How to choose the right welding wire

How to choose a welding wire - review of types and selection of the best welding wires for a semi-automatic machine

The popularity of mechanized welding equipment is increasing every year. It allows you to obtain a high-quality permanent connection at relatively low financial costs. In order to successfully work with such equipment, you need to know several nuances, the most important of which is the selection of welding wire for semi-automatic machines.

Wire classification

When welding in semi-automatic mode, the wire acts as a consumable electrode. The heat generated from the electric arc melts the edges of the metals and the electrode. A weld pool is formed, which, after final crystallization, forms a weld bead.

GOST 2246 establishes more than 70 names (grades) of wire, which are divided by application, type of materials being fused, and size.

Application area

Considering the types of wire, it should be noted that it is used not only for assembling two or more parts, but also in the following cases:

• surfacing. Surfacing wire is applied to the surface of the product to repair it or impart special properties (hardness, wear resistance);
• production of electrodes. This material has the letter “E” in its designation. The blanks are cut to a certain length, after which a special coating is applied to the rods.

For carbon steel

To connect low-carbon and low-alloy steels (st. 3, 09G2S), copper-plated welding wire is used. The process is carried out in a protective gas environment (carbon dioxide). Thanks to the copper coating, the seam is durable, with good mechanical properties and resistance to destruction.

Another advantage is minimal spatter, which reduces the labor intensity of cleaning after welding. Disadvantages include harmful copper fumes released during welding.

For stainless steel

For welding steels of austenitic, austenitic-ferritic classes with the addition of chromium, nickel (12Х18Н10Т, 08Х18Н10Т), a copper-plated electrode is not suitable - the welding site will quickly become covered with rust.

In this case, stainless steel wire is the best option. The material is characterized by corrosion resistance, high melting rate, and heat resistance. The same is true for welds.

The protective gas mixture is formed by inert argon, helium with the addition of a small amount of carbon dioxide. Among the disadvantages is the high price.

For aluminum

Alloys such as AMg2, AMg5, etc. welded with aluminum wire. Inexperienced welders may encounter a number of difficulties. To obtain a high-quality weld you need:

Remove the refractory oxide film from the surfaces of parts by mechanical treatment (circles, brushes with stainless bristles) or chemically (etching).

Select optimal welding modes. Aluminum wire is very soft and melts much faster than steel wire. Even slight resistance in the sleeve causes the material to begin to curl.

Powder

Many experienced welders, when asked which welding wire is better, answer – flux-cored wire. If all previous welding materials had a solid cross-section, then this one is a tube with a powder filler.

As the powder evaporates, it works like flux - it protects the weld pool from contact with the atmosphere. Therefore, the consumable is sometimes called self-protective - there is no need for gas cylinders.

Depending on the composition of the charge, fluorite, rutile, carbonate-fluorite and other varieties are distinguished. Factors that limit the mass use of flux-cored wire are high price, impossibility of use at the slightest deformation, and careful cleaning of the fused edges.

Marking

If you look at the photo of the welding wire, you will notice that it is supplied in coils. Each coil must have a tag containing information about the brand, batch, manufacturing plant, and quality control approval.

Domestic wire is designated according to GOST 2246. The marking consists of an alphanumeric code, where the letters are the names of chemical elements, and the numbers are their percentage content. If the amount does not exceed 1%, then the number is not indicated. The abbreviation “Sv” indicates that the wire is welding.

So, Sv-08G2S means that we have a welding wire with 0.08% carbon, 2% manganese and no more than 1% silicon.

Imported materials are labeled according to AWS standards.

How to choose the diameter

The diameter of the welding wire should be selected based on the thicknesses being welded. The standard range includes the following standard sizes: 0.6 mm; 0.8 mm; 1.0 mm; 1.2 mm; 1.6 mm. For powder electrodes this range is increased to 6 mm.

For welding parts with a thickness of 3-5 mm, wire with a diameter of up to 1.2-2 mm is suitable. For thin-walled products it is better to use 0.8-1 mm electrodes. This will protect you from through burns. Remember that the hole diameter of the welding tip must match the size of the wire.

The second selection criterion is the current value set during welding. To compare diameters and current, you need to familiarize yourself with the corresponding tables.

Requirements for welding wire

The correct wire is the key to a reliable welded connection. When purchasing materials, pay attention to the following parameters:

 The characteristic of welding wire is its chemical composition. It should be as close as possible to what is present in the metal being welded. The less sulfur and phosphorus in the wire, the better the connection.

The wire must be clean; no traces of dirt or oil are allowed on its surface. Otherwise, it is better to degrease the material in solvents.

The melting point of the electrode must be lower than that of the base metal. In this case, the melting should be uniform. This will help avoid seam defects and reduce sagging and unevenness.

Photo of welding wire

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How to choose a welding wire: rules for selection and features of the welding machine

Wire is a long metal product that is used in many areas of electrical engineering, mechanical engineering and construction:

1. In construction, steel wire is mainly used for constructing barriers, making meshes, and reinforcing structures.

2. In mechanical engineering they are used for the production of wire ropes, nails, springs, welding electrodes, hardware, and reinforcement of structures (including metal cord).

3. In electrical engineering - for creating heating elements, rheostats, current-carrying cables.

Since wire is considered a hardware product, almost all hardware factories produce it in large quantities. At the moment, the use of wire can be found in any area - in households and everyday life, in construction and industry. It is widely used for the manufacture of fences, chain-link mesh, welded mesh, electrodes, nails and springs.

It is an indispensable element in ropes and cables, rheostats, electrical wires and various heating devices. In addition, it is widely used for strengthening reinforced concrete structures as reinforcement

The diameter of the wire, depending on the future purpose of the rolled metal product, can vary from 0.3 to 6.3 mm.

In addition, this material can be produced galvanized, or without coating at all (this parameter depends on various operating conditions).

Test methods

The following methods have been developed for checking the quality of manufactured products:

• weight;
• volumetric gasometric;
• dives.

Their reliability is based on the sampling method of the general theory of statistics. Therefore, as experience shows, it is sufficient to sample one sample from each given batch.

The first method involves visual inspection and weighing. Visual inspection allows you to determine the condition of the selected sample, determine the diameter and depth of detected defects.

These parameters are usually measured using appropriate measuring instruments. The diameter and degree of ovality of the steel wire are measured in two planes using a micrometer. Then the obtained data is checked against GOST 6507-78.

