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Process characteristics and advantages of flux cored wire

Process characteristics and advantages of flux cored wire

Process characteristics and advantages of flux cored wire

Flux cored wire is a new type of welding material developed in recent decades. It combines the excellent process performance of electrode arc welding and the advantages of CO2 solid wire gas shielded high efficiency automatic welding. Under the action of high temperature of arc, all kinds of substances in the flux core make gas and slag, which is a combination of gas and slag protection for the droplet and molten pool. The welding process performance is obviously improved, the droplet is spray transition, the spatter is small (or no spatter), the weld shape is beautiful, suitable for all position welding. The deposition speed is higher than that of CO2 solid wire, about 4 times of that of electrode arc welding. The continuous welding process reduces the no-load loss of the welding machine; the welding current passes through the thin metal skin, which has a large current density, increases the resistance heat, improves the utilization rate of the heat source, and comprehensively saves 20% ~ 30% of the energy (compared with the electrode arc welding). The comprehensive cost per unit length of weld is significantly lower than that of electrode arc welding, and slightly lower than that of solid wire. Now, the data of welding big gear of Dahui group is used to analyze and compare.

Cost comparison and analysis of welding big gear with flux cored wire and electrode

Welding materials:

Yj502 flux cored wire

J507 manual electrode

Specification of welding consumables(mm)

Φ1.2

Φ4

Welding current(A)

260~280

160~180

Arc voltage(V)

30~31

22~24

Gas consumption(L/min)

17

-

Amount of filler metal(Kg)

40.17

40.17

Deposition rate(g/min)

112.94

23.97

Deposition efficiency(%)

88.84

50

Welding material consumption(kg)

45.22

80.34

Welding unit price(Yuan/kg)

14.80

6.5

Welding cost(Yuan)

669.26

522.21

Arcing time(h)

5.93

27.93

Gas demand(L)

6048.60

-

Gas unit price(Yuan/L)

0.007

-

Gas cost(Yuan)

42.34

-

Arc rate(%)

60

40

Operation time(h)

9.88

69.83

Unit price per hour(Yuan/h)

50

50

Man hour cost(Yuan)

494

3491.50

Power consumption(Kwh)

81.36

273.04

Unit price(Yuan/Kwh)

0.588

0.588

Electricity cost(Yuan)

47.84

160.55

Total cost(Yuan)

1253.44

4174.26

 

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