on a workpiece which satisfies the strength requirements under America Welding Society A5.5 standard's E11018M classification with no chromium added to the composition of the electrode.

Abstract: Electrodes for depositing hardfacing alloys containing boron, carbon, chromium, manganese, and silicon on the surface of metal components that are subjected to high thermal and mechanical stresses. The deposited hardfacing alloys have from about 2.5 to about 14.0 atomic weight percent boron and have a hardness on the Rockwell “C” scale of at least about 65 HRC in the first layer of the weld deposit.

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: A welding additive for electric arc welding and laser beam welding of mixed joins composed of austenitic and high-manganese-containing and ferritic steel, where the high-manganese-containing steel has a manganese content of at least 7-30% by weight includes of the following alloy elements in % by weight: C 0.04-1.0; Mn 7-30; Si?6; Al?4; Mo?2; Ti?0.5; Zr 0.01-01; B 0.001-0.01; P<0.005; S<0.002; N<0.008; balance iron and unavoidable steel accompanying elements.

Abstract: Embodiments of the invention relate to consumables that are used with non-arc deposition processes, including hot-wire deposition processes. Exemplary embodiments of the present invention eliminate the use of arc initiators or arc stabilizers in the consumable. Other embodiments add additional amounts of carbonates in the consumable than would otherwise be present in consumables for arc welding processes. Similarly, other exemplary embodiments of the present invention include additional amounts of nitrides than would otherwise be present in arc process consumables. Other exemplary embodiments include carbides that are desired to be deposited through the non-arc processes.

Abstract: An electric arc welding wire having an outer cylindrical surface and an electrically conductive layer on the surface wherein the layer comprises an alloy of copper with the copper content being about 60% to about 90% by weight of said alloy. Furthermore, the layer can be made thin with a thickness of less than about 0.50 microns while using essentially pure copper.

Abstract: Weld deposit compositions with improved crack resistance, improved wear resistance, and improved hardness are provided by controlling matrix grain size and balancing Titanium and/or Niobium with Carbon and/or Boron content. Additionally, the presence of coarse chromium carbides is drastically decreased to reduce the amount of check-cracking. Preferably, the weld deposit is produced from a flux-cored or metal-cored wire. The weld deposit characteristics include a matrix having a fine grain size, small evenly dispersed carbides within the matrix, and a small amount of Carbon in the matrix.

Abstract: A composition for welding or brazing aluminum comprises silicon (Si) and magnesium (Mg) along with aluminum in an alloy suitable for use in welding and brazing. The Si content may vary between approximately 4.7 and 10.9 wt %, and the Mg content may vary between approximately 0.15 wt % and 0.50 wt %. The alloy is well suited for operations in which little or no dilution from the base metal affects the Si and/or Mg content of the filler metal. The Si content promotes fluidity and avoids stress concentrations and cracking. The Mg content provides enhanced strength. Resulting joints may have a strength at least equal to that of the base metal with little or no dilution (e.g., draw of Mg). The joints may be both heat treated and artificially aged or naturally aged.

Abstract: A welding wire for austenitic stainless steel welding contains, in percent by mass, C: 0.005 through 0.05%, Si: 0.1 through 1.0%, Mn: 1.0 through 3.5%, Cr: 25.0 through 28.0%, Ni: 16.0 through 23.9%, Mo: 1.6 through 3.0%, Cu: 0.1 through 0.5%, Al: 0.001 through 0.02%, and N: more than 0.30 through 0.50%, limiting O to 0.03% or less, P to 0.03% or less, and S to 0.005% or less, and having a ratio of a Cr equivalent to Ni equivalent (Cr equivalent/Ni equivalent) within a range between 0.85 and 1.2 and a PI value of 35 or more, the remainder being iron and unavoidable impurities.

Abstract: The invention relates to a filler material for a thermal production of a joint or of a material layer metallically connected to the base material of or on objects of light metal and/or zinc alloys with a thermal conductivity of more than 110 W/mK, and to a method for producing the same with means for the preparation thereof in situ and/or storage. To improve the quality of the connection, it is provided according to the invention that the filler material is formed as unwindable filler wire, built up of a sheath optionally provided with a surface layer formed from polymer(s) and graphite and comprising aluminum and/or magnesium and/or zinc or a deformable alloy of these metals with a thermal conductivity of more than 110 W/mK and a core of compacted powder, whereby the core material comprises a metal powder and/or a powder of at least one metal compound and/or a non-metallic compound and/or an agent giving off gas at increased temperature and/or at least one component forming slag.

Abstract: The present application relates to iron based glass forming alloys and their manufacture in powder, cored wire and stick electrode form to produce feedstock for a wide variety of weld overlay hardfacing application techniques. The alloys when welded form structures which are extremely hard and correspondingly extremely wear resistant. The novel approach of these alloys allow the replacement of conventional high hardness and wear resistant hardfacing alloys which are often composite materials made up of a binder and hard particles such as carbides, borides, borocarbides, nitrides, etc.