A prerequisite for such measurements for galvanized wire is the absence of excessive sagging.

Wire quality control

Based on this method, the mass of zinc located on the surface of the sample is determined by calculating the difference in the mass of the sample with zinc and the mass of the sample with the coating removed. Next, the arithmetic mean is calculated using a well-known formula. The error of such estimates, when thoroughly tested, does not exceed 0.001 g.

Next, they begin to evaluate the sample according to the following indicators: bending, stretching, and tearing. If the diameter of the selected sample does not exceed 0.5 mm, it is possible to replace the conventional test with the size of the gap with a formed knot.

Download GOST 3282-74

After this, a test is carried out for the so-called winding. Wind the steel wire onto a rod of the same diameter as the wire itself. If the diameter exceeds 6 mm, then the diameter of the rod should be twice the diameter of the sample. Then the weight characteristics are measured.

It is used in resolving controversial situations and for conducting arbitration analyses.

Volumetric gasometric method

In preparation for research, the entire zinc coating of the sample is removed down to the steel surface. For this purpose, it is immersed in a special solution.

The final result is calculated as the arithmetic average of several test results.

Heat-treated steel wire

The order in which this method is implemented is determined by the following sequence of operations:

• from the presented sample, several pieces of wire of the same length are selected (the difference in length should not exceed 0.5 mm);
• each section is thoroughly degreased (degreasing solutions can be: alcohol, gasoline or other suitable chemical solutions);
• then, using the chemical properties of zinc, they dissolve it (they try to catch all the hydrogen released);
• in laboratory conditions, the volume of hydrogen produced is measured;
• using a well-known formula, the surface density of zinc is calculated;
• In sulfuric or hydrochloric acid, the so-called zinc stripping is performed.

Immersion method

In this method, the selected sample is immersed in a solution of copper sulfate. The density of the solution should be 1.116 g/cm3. At a temperature of 18 °C.

In this case, the following order is followed to obtain the results:

• prepare several test steel bars of the same length (usually 150 mm);
• carry out degreasing with washing with distilled water;
• each steel sample is thoroughly wiped from traces of liquid and dried;
• then dipped into the prepared solution (it contains copper sulfate);
• the distance from the location of the bars to the surface of the solution should be 100 mm, immersion time - 60 seconds;
• six steel samples are tested simultaneously;

After the test, the remaining copper coating on the surface of the bars is checked. If there are areas with remnants of copper coating on the surface of at least one steel bar, the sample did not pass the test. The assessment is made visually.

Calculation of section parameters using a table

Having made the necessary measurements, you can determine the cable cross-section using the indicators in a special table. By measuring the thickness of the core diameter using a special table, you can determine the cross-section.

The cable cross-section calculation table is as follows:

Thanks to this table, you can find out the necessary information very quickly and without unnecessary problems. The table shows the cross-sectional area of ​​different cables and allows you to significantly simplify the calculation process, because some novice electricians, using only a formula, find it difficult to determine this indicator.

Flexible cable cross-section measurement

For a multi-wire flexible cable, its own method of measuring cross-section is used. This method consists of the following points:

• wrap one vein from the bunch around a pencil;
• measure the length of all turns;
• divide the length by the number of turns and multiply the result by the total number of wires.

The method is quite simple and understandable, so absolutely everyone can use it. To take measurements correctly, you need to perform all actions as carefully as possible.

This procedure is not difficult for professional electricians, but it will not be so easy for beginners to cope with this task. In such a responsible process, the main thing is to do everything carefully and then you can get the most accurate result.

Determining cable cross-section using a ruler

It is possible to measure the cable cross-section by using a simple ruler. This is a very old method of taking measurements, but it is no less effective than carrying out the same actions using special instruments. To take a measurement using a regular ruler, follow these instructions:

• carefully strip the core of insulation;
• tightly screw the core onto a regular pencil;
• measure the total length of the winding using a ruler;
• divide the winding length by the total number of cores present in the cable.

When winding a core around a pencil, you need to make sure that you get at least 15 turns. The coils should be pressed very tightly against each other, so that there is no free space between them. It is necessary to take measurements not just once, but several times in order for the result to be as accurate as possible.

It is important! This method is only suitable for determining the diameter of thin wires. If the cable is thick, it will be very difficult to wind it, which will not allow you to do everything efficiently and take accurate measurements.

Where can I buy

Many companies, including manufacturers and suppliers, are engaged in the sale of welding wire. The assortment varies, some companies provide a complete list of consumables, others sell certain types or brands. In any case, each buyer has the opportunity to purchase the necessary products at the best prices.

Sections: Welding wire

Source: https://instanko.ru/drugoe/provoloka-eto.html

Welding wire for semi-automatic machines: types, comparison, review of the best models

Semi-automatic welding under MIG/MAG gas protection is easy to perform and allows you to quickly make continuous seams in all spatial positions, and therefore is popular. To figure out which welding wire is best for a semi-automatic machine, we have compiled a rating by type of filler material, taking into account the characteristics and positive reviews. This will help you select the wire for your specific application and ensure the best possible weld.

The selection of products was made on the basis of reviews, opinions and ratings of users posted on various resources on the Internet. All information is taken from public sources. We do not cooperate with manufacturers and brands and do not encourage the purchase of certain products. The article is for informational purposes only.

Best Copper Coated Welding Wire

This type of welding wire is used for welding carbon and structural steels. The interior is made of plain metal, while the outer coating is enriched with copper, which reduces spatter and delays the formation of hot cracks. This is also suitable for welding cast iron.

The wire has increased tensile strength and is perfect for use in the garage, country house and production where welding of “black iron” is required.

SV-08G2S-O (0.8 mm; coil 5 kg) Cedar	OK Autrod 12.51 (0.8 mm; 5 kg) ESAB
Weight, kg	5	5
Diameter, mm	0,8	0,8
Eurocoil	D200	D200
Homeland of the brand	Russia	Sweden

SV-08G2S-O (0.8 mm; coil 5 kg) Cedar

Domestic product for welding in inert gases. The convenient reel can be easily installed into the drum. A 5 kg spool of filler material lasts a long time.

+ Pros SV-08G2S-O (0.8 mm; coil 5 kg) Cedar

1. Suitable for all carbon and low alloy steels.
   The seam is really smooth and clean due to the absence of splashes.
2. This results in deep penetration.

