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Flux-cored welding wire and metal-cored welding wire offer different benefits and are used in different applications. The main differences between the two that will determine whether you choose one over the other include their composition, the use of shielding gas, their deposition rate, weld quality, welding positions available, and welded material thickness.
Flux-cored welding wire's composition is fundamentally different from metal-cored wire. Flux-cored wire contains a flux compound that provides shielding and helps to remove impurities from the weld, while metal-cored welding wire contains a core of metal powder that provides weld metal deposit alloying and helps to improve the quality of the weld. Though neither has a solid core, they function uniquely from each other.
Another major difference between the two wire types is that flux-cored welding wire has a lower deposition rate when factoring in flux removal, than metal-cored wire, meaning that metal-cored welding wire will be more efficient to use while offering great control (application dependent). Flux-cored wire, however, remains more efficient than solid wire. Despite being less efficient than metal-cored wire overall, flux-cored wire offers superior penetration, though metal-cored wire often produces a smoother bead appearance.
One of the most important deciding factors, however, is welding position; flux-cored welding wire offers the benefit of versatility regarding welding position and can be used vertically and overhead. Metal-cored welding wire requires flat and horizontal positions. The thickness of the material being welded also plays a role, as flux-cored wire’s superior penetration means that it is far better suited to welding thicker materials.
Overall, flux-cored wire is best for varied welding jobs that require welding position versatility, especially in outdoor environments. Flux-cored wire’s versatility lends itself well to both semi-automatic and fully automated welding. Metal-cored wire boasts less slag and easier cleanup, making it more efficient with greater control, but it is fixed to flat or horizontal positions. This makes the wire popular for semi-automatic welding.
Flux-cored welding wire can be used for welding most carbon steels and certain low alloy steels. It is ideal for welding thicknesses varying from 10-gauge sheet metal to heavy plate sections, where “all position” welding capability, stable arc characteristics, and excellent mechanical properties are needed. Industries that often deal with heavy-duty welding and working with thicker materials can benefit from this type of wire, including:
This demanding industry also takes advantage of the flux-cored wire for welding frames, chassis, and other components. This type of wire is known to produce results in a timely manner, allowing for high speed applications without sacrificing quality.
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Flux-cored wire is widely used in the construction industry for welding structural steel, bridges, and other infrastructure projects. It produces straightforward joint design that is necessary in this industry.
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Engineered for higher wire deposition rates, flux-cored wire is used in the energy industry for welding pipelines, power plants, wind towers, and other infrastructure. Its superior arc stability allows it to cleanly join thick materials with
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The wire also lends its strength to the manufacturing industry for welding metal parts, components, and machinery. When secure and consistent welds are absolutely necessary, the flux-cored welding wire tends to deliver optimal results.
Learn moreNS ARC Tru-Core® FC wire offers several benefits that set it apart from many other types of welding wire. These unique features and qualities make it a superior choice in certain applications. Some of the most prominent benefits include:
Flux-cored welding wire has a higher deposition rate than solid wire, which means that you can weld more quickly and cover a larger area in less time. This quality makes flux-cored welding wire especially popular in robotic and automated welding applications.
By producing a more stable arc and offering better penetration, flux-cored welding wire can help provide stronger, more durable welds from a welder who is skilled in flux-cored welding.
Flux-cored welding wire can be used in a variety of welding applications, including welding outdoors, and on dirty or rusty surfaces thanks to its gas shielding. NS ARC always recommends welding on clean, degreased, and prepared welding surfaces.
Less welding equipment may be needed when utilizing flux-cored welding wire since it can be used with a wider range of welding machines than some solid wires. This can be useful for smaller welding businesses and hobbyists.
Flux-cored welding wire may be used on surfaces that are not completely clean, reducing the need for extensive pre-weld preparation and saving time overall.
The shielding gas flux combination used when welding with flux-cored welding wire helps to prevent porosity in the weld. This can lead to stronger, more reliable welds when applied by a skilled welder.
Overall, utilizing flux-cored welding wire like NS ARC Tru-Core® FC Welding Wire is an excellent way to achieve high-quality welds with increased versatility, efficiency, and performance.
