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Though they both feature a filled core section and may appear similar at first glance, metal-cored welding wire and flux-cored welding wire offer distinct solutions, each with its own unique benefits for 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. Metal-cored wire features a different composition than flux-cored wire in that metal-cored wire contains metal powder alloying elements in its core while flux-cored wire contains a flux compound.
Another main difference between the two wire types is that metal-cored welding wire has a higher deposition rate than flux-cored wire, while flux-cored wire has a higher deposition rate than solid welding wire. The higher deposition rate means that the weld is much easier and faster to clean up, producing a smoother bead appearance and providing exceptional efficiency and control. However, flux-cored wire provides superior penetration, giving it an edge over metal-cored wire when welding thicker materials.
Welding position is one of the most prominent differences and may ultimately determine which welding wire is best for your application. Metal-cored wire is limited in that it can only be used in flat and horizontal positions (except pulse welding), while flux-cored wire offers the versatility of several positions, including vertical and overhead welding positions.
Overall, metal-cored welding wire boasts no 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, on the other hand, offers high versatility in position and use in harsh environments.
Metal-cored welding wire is suitable for welding a wide range of metals. As a versatile welding consumable, it is commonly used in various industries such as automotive, manufacturing, construction, transportation, and energy.
Metal-cored welding wire is commonly used in the automotive industry for welding exhaust systems, frames, and other components. Its ability to produce high-quality welds quickly and efficiently makes it an ideal choice for high-volume production environments.
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This industry takes advantage of this wire for welding structural steel as well as for repairing and maintaining heavy equipment. Its high deposition rate and its low spatter feature make it an ideal choice for many construction applications.
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Metal-cored welding wire is a popular choice for welding applications in the energy industry due to its high deposition rate and efficiency, which can lead to increased productivity. Offering better control and improved weld quality, this wire produces successfully welded components.
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Made to handle high-demanding jobs, this wire is also used in the manufacturing industry for welding various types of metals. Its ability to produce consistent and high-quality welds makes it a popular choice for many different applications.
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Metal-cored welding wire has high deposition rates, which allow for faster and more efficient welding. It can help improve productivity and reduce costs in this industry by reducing welding time and minimizing post-weld cleanup.
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Before you begin, make sure that you are utilizing the right welding machine and equipment that are suitable for metal-cored welding wire. This also involves choosing the appropriate diameter of metal-cored welding wire based on the thickness of the material being welded. Once you have the appropriate equipment lined up, you also need to make sure that you clean the surface of the material to be welded thoroughly to remove any contaminants, such as rust, oil, or paint, that could affect the quality of the weld.
Using metal-cored welding wire requires proper selection of equipment, shielding gas, wire diameter, voltage, wire feed speed, and welding technique, as well as careful preparation of the welding surface and post-welding inspection to ensure a high-quality, durable weld. If you have any questions regarding your metal-cored welding wire, check the manufacturer’s recommendations for the right settings, wire feed speed, and amperage range. Our service team is on standby to provide you with further information.
There are several benefits you can expect from using metal-cored welding wire like NS ARC Tru-Core® MC welding wire. Here are some of the most prominent benefits this type of wire provides:
Metal-cored wire has a high deposition rate—even higher than flux-cored welding wire—which means that it can weld more efficiently than other types of welding wire. This can help to increase productivity in welding operations.
The good penetration, low spatter, and smooth, stable arc that metal-cored welding wire provides help to improve overall weld quality. In fact, metal-cored welding wire has an even higher deposition rate than flux-cored wire, meaning that the need for post-weld cleanup is far less and the overall appearance of the welded part is improved.
Metal-cored welding wire provides superior control over the welding process, allowing the operator to adjust the welding parameters more precisely. This makes metal-cored wire a top pick for semi-automatic welding and can help to ensure consistent weld quality and reduce the risk of defects.
By producing a lower heat input than other types of welding wire, metal-cored welding wire can help to reduce distortion in the welded part. This is especially important when welding thin materials or when welding parts that are prone to warping. This, combined with the wire’s controlled penetration, make it excellent for welding thinner metals.
Metal-cored welding wire can achieve higher travel speeds than solid wire, which can help to reduce the overall welding time and bump up efficiency. This is especially applicable in high-volume production environments and semi-automatic production.
Air quality in the welding environment can also be improved by using metal-cored welding wire since it produces fewer fume emissions. Welders can therefore be more confident welding in smaller spaces by using metal-cored wire.
Welding using metal-cored welding wire like Tru-Core® MC from NS ARC can help to improve the control and quality of welding operations while providing exceptional efficiency compared to other welding wire types, making it a popular choice in many industries.
Metal-cored welding wire is a versatile and reliable welding consumable that offers better control, superior welding results, and greater welding speed for increased productivity. Many applications significantly benefit from the many advantages that this type of welding wire offers.
Metal-cored welding wire is commonly used for welding agricultural equipment, such as tractors and plows since it can produce a higher deposition rate and create a strong, durable bond, especially for thicker materials.
Automotive manufacturing can benefit from the use of metal-cored welding wire as it produces a clean, smooth weld bead. This smooth result makes it a great option for both chassis and cosmetic welds in automotive manufacturing.
Metal-cored welding wire offers high deposition rates, which makes it an excellent choice for fabricating automotive exhaust systems on a variety of vehicles.
Metal-cored welding wire can create strong welds that are resistant to wear and tear so it can be utilized to manufacture and repair frames and parts for heavy equipment like bulldozers and excavators, which require high durability.
Versatility is important when working with metal fabrication, so metal-cored welding wire is perfect for general fabrication. Smooth welds and good penetration help to weld and fabricate sheet metal, steel components, and a wide range of both thin and thick materials.
Pressure vessels can benefit from metal-cored welding wire thanks to its high penetration, high deposition rate, and consistent bead quality. These features help pressure vessels maintain structural integrity under high pressure and stress for years of safe use.
Metal-cored welding wire can be used for welding structural components, such as beams and columns. Its high-production rate combined with its higher travel rate allow it to function in high-demanding industries where structural security is essential.
Welding trailers requires strong, durable welds that can withstand the stress and weight of heavy loads, which can be attained by utilizing metal-cored welding wire.
Metal-cored wire is commonly used in the shipbuilding industry for welding various types of steel. Able to produce high-quality welds, it features good penetration and low spatter.
We understand that the quality of our wire is judged by the quality of our packaging, which is why our packaging options for our Tru-Core® MC metal-cored welding wire are each carefully manufactured to protect the wire up to and after it reaches your location. From simple spools to drums, we carry a range of packaging options 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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