— Cons SV-08G2S-O (0.8 mm; coil 5 kg) Cedar

1. It is not suitable for all semi-automatic machines due to the attachment to the drum (a Euro-reel is used).
2. Not suitable for working in an environment of active gases (carbon dioxide) - you need to be careful when choosing for welding car bodies and thin metals for ventilation.

Conclusion. This is the best welding wire for semi-automatic machines in cases where maximum purity of the metal after welding is important. It is characterized by a minimal amount of splashes, due to which the adjacent thread or front surface will remain undamaged.

A Swedish product from a famous brand, manufactured at production facilities in the Czech Republic. It is produced in rolls weighing 5 kg and complies with GOST SV-08G2S-O.

+ Pros OK Autrod 12.51 (0.8 mm; 5 kg) ESAB

1. The seam retains good impact strength even when the temperature drops to -20 degrees - in this case the figure will be 90 J/cm2.
2. Smooth, good seam without sagging.
3. Soft burning of the welding arc.

— Cons OK Autrod 12.51 (0.8 mm; 5 kg) ESAB

1. Not very even installation, despite the branded manufacturer - slipping in the channel is possible.
2. The design of the reel may differ from the photo in online stores.
3. The wire is stiff and difficult to thread into the feed mechanism.

Conclusion. Good wire, suitable for sealing cracks in the frames of various equipment and mechanisms. It has a tensile strength of 560 MPa, so it is resistant to stretching during impacts. Seams made semi-automatically with this wire have increased strength.

The wire has a tubular shape, inside which there is flux and metal powder. This allows you to even better protect the weld pool from the inclusion of the external environment when using inert gas or even weld without a cylinder.

This technology has found application in welding tanks for the chemical industry, installation of remote structures where it is not possible to deliver a gas cylinder, or underwater welding.

But a slag crust forms at the seam, which requires cleaning. Such wire costs much more, so it is justified only in the above cases.

Elitech 0606.016000 (0.8 mm; 1 kg)	E71T-GS (5 kg; 0.8 mm) Cedar	QUATTRO ELEMENTI 770-384 (0.45 kg; 0.8 mm)
Weight, kg	1	5	0,45
Diameter, mm	0,8	0,8	0,8
Eurocoil	D100	D200	D100
Homeland of the brand	Russia	Russia	Russia

Elitech 0606.016000 (0.8 mm; 1 kg)

Additive material from a Russian manufacturer. It is distinguished by its even laying on the reel and is fully designed for welding without gas.

+ Pros Elitech 0606.016000

1. Holds the arc perfectly and protects the weld pool from inclusions.
2. The seam is smooth, almost without scales.
3. The filler metal flows well.
4. A large amount of flux inside.

— Cons Elitech 0606.016000

1. Each kilogram of wire costs over 1000 rubles.
2. All users report an increased amount of spatter, which requires longer post-treatment.
3. It requires a long time to adjust the speed and voltage, since it can burn out before reaching the metal being welded.

Conclusion. This additive was included in the rating of welding wire due to its deep penetration even with narrow edge grooves. It is suitable for welding critical joints, where the priority is strength rather than the aesthetic beauty of the seam.

Another Russian product. Available in large 5 kg spools with a diameter of 0.8 mm. In addition to joining the sides, it is capable of slightly alloying the seam due to the available additives.

+ Pros E71T-GS (5 kg; 0.8 mm) Cedar

1. The price is much less than other powdered wires.
2. Supplied in secure packaging that prevents the flux from becoming damp.
3. Easy to melt and flow.
4. The results are strong and beautiful wide seams.

— Cons E71T-GS (5 kg; 0.8 mm) Cedar

1. Compatible only with inert gases.
2. The winding is not always smooth.
3. May leave some pores in the seam structure.

Conclusion . This is an excellent welding wire for surfacing metal in specific conditions. When properly adjusted, a thicker bead can be achieved than other versions of the additive, reducing the number of passes to achieve the desired height.

Italian welding wire in a euro spool with a weight of 450 g and a diameter of 0.8 mm. Suitable for welding with and without all types of shielding gas.

+ Pros QUATTRO ELEMENTI 770-384 (0.45 kg; 0.8 mm)

1. With the correct settings, you can weld even thin sheet metal with a cross-section of 0.3 mm.
2. The filler metal fits easily - it is especially convenient to weld holes.
3. Deep penetration.
4. Almost no pores.
5. Does not burn through metal and is not squeezed out from the reverse side.

— Cons QUATTRO ELEMENTI 770-384 (0.45 kg; 0.8 mm)

1. The filler metal fits easily - it is especially convenient to weld holes.
2. Deep penetration.
3. Almost no pores.
4. Does not burn through metal and is not squeezed out from the reverse side.

Conclusion. A good wire for semi-automatic machines and car repairs in the field. It is suitable for welding both a thin body and a thick frame and side members. It holds the arc well and will help you apply a strong suture in a short time.

Stainless steel wire is intended for welding alloy steels. Due to the same composition, it does not cause cracks when the metal cools and can be processed in the same way as the base material (grinded, polished), completely hiding welding marks.

This type of wire is widely used in welding manifolds, flanges in the chemical industry with aggressive environments, manufacturing heated towel rails and other stainless steel products.

Features of the wire are its high cost and increased amount of splashes on the metal, requiring the use of a special spray that prevents sticking.

WESTER STW08045b	Foxweld ER-308 LSi Sv-04Х19Н9 (1 kg; 0.8 mm; D100)
Weight, kg	0,45	5
Diameter, mm	0,8	0,8
Eurocoil	D100	D100
Homeland of the brand	China	Italy

WESTER STW08045b

Product from a Chinese brand. Sold in weights starting from 450 g. The wire is affordable and is characterized by increased resistance to intercrystalline corrosion.

+ Pros of WESTER STW08045b

1. Promotes the formation of a strong and thick weld in one pass.
2. Sealed connections that withstand fluid pressure well.

— Cons of WESTER STW08045b

1. Promotes the formation of a strong and thick weld in one pass.
2. Sealed connections that withstand fluid pressure well.

Conclusion. An excellent option for the manufacture or repair of containers used in the food industry. The wire is enriched with nickel and contains a very small amount of carbon, which makes the seams particularly resistant to corrosion.

Italian filler wire for semi-automatic machines, produced in China under the supervision of the company's European employees. Contains 5 additives that significantly improve the quality of the seam (C, Ni, Si, Cr, Mn).