Thanks to its high versatility, flux-cored wire is a popular choice for a wide range of welding applications that require effective consistency and reliable welding strength. Some of these applications for flux-cored welding wire include:
Flux-cored welding wire can provide a strong weld with excellent penetration and fusion for welding various components of agricultural equipment like plows, cultivators, and harvesters, which often require high strength and resistance to wear and tear.
Flux-cored welding wire is used in the fabrication and manufacturing of a wide range of different materials. Its reliable strength is especially helpful for welding metal parts, components, and machinery.
Flux-cored wire is often used in the heavy equipment industry for welding excavators, bulldozers, and cranes. While providing great weld penetration for efficient welding, this wire is also one of the more suitable types to use in outdoor environments.
Able to produce strong and reliable welds on large-diameter pipes, flux-cored wire is a popular choice for welding pipelines.
Flux-cored welding wire is frequently used in the construction industry for welding structural steel in buildings, bridges, and other infrastructure projects. The shielding gas produced from flux wire ensures the weld is protected from atmospheric elements.
Various components of trailers like hitches, frames, and axles can be easily repaired with flux-cored welding wire.
Pressure vessels must feature high strength, durability, and resistance to cracking. Flux-cored welding wire can provide these features along with high deposition rates, which can help reduce welding time and increase productivity. It can also be used to weld materials that are difficult to weld with other welding processes, such as high-alloy steels and dissimilar metals.
Because of its high versatility and weld strength, NS ARC Tru-Core® FC flux-cored welding wire can be used across a wide array of applications in several industries. Some of the most common and more general applications for flux-cored welding wire include:
This wire can be used for repair work on various metal surfaces, including equipment, vehicles, and machinery. It is an especially popular choice for repair jobs thanks to its high strength welding.
Flux-cored welding wire may be used on dirty or rusty surfaces without the need for extensive pre-weld preparation, but we still recommend thoroughly cleaning the surface before welding.
While flux-cored welding wire may be used on dirty surfaces, it is always best to ensure the surface is as clean as possible. The metal surface should be removed of any rust, dirt, or other contaminants. Proper surface preparation is essential for achieving a strong and reliable weld. You also need to ensure that you have selected the appropriate flux-cored welding wire for your current application. Consider the thickness of the metal being welded, the welding position, and any other special requirements.
Flux-cored welding wire utilizes a shielding gas to protect the weld from oxidation and other atmospheric contaminants. Additionally, the welding technique used for flux-cored welding wire depends on the specific application and the type of wire being used. Make sure you follow the manufacturer’s recommendations for the appropriate shielding gas to use and for the appropriate welding techniques, including the right welding parameters, such as voltage, amperage, and travel speed.
From individual spools to heavy-duty large-production drums, NS ARC carries a wide range of packaging options for our Tru-Core® FC flux-cored welding wire to suit your requirements. Each of our packages is designed to maximize your productivity.
For large-scale operations, drums are an excellent solution. We pack the wire inside in a loose coil form, and it takes on a large sine wave or an “S” shape. The drums can also be used for storage.
For smaller-scale productions, our fiber spools feature the wire randomly layer wound along the spool.
Our Smart Paks® are similar in function to our regular drums except inside our Smart Pak® package, a 12-sided cardboard core contains the wire, and the core is encompassed by a rugged outer cardboard box. All components of the Smart Pak® are 100% recyclable, helping to reduce waste and cut down on disposal costs. In addition, there are multiple engineered wire dispensing solutions for greater efficiency. Smart Paks® provide wire pay-off that produces quality welds, and reduce downtimes associated with change-outs. NS ARC Smart Paks® are also designed with a lifting strap for easier placement.
The proprietary winding technology of our Tru-Trac® Wood Reels features “twist-free” wire let-off that requires only a few ounces of drag. The design of this packaging maximizes productivity while lowering welding costs using the smaller dispersion pattern. The snag-free operations without the drive roll overload are there to deliver precise joint tracking.
If you have any questions before making a purchase chat with our online operators to get more information.
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