4.4.3 Advantages and Applications of the Cored Wire Processes
The cored wire processes offer a high quality weld deposit with higher deposition rate and productivity
than the SMAW process. Higher productivity is a result of a high duty cycle, high deposition efficiency
and high travel speeds. Compared to GMAW, the cored wire processes are more tolerant of small
deviations in welding current, voltage, tip to work distance, etc., and therefore are more likely to
provide weld deposits free from incomplete fusion flaws.
Among the three cored wire variations covered here, the self shielded flux cored wires are better able
to tolerate air currents than the others and therefore are a more suitable candidate for field work. In
automatic applications, very high travel speeds are possible with self shielded wires, leading to high
productivity. However, these wires should be properly selected since some formulations are not
designed for multipass welds. Metal cored electrodes produce little if any slag or oxide, similar to the
GMAW process. However, the metal cored wires provide a higher deposition rate than does GMAW,
and also a wider, more rounded bead shape when argon rich gas shielding is used (Figure 4.24).