Weld wire electrode for gas metal arc welding

A weld electrode wire comprising a solid core nested within a solid sheath, the solid core having a non-cylindrical cross section.

A weld wire electrode comprising a solid Mn-alloyed core nested within a metal sheath.

A weld wire electrode comprising a solid metal core made of a metal strip and a solid sheath wrapped around the solid core, the weld wire electrode achieving a deposition rate up to 10.3 lbs/hr at 250 A, up to 15 lbs/hr at 300 A, or up to 18.7 lbs/hr at 350 A in a gas-metal arc welding process.

A weld wire electrode comprising a solid metal core and a solid sheath wrapped around the solid core, the weld wire electrode exhibits a tensile strength up to 75 ksi and impact strength up to 70 ft-lbs at about −20 F.

A gas-metal arc welding apparatus comprising:

• a gas-metal arc welding gun having means for feeding a consumable weld wire electrode, comprising a metal strip bent to form a solid core nested within a solid sheath, into the welding gun;
• and
• an external or internal power source for supplying electrical current to the electrode.

A process of manufacturing a consumable weld wire electrode comprising

• passing at least two continuous steel strips through a series of forming rolls to bent the strips coaxially or non-coaxially, one strip forming a solid core and another strip being wrapped around the solid core;
• and
• drawing the bent strips to a desired diameter of the wire.

A weld wire electrode comprising a non-powdered metal core nested within a solid sheath, the wire having interstices within the metal core and an interface between the core and the sheath, the wire achieving a deposition rate of 10.3 lbs/hr at 250 A in a gas metal arc welding process.

A weld wire electrode comprising a non-powdered metal core nested within a solid sheath, the wire having interstices within the metal core and an interface between the core and the sheath, the wire achieving a deposition rate of 15 lbs/hr at 300 A in a gas metal arc welding process.

A weld wire electrode comprising a non-powdered metal core nested within a solid sheath, the wire having interstices within the metal core and an interface between the core and the sheath, the wire achieving a deposition rate of 18.7 lbs/hr at 350 A in a gas metal arc welding process.