Process Pipe Welding Alternative for Filler Metal to Boost Output and Quality

Process Pipe Welding Alternative for Filler Metal

The needs and difficulties specific to processing pipes are the same as for any other welding application. When welding in these applications, welders must follow rigorous regulations and take steps to eliminate potential flaws including lack of fusion, porosity, or other weld flaws that could jeopardize the integrity of the finished weld.


In Process Pipe Welding many welders experience the same limitations as workers in other professions. Tight timelines, a scarcity of qualified workers, the desire to cut costs, and the requirement to produce high-quality welds are all factors.


Some welders have decided to switch from the common gas tungsten arc welding (GTAW) or shielded metal arc welding (SMAW) techniques to wire processes to acquire a competitive edge. Process pipe applications can benefit from advanced technologies like modified short-circuit gas metal arc welding (GMAW) or pulsed gas metal arc welding (GMAW-P), as well as conventional GMAW and flux-cored arc welding (FCAW), which can speed up production, make training easier, and produce high-quality welds.


A Different Filler Metal Is a Metal Cored Wire


The root, fill, and cap passes of process pipes can also be welded using metal-cored wires. Similar to solid wires, these wires can be welded using a modified short-circuit GMAW technique for the root pass and a GMAW-P for the fill and cap passes, allowing welders to standardize on one wire and gas for the whole application. Metal-cored wires, which are also similar to solid wires, offer consistent arcs, little spatter, and calm, manageable weld pools when utilized in conjunction with these welding methods. When compared to solid wires, these wires can occasionally be found in a greater range of metals.


Metallic powders, alloys, and arc stabilizers are encased in a hollow metal sheath that makes up metal-cored wires. Due to the nature of these wires, a wider arc is created when the current passes through the outer sheath than with solid wires, resulting in a wider penetration profile.

The fill and cap pass in the 1G rolled position are welded exceptionally well with these wires. Although there is less apparent smoke, they offer high deposition rates comparable to flux-cored wires. Slag entrapment is not a concern with metal-cored wires, and inter-pass and post-weld cleaning are decreased as a result of the lack of slag production. After welding, some islands of silicon may form, and these islands may need to be brushed away.