+ Pros Foxweld ER-308 LSi Sv-04Х19Н9 (1 kg; 0.8 mm; D100)

1. High corrosion resistance.
2. Particularly strong seams that can withstand bending and tensile pressure.
3. The product is well sealed (polyethylene and cardboard packaging), which protects it from environmental influences and damage during transportation.

— Cons Foxweld ER-308 LSi Sv-04Х19Н9 (1 kg; 0.8 mm; D100)

1. To weld with this wire you need a device with direct current.
2. Bad seams in carbon dioxide - you need pure argon or a mixture.
3. The product uses a marketing trick - filler material weighing 900 g is sold in a box labeled 1 kg.

Conclusion. This product was included in the rating of semi-automatic welding wire due to its high silicon content. This makes the seam stronger and is suitable for welding joints that will be subject to increased stress.

Used for making seams on structures made of aluminum and its alloys. This is a highly specialized type of welding, which is in demand in car services, the food industry, the chemical industry and in the repair of water transport. This type of additive is not suitable for joining other types of metals, and welding with its use requires some skill.

ER 5356 (ALMG5)

Aluminum wire with in-line winding. Sold in weights from 500 g to 7 kg. Suitable for semi-automatic welding of aluminum plates, pipes and profiles with a magnesium content of less than 3%.

+ Pros of ER 5356 (ALMG5)

1. Good preservation of the reel during transportation thanks to the film cover and cardboard packaging.
2. The seam is completely free of pores.
3. Suitable not only for butt joints in the lower position, but also for corner joints on both the inside and outside.
4. There are no undercuts on the top wall with a fillet weld.

— Cons of ER 5356 (ALMG5)

1. High-quality welding is possible only with direct current.
2. The seam is high and has rough scales.
3. The tensile strength of 265 MPa is not the highest in the category.
4. You need to set the feed speed to high - it melts quickly.
5. After welding there is a strong black coating.
6. Suitable for long seams, since on short ones it does not allow the metal to heat up properly and only lies on top.

Conclusion. Excellent aluminum wire for welding cylinder heads or crankcase covers, which will be useful in the auto repair shop. It has an elongation of 26%, which promotes good transfer of thermal expansion.

Flux Cored Wire vs Solid Wire:

Which wire to choose for a semi-automatic machine:

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How to choose wire for welding: how to choose the right one and the features of using the material

In physical and chemical reactions, in addition to the main components, auxiliary components are also used: additives, catalysts, accelerators, retarders and dozens of other ways to improve the quality of the final results. An example immediately from our topic.

The additive strengthens the seam

Welding with a welding wire with gas occurs like this: the worker holds a gas cutter with one hand, and with the other moves a thin piece of metal along the hot seam. Towards the end or middle of the seam it melts completely and changes to another. Why is this support material needed?

After all, when carrying out electric arc welding, only one rod melts the surface of the metal. And here it’s like a double technology. But these are different types of welding, each with its own pros and cons.

The answer is in the top paragraph: it is an additive to the metal melt. Flux-cored welding wire is a synonym for filler wire. It helps form a strong seam. Let us briefly consider the composition of the additive.

Its main content is the base steel metal. Additional chemical composition is added according to state standardization under the number 2246-70 in the melting chamber. It talks about three grades of steel, differing in carbon content and with two degrees of bonding, this is how the word alloying is translated

Finished products from open-hearth furnaces are poured according to their intended purpose - for a garden fence or for gas welding - hot- or cold-rolled.

Only the second one, which will be used to fill the seams during welding, is pulled through the template along a given diameter when completely cooled. To speed up cooling, pour water over it while drawing.

How do the products differ from each other?

Sometimes novice welders themselves, although they have studied the brands of filler materials in courses to obtain permission for this type of work, are confused about the markings and properties. After all, one type of wire cannot be used for both ferrous and non-ferrous metals. Stainless steel welding wire only bonds metal with the same properties.

Silicon and manganese, carbon and nickel, chromium and phosphorus were introduced into the composition of all three types of products to alloy the filler steel thread. And only titanium and molybdenum are absent where the carbon content is low.

Alloying a given steel with these chemical elements of the periodic table improves the physical and chemical composition of metals and especially their alloys.

Thickness is also important, in other words, which diameter is better? The answer is simple: it should be equal to the thickness of the welded parts.

Oxidation and deoxidation during welding

Most metals oxidize even in plain air. When welding, its main element is oxygen, or O2, of high concentration. The metal not only melts better, but also the characteristics of the welded products deteriorate from exposure to oxygen. It ages before the time allotted to it by the technology of melting and rolling.

As the saying goes: we improve some, and immediately worsen others. That is, the seam is smooth and looks good, but its strength characteristics, if welded without filler wire, would leave much to be desired.

Therefore, to deoxidize the melting seam, so-called chemical deoxidizers were introduced into the welding wire: manganese and silicon.

During welding, these chemical elements themselves react with oxygen, forming metal oxides, and O2 no longer has a negative effect on the quality of the weld. Sulfur and phosphorus are considered harmful impurities.

Additive standards

• The combination of melting temperatures of the additive and the parts to be joined.
• No layers, oils or dyes.
• Melting proceeds evenly, without spreading or sparking to the sides.
• The line is welded without cavities or layers on the metal.

Photo of wire for welding

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Selecting welding wire. Informed solutions for efficient work

01/19/2020 Popular representatives of welding wire Marking of welding wire Types of welding wire by composition and diameter How to choose the right welding wire

Tekhresurs LLC has been working as a supplier of branded welding materials produced by leading Russian manufacturers for more than 20 years.

An important place in the trade assortment is occupied by welding wire, represented by the best products of this market. It is this consumable that affects the quality of welding and weld seams, requiring the correct selection for specific work processes. In this case, it is necessary to take into account not only the characteristics of the metals being welded, but also the presence of various impurities.

The correct choice of welding wire will ensure the highest strength and corrosion resistance of the joints created.

Popular representatives of welding wire

Currently, welding wire is represented by 77 types of consumables for welding, differing in composition and diameter. This category of goods is determined by the technical conditions of GOST 2246-70.

However, no more than 5-8 varieties are widely used in construction and repair. The remaining representatives of this product group are used in specific work processes.