Abstract: A self-shielding welding electrode and a method of making the same are provided. The self-shielding welding electrode contains lithium aluminate in either the flux or the electrode portion of the electrode.

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: Weld deposit compositions with improved crack resistance, improved wear resistance, and improved hardness are provided by controlling matrix grain size and balancing Titanium and/or Niobium with Carbon and/or Boron content. Additionally, the presence of coarse chromium carbides is drastically decreased to reduce the amount of check-cracking. Preferably, the weld deposit is produced from a flux-cored or metal-cored wire. The weld deposit characteristics include a matrix having a fine grain size, small evenly dispersed carbides within the matrix, and a small amount of Carbon in the matrix.

Abstract: The present invention is a weld wire comprising a sheath encapsulating a metal core made of powdered metal, wherein a fill percentage of the metal core is no less than approximately 12%. The metal core comprises a core composition alloyed with an alloying element or an combination of elements comprising Cr, Mo, V, W, Hf and Nb or combinations thereof, wherein a total weight percentage of the alloying element or the combination of elements in the core composition does not exceed approximately 1%. In a particular embodiment, the alloying element is Mo in the amounts selected from the range of about 0 to about 0.5 percent by weight and the fill percentage of the metal core is selected from the range of about 12% to about 30%. In a particular embodiment of the invention, the total percentage of the combination of elements is selected from the range of about 0.4% to about 0.8%.

Abstract: Provided is a welding wire and method for manufacturing a welding wire providing for quality welds on 300 series stainless steel and similar materials. A metal powder core is encapsulated in a metal sheath. The metal sheath composition comprising up to about 6% nickel, by weight, and may correspond to a series 400 stainless steel. A combination of the metal sheath and the metal powder core provides an overall alloy content of a series 300 stainless steel.

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: A cored electrode to form a weld bead with a low diffusible hydrogen is described in a gas shielded electric arc welding process. The cored electrode includes a metal sheath and a fill composition. The filling composition includes a slag forming agent and at least two fluorine containing compounds.

Abstract: A titanium based welding flux that includes titanium dioxide and a moisture resistant agent. The titanium oxide includes purified titanium dioxide that includes little or no impurities that can act as nucleation sites for carbide formation in a weld metal. The moisture resistant compound includes a colloidal metal oxide.

Abstract: A welding wire is formed from a hoop having an inner surface and formed from a metal material, a core wire having a surface and formed from a metal material, and an alkaline metal compound. The hoop metal material and the core wire metal material are different from each other. A composition of the welding wire is divided into the hoop metal material and the core wire metal material. The alkaline metal compound is disposed between the inner face of the hoop and the surface of the core wire. An amount of the alkaline metal compound is from more than 10 ppm to 1000 ppm based on a weight of the welding wire.

Abstract: A method and system to weld or join workpieces of different materials employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: A weld wire electrode for use as a consumable in a gas-metal arc welding process comprises two or more strips wrapped around one another and drawn to a desired wire diameter.

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: A weld deposit produced from a coated welding electrode for use in welding cast irons is provided by the present invention. Preferably, in one form of the present invention, the weld deposit composition comprises between approximately 54% and approximately 60% Nickel, between approximately 3.5% and approximately 5.5% Manganese, and between approximately 0.9% and approximately 1.4% Carbon. The weld deposit is preferably formed by using a coated welding electrode having a coating composition between approximately 0.3% and approximately 4.0% Magnesium and rare earth metals and oxides. The resulting weld deposit exhibits improved ductility, fracture toughness, and resistance to cracking.

Abstract: Weld metals and methods for welding ferritic steels are provided. The weld metals have high strength and high ductile tearing resistance and are suitable for use in strain based pipelines. The weld metal contains retained austenite and has a cellular microstructure with cell walls containing lath martensite and cell interiors containing degenerate upper bainite. The weld metals are comprised of between 0.02 and 0.12 wt % carbon, between 7.50 and 14.50 wt % nickel, not greater than about 1.00 wt % manganese, not greater than about 0.30 wt % silicon, not greater than about 150 ppm oxygen, not greater than about 100 ppm sulfur, not greater than about 75 ppm phosphorus, and the balance essentially iron. Other elements may be added to enhance the properties of the weld metal. The weld metals are applied using a power source with current waveform control which produces a smooth, controlled welding arc and weld pool in the absence of CO2 or oxygen in the shielding gas.

