Dual Shield Flux-Cored Wire Benefits

ESAB Dual Shield Flux-Cored Wire Advantages

There’s a growing popularity in flux cored arc welding due to the versatility it offers. However, before you decide whether it’s the most efficient process for your application, you must consider a number of factors. While cost is obviously an important one, there are additional aspects to take into account.

First, How Flux-Cored Wire is Made

At ESAB, we maintain a 400,000-square-foot manufacturing plant in Hanover, PA. It is one of the most sophisticated and complete facilities for the development and manufacture of welding electrodes in the country. Not only that, but it includes a lab staffed with technicians and engineers devoted to research and experimentation, including with our Dual Shield flux-cored electrodes.

These are made by slitting coiled sheet steel into strips. Strips are passed through rollers that form it into a U-shaped cross-section. The formed strip is then filled with a measured amount of core ingredients. It is passed through closing rolls, shaping it into a tube and tightly compressing the granular core material. The tube is then passed through drawing dies that reduce the diameter and compress the core ingredients to prevent any movement within the tube.

7 Advantages of Flux-Cored Wire

There is no one-size-fits-all welding solution and many variables to consider. However, if you’re wondering about the basics of using flux-cored wire versus MIG welding in your welding application, the information below will help you understand how it can maximize productivity and help you weld cleaner and at faster travel speeds. This includes through:

#1: High Deposition Rates

The ratio of current (amperes) to the cross-sectional area of an electrode is known as the “current density.” Dual Shield flux-cored wire electrodes are capable of high deposition rates because of their relatively high current density.

The current density within a conductor will increase as the cross-sectional area of a conductor is reduced. Resistance to current flow through a conductor also increases as the cross-sectional area of the conductor decreases.

Since the thin metal sheath provides the primary current path in a flux cored electrode, the resistance heating is concentrated in a very small area and the flux cored electrode reaches its melting point very quickly. This results in high deposition rates.

#2: Deep Penetration Profile

The small cross-sectional current path from the Dual Shield flux-cored wire electrodes makes the arc stream assume a more columnar pattern. This leads to deep penetration. The deepest penetration occurs when straight CO₂ gas shielding is used.

Deeper penetration also results in an increase in the effective throat of a fillet joint. A fillet weld made with a coated stick electrode has shallow root penetration. However, when the effective throat of the fillet is increased because of deep penetration, the strength of the joint does not depend as much on the exterior size of the weld.

Oftentimes, the leg dimensions can be reduced, as well. Decreasing the fillet size by as little as 1/16" (1.6 mm) can reduce the total required weld metal by as much as 50 to 60%.

#3: Improved Joint Design

The included angle and/or the root opening of a joint can be decreased with Dual Shield flux-cored wire electrodes because of their small diameter and deep penetration. This tighter joint design significantly reduces the volume of weld metal needed to fill the joint.

The deep penetration of the flux cored electrode has other advantages in the joint design when compared to solid MIG wires. For instance, penetration is substantially reduced with solid wires in out-of-position work due to the low current used with short circuit transfer. Reduced penetration means extra care must be taken to prevent lack of sidewall fusion.

In general, flux cored electrodes can operate at higher welding currents in out-of-position work, greatly improving sidewall fusion. This increased weld integrity minimizes expensive rework.

#4: Rapid Operator Training

Welding with Dual Shield flux-cored electrodes requires a minimum amount of training. In fact, it is much easier to train an inexperienced welder to weld in all positions with flux-cored electrodes than with other welding processes. This is because the fast freezing slag holds the weld puddle or weld pool in place, permitting greater control.

This means it takes less time to train and there’s a lower chance for poor fit. In addition, welders will be producing high quality weldments in a short amount of time.

#5: Better Bead Appearance

Welds produced with flux-cored electrodes are smooth with almost no ripple. The metal transfer of Dual Shield electrodes also produces very little spatter, which significantly reduces clean-up time.

#6: All-Position Versatility

ESAB produces the greatest variety of all-position flux cored electrodes on the market today. With all-position electrodes, the set-up time and expense of fixturing is eliminated.

#7: Cost Savings

Even though some flux cored electrodes may cost more to buy than coated electrodes or solid wires, the real costs of a welding operation are in the labor and overhead expenses. These account for 80 to 85% of the total cost of operations. Dual Shield wires, with their high efficiencies and high deposition rates, reduce both labor and overhead costs. As a result, in many cases, they are actually less expensive to use.

What’s more is that welding with high deposition Dual Shield flux-cored wires produces an immediate means of cost reduction without a significant investment in equipment. Savings with Dual Shield range as high as 60% of the total cost of depositing one lb. (0.45 kg) of weld metal when compared to coated electrodes. They also offer excellent weld metal quality, high deposition rates, and ease of operation.