All welding wire used for welding stainless and conventional rolled metal is divided into three large categories:

• alloyed wire containing from 2.5% to 10% alloying components;
• low alloy welding wire (less than 2.5%)
• high-alloy consumables (more than 10%)

1. The undisputed leader in sales in this market is welding wire SV 08G2S and its analogues, produced both in a regular version and with a copper coating. This material can be used in semi-automatic welding units with a power of up to 500A.
2. Second place in the popularity ranking is occupied by welding wire SV 08A, used for mechanized welding of low-carbon and carbon steel alloys, as well as for the manufacture of manual welding electrodes.
3. The third position in sales remains with modifications SV08G2A and SV-08, which are actively used in argon-arc and gas welding when welding low-carbon pipe and channel structures.

For welding rolled stainless steel in carbon dioxide or a gas mixture, welded wire of the ER 316L Si and ER 308L grades in foreign markings is used. Russian analogues are represented by a line of high-alloy modifications SV01Х19Н9, SV01Х18Н10, SV06Х19Н9Т.

Welding wire marking

Abbreviations in the names of welding wire brands are intended to demonstrate the purpose and composition of consumables. The abbreviations used are deciphered as follows in the appropriate sequence:

1. The first two letters “SV” indicate that this wire is intended for welding metals. In foreign analogues, the abbreviation looks like “ER”. In some markings, the first position contains the symbols “P” and “B”, reflecting the methods of manufacturing the material - pressed or drawn, respectively.
2. The next two digits indicate the percentage of carbon in hundredths of a percent. For example, the pair “08” indicates that the wire contains 0.08% carbon.
3. Next comes the letter designation of the main alloying element, and the number following the letter is the percentage inclusion in full percentages. Alloying components are indicated by the following symbols:

• "A" - nitrogen
• “B” - niobium;
• “B” - tungsten;
• "G" - manganese
• "D" - copper;
• "M" - molybdenum;
• "C" - silicon
• "T" - titanium;
• "X" - chrome
• "N" - nickel
• "U" - aluminum;
• "F" - vanadium;
• "C" - zirconium.

If the letter “A” is at the end, this indicates that the material has been additionally purified from impurities of phosphorus and sulfur. Two letters “AA” - the highest degree of purification.

1. The last letter indicates the second alloying element. If it is not followed by a number, this indicates that the wire composition contains more than 0.5% but less than 1% of this component.

If, according to the specified rules, we decipher the modification SV 08G2S, we will receive the following information. Wire for welding with a carbon content of 0.08%, manganese 2%, and silicon - more than 0.5%. It belongs to the category of alloyed materials, since the inclusion of alloying elements in total is above 2.5%.

Types of welding wire by composition and diameter

• Flux cored is a hollow welding wire with a special flux filler. In this case, flux evaporation forms a protective gas bubble in the weld pool, which allows the use of consumables without a gas flow. Welding with flux-cored wires can be carried out under intense wind currents. The technique of using self-shielding wire is similar to the technology of welding using conventional wire material. Flux-cored wire has differences in marking with the designation “PP” and “PS”; with digital indication of brand and diameter.
• Copper-plated welding wire - with a copper alloy coating up to 6 microns thick. The key role of this layer is to ensure the tightest possible contact between the structures being welded. Welds created using such wire are distinguished by high mechanical endurance and weak response to strong temperature changes. Another indisputable advantage is the saving of consumables by up to 40% compared to welding with conventional wire. Note - this variety is absolutely not suitable for welding stainless steels.
• Aluminum is a welding wire used for welding in a protective gas environment with automatic and semi-automatic units. The consumable material is used for welding products made of aluminum alloys. The aluminum additive requires hermetically sealed storage due to the fairly rapid oxidation of the aluminum layer with oxygen in the open air.
• Welding wire for welding stainless steel. Material in this category is alloyed with chromium or nickel. Accordingly, the marking will contain the symbols “H” or “X”, as well as numbers for the percentage of alloying elements.

For use in semi-automatic welding units, wire with diameters of 0.6 mm, 0.8 mm, 1 mm, 1.2 mm, 1.6 mm is produced. Flux cored (flux) wires are manufactured in a thickness range from 0.6 to 6 mm. Filler rods, like the wire materials used for the manufacture of electrodes, are produced in a range of diameters from 1.6 to 5 mm.

How to choose the right welding wire

1. For welding low-carbon and low-alloy steel parts, it is recommended to use copper-plated wire (type 09G2S) in a carbon dioxide atmosphere. Copper coating will provide the welds with the necessary strength and tensile strength.
2. Stainless alloys (austenitic and austenitic-ferritic alloyed with chromium or nickel) are welded with stainless wire alloyed with the same elements.

   The protective gas environment is inert argon or helium with the addition of a carbon dioxide mixture.

3. Aluminum welding wire is used for welding aluminum alloys. An important nuance is the need to carefully remove the oxide film from the surfaces being welded.
4. Powder “self-protective” film is used for welding a wide class of ferrous metals, where the use of gas cylinders is impossible or impractical.

   The only negative is the high cost of consumables.

5. The diameter of the welding wire is selected in accordance with the thickness of the parts being welded. For example, it is better to weld products with thin walls using wire with a diameter of 0.8-1 mm. If the surfaces to be welded have a thickness of more than 5 mm, then the diameter of the wire material must be at least 1.6-2 mm.

The Tekhresurs LLC company will offer you a wide range of welding wire of various brands, allowing you to make the right choice for high-quality welding of various types of metals.

Source: https://tr78.ru/articles/3847/

Welding wire. Diameters, markings and types

Since semi-automatic welding machines are now quite in demand, this has made it possible to create a wide market for the production of welding wire for semi-automatic machines. The correct choice of wire can significantly increase productivity, as well as the quality of the welding itself and the weld seam. Safety is also increased, which is also important for qualified welders.

Types and markings of welding wire

Welding wire for semi-automatic machines is used as a consumable electrode when carrying out welding work on a semi-automatic machine.

There are about 77 grades of welding wire, the quality and composition of which is regulated by GOST 2246-70.
Cold-drawn wire produced from low-carbon steel, alloy steel, and high-alloy steel fully complies with this standard. Welding wire for semi-automatic machines is divided according to its purpose into:

• directly for welding;
• for the manufacture of electrodes (additional designation E).

Low-carbon and alloy wires are sorted according to the type of surface treatment into non-copper-plated and copper-plated (O).

Despite the large number of different brands of wire for semi-automatic welding, only a few are widely used in production and construction. The rest are special or narrow-profile brands.

During production, they are subject to special requirements.

