Flux-cored wire machines

The manufacturing process of a flux-cored electrode begins by cutting coiled sheet steel into strips. Special rollers then bend the strips into U-shaped parts. Simultaneously, the formed strip is filled with a specific amount of core materials. The U-shaped strip then goes through closing rolls which form it into a tube, tightly compressing the granular core material.
Special drawing dies then reduce the diameter of the tube and further compress the core materials to prevent any movement within the tube.

Equipments required

Rewinding line composed by:
- strip coil payoff;
- strip butt welding;
- strip washing unit;
- strip spooling machine.

Forming and pre-drawing line composed by:
- spool payoff;
- tube forming, filling, and closing units;
- wire drawing machine;
- spooler.

Redrawing line composed of:
- spool payoff;
- wire annealing oven;
- wire drawing machine;
- lubrication unit;
- spooler.

Layer rewinding line composed of:
- motorized spool payoff;
- pneumatic dancer synchronizer;
- layer winder for steel baskets or plastic spools.

Flux cored wire advantages

The flux cored wire (FCW) provides many advantages, including excellent welding quality, high deposit rates, and ease of operation. Labour and overhead are the most expensive factors in any welding operation, usually around 80%-85% of the total cost. Welding with high-deposit FCW electrodes provides an immediate cost reduction without major investments in specialized equipment.

- Excellent weld quality due to deep penetration and lower root opening of the joint.
- All-position versatility with the right filler metals, with or without gas shielding, reduces setup time and the need for special fixtures.
- Shielding gas is not mandatory. Thus, these products are suitable for outdoor welding and/or welding in windy conditions.
- Less post-processing cleaning required, as weld joints are smooth with almost no ripples and very little spatter.
- Metallurgical benefits, such as the weld metal being protected from external agents until the flux is chipped away.

Alloys on which flux cored wire is used:
- mild and low alloy steel;
- stainless steel;
- high nickel alloys;
- hard facing/resurfacing alloys.

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