Abstract: Provided is a welding wire and method for manufacturing a welding wire providing for quality welds on 300 series stainless steel and similar materials. A metal powder core is encapsulated in a metal sheath. The metal sheath composition comprising up to about 6% nickel, by weight, and may correspond to a series 400 stainless steel. A combination of the metal sheath and the metal powder core provides an overall alloy content of a series 300 stainless steel.

Abstract: An anti-spatter composition for use with the laser cutting of titanium or titanium containing materials. The anti-spatter composition includes Lecithin and one or more organic solvents. The one or more organic solvents are absent halogen and halogen containing compound. The anti-spatter composition can also include surfactant and water. The surfactant is generally halogen free.

Abstract: A solid wire contains in mass percent C 0.005 to 0.080%, Si 0.30 to 1.20%, Mn 1.15 to 1.65%, S 0.050 to 0.200%, P 0.017% or less, O 0.0070% or less, and N 0.0050% or less, wherein C+(P*5)?0.135 mass percent is satisfied, and the remainder includes Fe and impurities, and the content of each of Ti, B, Cr, Ni, Nb, V, Zr, La and Ce as the impurities is controlled to be a certain content or less, and the amount of adhered oil on a surface of the relevant solid wire is controlled to be 1.2 g or less per wire of 10 kg. According to such a configuration, while increase in welding cost is controlled to the minimum, stability of wire feed, burn-through resistance, undercut resistance, and crack resistance becomes excellent, slag and spatter becomes hard to be generated, hardness of weld metal becomes equal to or higher than that of base metal, and brittle fracture becomes hard to occur.

Abstract: A self-shielding welding electrode and a method of making the same are provided. The self-shielding welding electrode contains lithium aluminate in either the flux or the electrode portion of the electrode.

Abstract: A welding electrode comprising a metal core and a flux coating at least partially coated on an outer surface of said metal core, and also including a end coating material which at least partially inhibits porosity of a weld bead formed during the welding operation.

Abstract: A welding electrode hybrid laser arc welding is provided which is either a solid or metal core electrode. The electrode contains at least carbon, manganese, silicon, sulfur and phosphorus. The electrode has is no more than 0.02% carbon, manganese in the range of 0.6 to 1.2%, silicon in the range of 0.3 to 0.6%, no more than 0.01% sulfur, and no more than 0.01% phosphorus in % by weight of the electrode.

Abstract: A shielded metal arc welding electrode for depositing a high strength weld metal bead on a workpiece which satisfies the strength requirements under America Welding Society A5.5 standard's E11018M classification with no chromium added to the composition of the electrode.

Abstract: An electrode for use in a welding process may comprise a finite length electrode core. The electrode core may be encapsulated at least partially within a coating comprising a flux material. One end of the electrode core may be tapered from a first diameter D to a second smaller diameter D1. The tapered end may further be covered with a coating that enhances the arc starting capabilities of the electrode.

Abstract: A process for producing a coating material for coating welding electrodes and/or for producing a welding powder which can be used in an electric welding, such as in an under-powder welding, a welding powder additive, and/or a flux additive, includes obtaining a titanium-containing by-product or waste product, such as a titanium dioxide-containing material, in at least one of a production step and a production stage during a titanium dioxide production process, such as a titanium dioxide pigment production process. The titanium-containing by-product or waste product is added and/or mixed into a coating material, a welding powder, a welding powder additive, and/or a flux additive so as to obtain a titanium-containing material mixture. The titanium-containing material mixture is processed so as to provide the coating material, the welding powder, the welding powder additive, and/or the flux additive.

Abstract: A wire (10) for use in a brazing or soldering operation has an elongated body (12) of a metallic material. The elongated body (12) has an outer surface (18). A channel (14) is formed along a length of the body. The channel (14) has an opening (A1). A flux solution (22) is deposited within the channel (14) and along the length of the body. The flux solution (22) covers a portion of the outer surface (18). A portion of the flux solution (22) is exposed through the opening (A1) in the channel (14).

Abstract: A shielded metal arc welding electrode for depositing a high strength weld metal bead on a workpiece which satisfies the strength requirements under America Welding Society A5.5 standard's E11018M classification with no chromium added to the composition of the electrode.

Abstract: A method for preparing a filler-metal weld rod of a filler-metal composition includes the steps of centerless grinding the filler metal weld rod of a forced mixture of a mass of titanium aluminide intermetallic alloy powder that was used to form the weld rod, and hot isostatic pressing the filler-metal weld rod at a temperature greater than 2150° F., at a pressure between about 15,000 pounds per square inch and about 25,000 pounds per square inch and for a time of about 1 to 5 hours, thereby increasing the relative density to between about 98% and about 99%.

Abstract: A cored electrode to form a high manganese metal deposition that includes at least about 4 weight percent manganese and at least about 10 weight percent chromium which is useful in joining dissimilar metals and/or for depositing buffer layers on carbon steel and/or low alloy steels.