This wire is intended for welding work during the construction of scientific complexes and laboratories, nuclear industry facilities and for other modern industries that use high technology.

Currently, technologies are used that allow semi-automatic welding not only in a neutral shielding gas environment, but also using wire, under a layer of flux. The type of wire used, its diameter and grade always depend on the thickness and chemical composition of the structures and parts to be welded. In this regard, welding wire for semi-automatic machines is divided into three main categories:

• low-carbon - wire grades such as Sv-08AA, Sv-08, Sv-10GA, Sv-08GA and Sv-10G2;
• alloyed - wire grades Sv-12GS, Sv-08GS, Sv-10GN, Sv-08G2S, as well as Sv-08GSMT, etc.;
• high-alloy – grades Sv-10Х11НВМФ, Sv-12Х11НММФ, Sv-Х13, Sv-20Х13, etc.

If you know the labeling, then one glance at the name will be enough to find out its composition.
Thus, the name Sv-08G2S says the following: The abbreviation Sv means that this wire is welding. The letters and numbers that follow tell about the content of the constituent elements in a particular wire.

Further, the numbers 08 indicate the mass of carbon in hundredths of a percent, in this case it is 0.08%. G - indicates that the wire contains manganese, the next number 2 indicates its two percent content. The letter C indicates silicon in the wire; if there are no further numbers, then its content does not exceed 1%.

In some cases, it is necessary to know additional wire markings:

A - at the end of the marking means that this wire has a reduced content of harmful substances, such as sulfur or phosphorus, and two letters (AA) indicate that the wire contains a minimum of harmful impurities, and the wire itself is made of highly purified metal. In addition, inside the marking A indicates the presence of nitrogen in the composition.

X and N – (chromium, nickel), are mainly used as alloying additives when welding wire for stainless steel is produced.

Other elements found in the markings:

B - tungsten; T - titanium; Yu - aluminum; F - vanadium; B - niobium; D - copper; M - molybdenum; C—silicon;

C - zirconium.

There are several of the most famous manufacturers of welding wire. This is the Petromet LLC Company, which produces such popular wire brands in our industry as Sv-08GSNTi Sv-08G2S, Sv-08GNM, Sv-08ХМ, etc. Svarmontazhstroy LLC, whose production is based on a number of foreign technologies and the quality of its products complies with basic international standards. Moscow manufacturer Veld-Metiz LLC.

Welding wire diameters

The nominal diameters of the wire used for semi-automatic welding range from 0.3 mm to 12 mm. There are 17 standard diameters in total. Previously, when welding automatically, a wire with a diameter of up to 5 mm is selected, and when welding semi-automatically, mechanized - up to 2 mm, its diameter mainly depends on the thickness of the metal.

To achieve the required quality of the weld, when welding parts and structures made of alloy and high-alloy steels, the chemical composition of the wire itself must be such that in the resulting weld the carbon content is limited to 0.10 - 0.12%, and silicon is less than 0.5 %.

Highly alloyed austenitic and ferritic welding wires are used for welding specialized steels. However, austenitic high-alloy welding wire for semi-automatic machines after drawing is cold-worked (cold-hardening) and becomes more rigid, and its ductility decreases. In this regard, feeding wire of such a small diameter from 2 - 3 mm through hoses when welding with a semi-automatic machine is easier, in contrast to feeding wire of a larger diameter.

Welding using a gas mixture has better technical performance. Therefore, at present, a mixture of carbon dioxide and neutral argon is widely used, having a percentage ratio of 75-80% Ar and 20-25% CO2.

Welding wire consumption control

During the semi-automatic welding process, it is necessary to keep track of the consumption of welding wire and gas mixtures. This ensures savings in consumables in production and leads to a reduction in the cost of the work itself.

The consumption of wire for welding is influenced by such indicators as:

• chemical composition of the metal;
• diameter and quality of the wire itself;
• data on the technical characteristics of the working semi-automatic welding machine;
• carrying out welding in a neutral gas environment.

In many cases, the consumption of welding wire used is considered to be up to 1.5% of the weight of the entire structure. And the weight of the wire exceeds the weight of the deposited material by up to 6%, since waste and waste occur.

The consumption rates of certain grades of wire per meter of welding seam are determined by the formula M = HP ∙ KR.
(where M is the mass of the deposited metal, which directly depends on both the metal and the type of weld). KR – consumption coefficient of the wire used (the value is taken from the tables). Based on this formula, the need for welding wire is calculated not only for a specific type of work, but also for the entire enterprise over time.

Modern mechanisms and welding wire feed speed

Semi-automatic welding machines are classified as follows:

• for welding products in shielding gases;
• for welding using flux-cored wire;
• for performing submerged arc welding;
• universal.

Semiautomatic machines for welding using shielding gases are equipped with a special valve that stops the supply of working gas at the end of welding.
Semi-automatic submerged arc welding machines always have a torch with a funnel. The wire feed is more powerful than other equipment, since this welding requires large diameter wire.

Semi-automatic welding machines are divided into household, semi-professional and professional, depending on the current strength and duration of operation of the device itself. They are also mobile, stationary and portable. Industrial semiautomatic devices are manufactured only for operation in three-phase current mode. The seams obtained when using such devices are much better and smoother.

Semi-automatic machines for welding with modern flux-cored wire are equipped with a special feed roller device to prevent deformation of the working wire.
Universal semi-automatic machines are equipped with auxiliary devices (welding torches, wire feed rollers, etc.), which makes it possible to successfully use them for various types of welding.

The mechanism for feeding the wire to the torch includes an electric motor, a gearbox and, of course, feed rollers. The type of feeding device (relative to the gas burner) can be pulling, pushing or universal. When feeding wire with a push-type device, the feed rollers are located right next to the welding torch hose and evenly push the wire directly into the torch channel. Always used when welding steel.

Using a semi-automatic wire feed with a pull-type mechanism, the wire enters the burner channel. This gives it additional weight, but nevertheless, such a mechanism is often installed in semi-automatic aluminum welding machines. Welding wire for semi-automatic machines serves not only to improve the quality of the seam, but also the continuity of welding work. The push-pull type feed is used for welding aluminum in the case of a significant distance of the main welding mechanism from the welding site.

The wire feed speed must be adjusted for each case and adjusted as work progresses. The main adjustment of the feed speed is performed by the gearbox and a set of gears. In this case, the drive is a three-phase asynchronous motor. The disadvantage of this speed adjustment is the difficulty of selecting the required mode for welding. Especially when working with thin metal.

