Systems and methods for welding mill scaled workpieces
AssigneeHobart Brothers Company
InventorsSteven Edward Barhorst, Daryl L. Duncan, Joseph C. Bundy, Zhigang Xiao
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Abstract
This disclosure relates generally to Gas Metal Arc Welding (GMAW) and, more specifically, to Metal-cored Arc Welding (MCAW) of mill scaled steel workpieces. A metal-cored welding wire, including a sheath and a core, capable of welding mill scaled workpieces without prior descaling is disclosed. The metal-cored welding wire has a sulfur source that occupies between approximately 0.04% and approximately 0.18% of the weight of the metal-cored welding wire, and has a cellulose source that occupies between approximately 0.09% and approximately 0.54% of the weight of the metal-cored welding wire.
Claims23
A metal-cored welding wire, comprising a metallic sheath that encapsulates a granular core, capable of welding mill scaled workpieces without prior descaling, wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire:
- between approximately 0.04% and approximately 0.18% of a sulfur source;
- between approximately 0.09% and approximately 0.54% of a cellulose source;
- between approximately 0.25% and approximately 0.75% nickel;
- and
- between approximately 0.13% and approximately 0.21% carbon, and
- wherein the granular core of the metal-cored welding wire comprises by weight of the granular core:
- between approximately 0.2% and approximately 1% of the sulfur source, and
- between approximately 1% and approximately 3% of the cellulose source.
A method of welding a mill scaled steel workpiece, comprising:
- advancing a metal-cored welding wire toward a mill scaled steel workpiece, wherein the metal-cored welding wire comprises a metallic sheath and a granular core, and wherein the metal-cored welding wire comprises a sulfur source and a cellulose source;
- providing a shielding gas flow near a surface of the mill scaled steel workpiece;
- electrifying the metal-cored welding wire to establish an arc between the metal-cored welding wire and the mill scaled steel workpiece;
- and
- forming a weld deposit on the mill scaled steel workpiece without forming a substantial slag layer over the weld deposit;
- wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire between approximately 0.04% and approximately 0.18% of a sulfur source, between approximately 0.09% and approximately 0.54% of a cellulose source, between approximately 0.25% and approximately 0.75% nickel, and between approximately 0.13% and approximately 0.21% carbon.
A method of manufacturing a metal-cored welding wire, comprising:
- disposing a granular core within a metallic sheath to form the metal-cored welding wire, wherein the granular core of the metal-cored welding wire comprises by weight of the granular core:
- between approximately 0.2% and approximately 1% of a sulfur source;
- and
- between approximately 1% and approximately 3% of a cellulose source;
- and
- compressing the metallic sheath around the granular core to form the metal-cored welding wire;
- wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire between approximately 0.25% and approximately 0.75% nickel, and between approximately 0.13% and approximately 0.21% carbon.
Dependencies are inferred from the claim text.