Systems and methods for welding mill scaled workpieces
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.
1. A metal-cored welding wire, comprising a metallic sheath that encapsulates a granular core, wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire:
a sulfur source;
an antimony source; and
between 0.05% and 0.14% of a carbon source.
2. The metal-cored welding wire of claim 1 , wherein the sulfur source comprises at least one of potassium sulfate, iron sulfide, and molybdenum disulfide.
3. The metal-cored welding wire of claim 1 , wherein the metal-cored welding wire comprises between 0.04% and 0.18% of the sulfur source by weight of the metal-cored welding wire.
4. The metal-cored welding wire of claim 3 , wherein the granular core comprises between 0.2% and 1% of the sulfur source by weight of the granular core.
5. The metal-cored welding wire of claim 1 , wherein the metal-cored welding wire comprises between 0.09% and 0.36% of the antimony source by weight of the metal-cored welding wire.
6. The metal-cored welding wire of claim 1 , wherein the antimony source comprises antimony alloyed into the metallic sheath.
7. The metal-cored welding wire of claim 1 , wherein the antimony source comprises antimony oxide disposed in the granular core.
8. The metal-cored welding wire of claim 1 , wherein the metal-cored welding wire further comprises a cellulose source.
9. The metal-cored welding wire of claim 8 , wherein the metal-cored welding wire comprises between 0.09% and 0.54% of the cellulose source by weight of the metal-cored welding wire.
10. The metal-cored welding wire of claim 8 , wherein the cellulose source comprises sodium carboxymethyl cellulose.
11. The metal-cored welding wire of claim 1 , wherein the metal-cored welding wire comprises between 0.25% and 0.75% nickel by weight of the metal-cored welding wire.
12. The metal-cored welding wire of claim 11 , wherein the metal-cored welding wire comprises between 0.3% and 0.4% nickel by weight of the metal-cored welding wire.
13. The metal-cored welding wire of claim 1 , wherein the granular core accounts for between 5% and 40% of the metal-cored welding wire by weight.
14. The metal-cored welding wire of claim 13 , wherein the granular core accounts for between 10% and 20% of the metal-cored welding wire by weight.
15. The metal-cored welding wire of claim 13 , wherein the granular core accounts for between 20% and 40% of the metal-cored welding wire by weight.
16. The metal-cored welding wire of claim 1 , wherein the metal-cored welding wire is substantially free of indium.
17. The metal-cored welding wire of claim 1 , wherein the carbon source comprises at least one of graphite or carbon black.
18. The metal-cored welding wire of claim 1 , wherein the metal-cored welding wire further comprises manganese.
19. The metal-cored welding wire of claim 18 , wherein the metal-cored welding wire comprises between 2% and 2.5% manganese by weight of the metal-colored welding wire.
20. A metal-cored welding wire, comprising a metallic sheath that encapsulates a granular core, wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire:
a sulfur source;
an antimony source; and
between 0.05% and 0.14% of a carbon source; and
between 0.25% and 0.75% nickel;
wherein the granular core accounts for between 20% and 40% of the metal-cored welding wire by weight.
21. The metal-cored welding wire of claim 20 , wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire at least 0.025% sulfur.
22. The metal-cored welding wire of claim 20 , wherein the metal-cored welding wire comprises by weight of the metal-cored welding wire between 0.09% and 0.36% of the antimony source.
23. The metal-cored welding wire of claim 20 , wherein the metal-cored welding wire further comprises by weight of the metal-cored welding wire between 0.12% and 1.5% silicon.
24. The metal-cored welding wire of claim 20 , wherein the metal-cored welding wire further comprises by weight of the metal-cored welding wire between 2% and 2.5% manganese by weight of the metal-colored welding wire.