Consumables Articles

The devil is in the details, especially when it comes to welding processes. This technology area has information on consumables, including cutting tips, electrodes and wire, spatter prevention compounds, temporary purge dams, and welding torch components.

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Consumables Corner: Welding dissimilar metals using 309 stainless steel

July 27, 2015 | By Nino Mascalco, Rob Koltz, Steve Sigler

The Consumables Corner team counsels a company struggling with weld fusion when joining ferritic to carbon steel.

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Getting to Know Flux-cored Wires

July 15, 2015 | By Jonathan Will

Flux-cored wires have unique welding characteristics and requirements, advantages, and limitations. Knowing these can help in determining whether they are the right choice for your application.

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Using cored wire in submerged arc welding applications

June 11, 2015 | By Robert Fox

Like all arc welding processes, submerged arc welding (SAW) requires the right consumables for the specific application to achieve optimal results. Are cored wires right for yours?

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Consumables Corner: Eliminating weld cracking in restrained joints on high-strength steel

May 12, 2015 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We're a construction equipment manufacturer that is finding that our customers increasingly require more components designed and manufactured from high-strength steels such as A514 or 4130. This means we have to preheat and follow slow cooling conditions, but even then certain joints or...

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Consumables Corner: The right filler metal to weld duplex stainless steel

March 16, 2015 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We manufacture stainless steel tanks used in various industries and we aren’t always informed of service conditions and chemical exposures. We would like to reduce or minimize the number of filler metals we use to cut down on costs and prevent accidental use of the wrong filler metal. The...

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Consumables Corner: Causes of centerline cracking in FCAW root passes

January 20, 2015 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We are a bridge and structural steel manufacturing shop that uses a mixture of common base materials such as A36, A572, and A992. Recently we’ve been experiencing sporadic centerline cracks in the root passes of fabricated I-beams that we weld with flux-cored arc welding (FCAW). Oddly enough,...

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Consumables Corner: Understanding heat input and its limitations

November 21, 2014 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We manufacture structures for the utility industry and primarily weld A36, A572-Gr. 50 and A871-Gr. 65. Recently we converted some of our welding processes to higher-deposition submerged-arc welding (SAW) but are concerned about the amount of heat we are adding from welding. What is the...

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The case for consumables

November 21, 2014 | By Ross Fleischmann

New-generation GMAW consumables reduce the number of components, eliminate threads in the electrical path, and feature gas ported contact tips that run cooler and can accommodate more wire in a single tip.

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Low-alloy filler metals: From A to W

October 22, 2014 | By Blaine Guy

Low alloy steels gain their mechanical and chemical properties from the addition of alloying elements, including nickel, chromium, molybdenum, and manganese. They typically offer an ultimate tensile strength of 80,000 PSI or greater, and as with any material, they require a filler metal that matches their chemistry and provides the desired strength.

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Filler metal facts

October 6, 2014 | By Robert Fox

The factors that influence filler metal consumption, such as joint design and the choice of welding process, are key to helping you better understand, anticipate, and monitor operational costs and the bottom line.

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Consumables Corner: Selecting filler metals for stainless steel welding

September 23, 2014 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We're a midsize job shop that manufactures a wide variety of products from various types of metal. Currently we have a project that requires welding 304L to 316L stainless steel and welding both of these alloys to A572 Grade 50 steel. Some of the welds are structural and some are used in...

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Choosing the right aluminum filler alloy

September 22, 2014 | By Gregory Doria

How do you know which aluminum filler alloy to use? With several varieties out there, it’s important to be familiar with the type of application and the type of results you are looking for. Those and other considerations will lead you to choosing the right alloy.

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Metal-cored wires: Your questions answered

September 8, 2014 | By Blaine Guy

When does switching to metal-cored wires make sense? Answers to the most commonly asked questions about this consumable can help you decide if it’s right for your operation.

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Consumables Corner: Advancements in SAW

August 29, 2014 | By Michael Ostaffe

Q: What role does flux and wire play in submerged arc welding? A: It is important to choose the right flux and wire combination for submerged arc welding (SAW) processes. This will allow you to gain efficiency while meeting your performance requirements. Basic submerged arc welding uses a single...

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Consumables Corner: Eliminating porosity on galvanized steel

August 28, 2014 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: Our company manufactures storage rack systems made from mild steel and galvanized tubing. A majority of our parts are fixture-welded on a robot using 0.045-in.-diameter ER70S-6 wire with 90 percent argon/10 percent CO2 shielding gas. We have experienced problems with weld appearance quality and...

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