Smooth control of the required speed of feeding wire of a very small diameter is achieved when using a DC motor in operation, by smoothly changing the speed of the motor head.
The feed speed can reach up to 150 m/hour. When setting the feed speed, the thickness of the metal, the composition and diameter of the selected welding wire are important. It is possible to obtain a high-quality welding seam only by carefully adjusting the speed through several test welds.

Source: https://proinstrumentinfo.ru/svarochnaya-provoloka-dlya-poluavtomatov-mehanizm-skorost-podachi-diametr/

Selecting welding wire for a semi-automatic machine

Welding wire plays a decisive role in the welding process - it helps to connect two or more elements into a single structure made of different types of metal. A distinctive feature of the filler material is the high quality of the weld. This is partly due to the mechanized supply of the electrode, which is the wire, however, it is also important that the operator has some experience.

Where is filler material used?

Welding wire-electrode for semi-automatic machines is in great demand today, since it is the main consumable material of such equipment. In composition, it should be as close as possible to the main type of metal used for welding.

Therefore, there are many variations of the additive, however, stainless steel wire is the most common.

It is used almost everywhere (various industries, medical equipment production, energy and many others), due to its anti-corrosion properties and high-quality welded joint.

Watch the video, material selection criteria:

Depending on the operating conditions and type of unit, materials of different compositions are used. For example, welding wire for a semi-automatic machine without gas may differ in appearance. In this case, it is recommended to use flux or cored wire, which will provide a cloud of shielding gas without the need for gas cylinders. As this additive burns, it releases a protective gas, which is quite enough to make a high-quality seam.

Types of wire for welding work

To create a high-quality connection of metal parts, different types of additives are used, each of which is designed to work under certain conditions. The semi-automatic wire welding machine can make seams using the following types of wire:

1. With a solid section;
2. Powder;
3. Activated.

If the structure of a solid filler material is quite clear, it is a product made entirely of a certain type of alloy for welding different metals. But flux-cored welding wire for inverter semi-automatic machines is manufactured using a different technology. This is a hollow product containing powdery material inside. When burning during welding, it forms a protective gas cloud precisely due to this filling.

This type of product is found in different designs: two-layer wire, with one or two bends of the tubular shell, the classic version without changing the configuration of the shell. This variety of designs is explained by the need to avoid deformation of the product and premature spillage of the internal contents of the wire. However, in addition to design features, there are different options for the composition of the powdery substance:

• Fluorite;
• Rutile;
• Rutile-fluorite;
• Rutile-organic;
• Carbonate-fluorite.

There are versions designed to work in a carbon dioxide environment, and in other cases, a semi-automatic inverter wire welding machine using a powder additive can function without a specially created gas protection, and then this function is performed by the wire itself. Each of the compositions of the powder substance is created for welding a certain type of metal.

The activated type is somewhat similar to the powder version, but in this case an order of magnitude smaller amount of powdered substance is used (no more than 7% of the total mass of the product). Thanks to the use of only a small fraction of such filler, the manufacturing technology allows it to be pressed into a solid wire.

Steel Welding Material

Steel wire is represented by 77 grades, which are regulated by GOST 2246-70. The choice of diameters is quite wide: from 0.3 to 12.0 mm. For certain applications, it is recommended to use a specific filler material size.

For example, a flux-cored welding wire for a semi-automatic unit should have a diameter in the range of values ​​from 2 to 6 mm; sizes from 0.3 to 1.6 mm are suitable for semi-automatic welding in a shielding gas environment.

Aluminum Welding Material

For aluminum and alloys, a product with diameters from 0.8 to 12.5 mm is used. The designation indicates the manufacturing method: B – drawn, P – pressed. If the product is annealed, the letter M will be present; for cold-worked wire, the letter N will be present. In addition to the marking, the designation indicates the diameter of the product and the method of delivery (in coils).

Welding of aluminum and its alloys is carried out in a protective gas environment - argon. This is due to the fact that such material oxidizes very quickly upon contact with air. For the same reason, it is recommended to use the wire as quickly as possible after opening the package.

Stainless steel welding material

This type of additive is extremely common due to the reliability of the welding joint using it. Stainless steel welding wire for semi-automatic units is manufactured according to GOST 18143-72. High-alloy heat-resistant steel is used as the starting material for the production of such wire.

It is the presence of this type of metal that allows us to obtain a highly reliable and corrosion-resistant connection of metal parts.

Copper Welding Wire

Depending on the design, this material can be used for welding work in various fields: in the automotive industry, for connecting pipeline sections, manufacturing and repairing plain bearings, galvanized parts, etc.

Types of Copper Welding Wire

Such material is cooked in a protective gas environment - argon. Depending on the composition of the wire, it can be used for welding different metal alloys.

Material for cast iron and nickel alloys

This group is also characterized by corrosion and heat resistance, which allows the use of such wire for welding work on products based on nickel alloys, high-alloy steels and dissimilar materials.

It is recommended to cook in pure argon gas or a mixture with helium.

Titanium Welding Wire

The best option in this case would be cold-drawn wire made from sheet metal. As with any other type of material, its composition should be as close as possible to the composition of the metal being welded. The most popular option for welding titanium is flux-cored wire PPT-1 and PPT-3. It is recommended to carry out work in a protective gas environment - argon.

What types of welding wire for semi-automatic machines exist: flux-cored and copper-plated

In many technologies for durable joining of metal structures, welding wire is used as an additive instead of an electrode. What is it for? This application is justified in semi-automatic machines and on automatic production lines.

After manufacturing, the additive is wound onto cassettes and reels, then sold through retail outlets or directly from the manufacturer’s warehouse.

Brief information

Wire for welding is made solid, hollow, or has special inclusions that facilitate the process of joining metals. The material used is different; for example, for welding aluminum, an additive made from a similar metal is used . This allows you to find out which one to choose for your needs. For ease of use, the wire is wound onto reels and then inserted into the feeder.

Types of products

In technology, there are three main compositions:

1. Solid . Wire of a similar cross-section is made of pure material, without inclusions. Often used for welding with shielding gas.
2. Containing flux or powder version , used for welding without gas, because inside there is flux or substances that replace oxidation protection. This welding method is used, for example, in the construction of multi-story buildings.
3. The activated composition has absorbed all the useful functions - the design from the first option, and the protective properties from the second type. All necessary components are proportionally placed throughout the additive body.

