Tips for Selecting a Solid Welding Wire for Applications

A welder’s performance is never the same twice. However, in many instances, businesses learn to depend on comparable filler metals to do the work. Solid welding wire is one of the filler metals that is most frequently used in the industry. It is a popular option for a variety of applications, including welding, maintenance/repair, and general fabrication and manufacturing. The popularity of the wire can be attributed to its versatility in welding many types and thicknesses of materials, as well as its ease of usage. Today’s welding technology also makes it simpler for welders with different skill levels to produce high-quality welds using solid wire. 

When selecting a solid welding wire for an application, there are a few things to keep in mind, just as with any other form of filler metal. For every solid wire, there are different categories with differing features that might affect the strength and quality of the weld as well as the quantity of post-weld cleanup required.

What is a solid welding wire?

A single metal strand makes up solid wire, a kind of welding wire. It is simple to use and perfect for inexperienced welders because it penetrates deeply and produces little spatter. Flux-cored wires can be welded at greater amperages than solid wire without the weld puddle getting too fluid because of their slag system.

Conversely, solid wire works well in horizontal and flat welding settings. For vertical up applications, 4 mm gas-shielded flux-cored wire is preferable because it can deposit more weld metal than solid wire. 

An Overview of Solid Welding Wire

Solid wire is divided into several categories by the American Welding Society (AWS) according to the mechanical and chemical characteristics that each category offers. In its name, every letter and number denotes a distinct feature. For instance, the designation AWS ER70S-6, which is often used for solid wire, has three distinct meanings: the electrode or rod-like filler metal is indicated by the letter “ER,” its tensile strength is 70,000 pounds per square inch (psi), and its solid nature is indicated by the letter “S.” The criteria for shielding gas and chemical composition are shown in the 6. 

S-3 and S-6 solid wire ends are among the most widely utilized in the industry for MIG welding. In TIG welding, an ER70S-2 cut-length (or rod) is frequently utilized. There are several sizes for solid wires. Solid wires used in submerged arc welding (SAW) operations can have diameters of up to 1/8 inch, while MIG welding applications use wires with diameters ranging from 0.023 to 1/16 inch. The diameters of TIG cut lengths range from 1/16 to 5/32 inches. These sizes, as well as wire-feed speed in a MIG or SAW process, determine typical solid wire working conditions. The welding application’s amperage and the wire feed speed are proportionate. The voltage might be anywhere between 14 and over 30 volts.

Common Types Of Solid Welding Wire

Each category of solid wire has special advantages, rules, and best uses. Following are some typical types of solid wires, along with their details. 

Aws Er70s-6 Solid Welding Wire 

An ER70S-6 solid wire is the most standard option for welding mild steel. This widely general wire is found in available fabrication, and automotive welding applications and can be utilized for automatic welding, as well as to conduct root passes for tube welding and additional required or industrial applications. It delivers soft and even wire feeding, which allows support for greater productivity (there is less rest to handle feeding issues), and the wire supports improve consumable life. With the right use, it makes smooth weld dots with a constant tie-in.

To enhance joint penetration, welding operators can utilize ER70S-6 solid wire with 100% CO2, or they can use a blend of argon and CO2 to reduce spatter. Additionally, they must be informed that these wires frequently cause silicon island deposits to form on the surface of the finished weld. Post-weld cleaning may take longer since they have to remove these residues before painting or applying other surface conditioning techniques. 

Solid wires might not be the ideal choice for welding contaminated metals, even if they typically produce low levels of spatter on clean base materials. An ER70S-6 wire, on the other hand, might be useful for welding through mill scale or minor rust if there is no other option. Higher concentrations of silicon and manganese in this wire work wonders as deoxidizers. 

AWS ER70S-3 Solid Welding Wire 

Another popular option is ER70S-3 solid wire, which is primarily utilized in situations where a clean weld is crucial. This wire produces a clean weld deposit that may be painted or plated with minimal post-weld cleaning, much like an ER70S-6 product. It also offers good wire feeding. This solid wire is a popular option for general fabrication, light sheet metal fabrication, automated welding, automotive applications, and applications needing fast wire feed rates. 

Similar to an ER70S-6, this wire can be utilized with either argon/CO2 or 100% CO2, depending on whether less spatter or increased joint penetration is required. 

AWS ER80S-D2 Solid Welding Wire 

An ER80S-D2 low-alloy solid wire offers greater tensile and yield strength when welding carbon and low-alloy steels. This wire produces high-quality welds that are suitable for a variety of high-strength applications, including welding trailers, pipes, construction equipment, and more. This wire is identified as a manganese-moly alloy by the D2 designator. This wire works well with rusted or filthy metals because manganese acts as a deoxidizer and boosts tensile strength. Molybdenum has strength at high temperatures, but it also has hardenability.

The ER80S-D2 wire’s higher alloy percentage may make controlling the arc in a spray transfer mode a little trickier, leading to more spatter. Welding operators may choose to employ a pulsed MIG procedure in place of this one to address this problem. 

Copper-Free Solid Welding Wire  

The majority of solid wires on the market have a thin layer of copper plating. In addition to preventing wire corrosion, this coating improves electrical conductivity between the steel base material and the copper contact tip. On the other hand, there can be issues with adding copper to some steel base materials. Welding operators may choose to utilize a copper-free wire in circumstances where that is a concern.

Compared to the identical wire with copper plating, copper-free wire has the advantage of being able to be employed in spray transfer mode at a little lower voltage. Compared to short-circuit welding, spray transfer mode enables faster welding and a higher deposition rate for thinner materials. In order to lower the risk of burn-through, this process modification can assist prevent spatter and minimize heat in the arc.

Businesses that utilize copper-free wire must make sure that the coil or spool isn’t kept in storage for extended periods of time at the shop or on the project site because the lack of copper might lead to rusting. If the surface finish or lubrication is incorrect, a copper-free wire may also result in arcing between the contact tip and base material; the welding operator may need to modify welding conditions to prevent this issue. 

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