Enterprises that constantly use similar additives on semi-automatic or automated lines purchase welding wire in coils weighing from one ton, and then independently wind it or immediately deliver it to the welding site.

Stainless steel

The main purpose of stainless steel welding wire is to firmly join steels containing chromium and nickel while protecting gases of various compositions. Advantages:

• high strength, quality of seam connection;
• resistance to moisture;
• minimum splashing of molten metal;
• absence of microcracks at finished joints;
• arc stability;
• increased service resource.

The wire is made from alloy steels with a high content of nickel and chromium, ensuring minimal traces of rust. The diameter varies from 0.13 to 6.0 mm, the most famous markings are: SV06Х20Н11М3 and SV01Х18Н10 .

Copper plated version

Reduces melting of the tips of non-consumable electrodes, therefore it is used as a wire for semi-automatic devices. For effective use, it is sold wound on cassettes, reels or reels made of plastic ; the performer just needs to insert the product into the feeder and start working.

Section thickness standard: 0.6; 0.8 and 1.0 mm, helps to quickly reactivate the welding arc and stabilize its stable combustion. The most well-known additives are domestically produced with the marking SV-08G2S and from the Swedish company ESAB. The second option is used for welding steel - stamped, tool, stainless steel; used for connecting cast iron parts.

Steel products

They are marked with the letters SV, a diameter of 0.3-12.0 mm is used, there are spring, rope, welding, reinforced, etc., about 50 options in total. In technology, three large groups are used for welding such steels:

1. Carbon - 08, YuGL and 10G2.
2. Medium and low alloyed - 18ХС, 08ГС and 08Г2С.
3. Highly alloyed - 08Х14ГНТ and 12Х13.

In some cases, the wire is copper-coated on top to protect against oxidation and improve current conductivity. The optimal use case is argon arc welding , the presence of a percentage of alloying metals allows you to join high-carbon steels.

Made of aluminum

It is used for joining structures of similar composition, as well as metals based on it, with the following content: silicon - 3%, copper 3-5%, which produces a seam with the following advantages:

• increased strength;
• color identity;
• high corrosion resistance.

Used in the automotive and shipbuilding industries . The material has high ductility and light weight; it is used for gas welding and joining stainless metal workpieces. It is not produced in its pure form, but only with additives, for example, adding 0.2% titanium produces a fine-grained weld, which is important when performing precision work.

Activated

The powder is concentrated in the inner hollow part and plays the role of a wick ; this option is used when welding with carbon dioxide protection. The active part is performed by: carbonates, metal oxides such as barium, titanium, magnesium and silicon. The result is that the welding arc burns stably, the metal does not spatter, and the seam is smooth and free of cavities.

Powder look

The hollow steel wire is filled inside with fleece by 15-40% , the specific content is indicated in the accompanying certificate. The advantages of the technique: high-quality connection, easy removal of solidified slag and stable arc burning. Manufacturers often call it steel, which misleads users.

The flux option should be placed in a separate category, since it increases the productivity and capabilities of semi-automatic welding, guarantees the quality of the weld joint, compared to a simple steel additive.

Labeling nuances

The main characteristics of any type of solder are encrypted by a set of letters and numbers; all types of welding wire have this designation, which does not depend on the type and purpose of the solder. The first letters indicate the application:

• SV - for welding work;
• NP - surfacing type;
• PP - powder version.

For example, SV-06Х19Н9Т is a wire for welding, followed by numbers indicating the percentage of carbon content (0.06%) of the total mass. Then there are the letters A or AA - harmful content of phosphorus and sulfur. Then indicate the metal content: X19 - 19% chromium; H9 - 9% nickel, when the content is less than 1%, then the numbers are not indicated, but only the letter is put..

It is customary to designate metals with the following letters: B - tungsten; B - niobium; G - manganese; D - copper; M - molybdenum; C—silicon; T - titanium; F - vanadium; C - zirconium and Y - aluminum.

Choice for semi-automatic welding

To find out which wire is best for a semi-automatic machine, you need to know that this type of welding work is considered universal and can easily cope with parts of various thicknesses; non-ferrous and ferrous metals are welded with the same quality. A similar selection of additives is made for a specific type.

The main thing is the chemical composition, which is recognized from the marking of the wire , for example, SV08G2S; an experienced performer will immediately determine for which metal such solder should be used. Only wire is used that is manufactured in accordance with GOST requirements, has a quality certificate and original packaging, which protects against mechanical damage.

Compatibility with devices

For semi-automatic machines, various types of welding wire are used - this depends on the chemical composition of the metal, which must be identical to the same parameter of the solder. Correct operation of devices with solder depends on the following parameters:

• current strength is not less than 35 A;
• power 1.5 kW and above;
• solder cross section 0.5-2.0 mm.

The first parameter is regulated by a rheostat, which is located on the control panel, and the correct selection of diameter depends on the thickness of the products and welding conditions.

Dependence of weldability and chemical composition

The quality of welding depends on the carbon content; the higher it is, the more difficult it is to weld steel structures using conventional methods . The percentage of manganese affects the strength characteristics and hardness of the metal, as well as hardening. sulfur harms the process of metal fusion - burning cracks form.

If the presence of silicon is more than 0.5%, slags are formed, which complicate welding: if in the range of 0.8-1.5%, then the steel becomes elastic, ductility decreases, and fragility progresses. The presence of phosphorus 0.1-0.2% makes the metal brittle under normal conditions. Other metals involved in marking the filler wire are introduced to give it specific properties.

Manufacturers of welding wire products

Among Russian companies the following stand out:

1. SMS LLC , the company is distinguished by modern equipment that allows the production of products using European technology in accordance with accepted standards.
2. Petromet LLC - belongs to the St. Petersburg Steel Rolling Plant.
3. Weld-Metiz LLC , production facilities are located in Moscow.
4. OJSC Volgograd Steel Wire and Rope Plant.
5. OJSC West Siberian Metallurgical Plant , located in the city of Novokuznetsk.

Thanks to the listed manufacturers, all enterprises in the Russian Federation are provided with high-quality filler wire, which allows them to perform all types of metal welding.

conclusions

Despite the large assortment of filler wire brands, choosing the best option for your needs is not so difficult; you just need to find out the chemical composition of the metal structures and then select the solder.

Source: https://svarka.guru/oborudovanie/rashodniki-i-kompletuyushie/provoloka-dlya-poluavtomatov.html