Productivity and profitability with Elga

Elga is one of the biggest operators in the European welding business for
consumables.


Cored wires experienced a real breakthrough in the 80´s and rapidly gained in
popularity. The objective was to weld more efficiently, compared to the coated
electrode.

Since then a great deal of research and development has been invested in the areas
of arc characteristics, operability and mechanical properties. The result is that
today welding with cored wires offers a whole range of advantages compared to
both stick electrodes and solid wire. The key word is productivity, achieved by
the twin advantages of higher deposition rate and increased arc time factor.

In addition, Elga cored wires also help reduce interuptions to production caused
by wire feed problems and the need to change wear parts such as contact tips,
gas nozzles and liners. Compared with other processes post-weld dressing, e.g.
spatter removal, can also be minimised.

In short, the use of cored wires reduces total labour costs – the prime objective.
Initially cored wires were only suitable for thicker materials and had limited
positionality. Today fully positional welding in material thicknesses down to
2-3 mm presents no problems, thanks to continuous product development in
cooperation with end users.

Elga flux cored wires

The distinguishing feature of flux cored wires is that they form a slag which can

support the weld pool and thereby provide positional welding characteristics.

There are both rutile and basic flux cored wires but the rutile type dominates on

the market due to superior operability.

Elga rutile wires provide very good operability in all positions. The low alloyed

range offers excellent fracture toughness at temperatures down to -60°C, both in

the as-welded and stress relieved condition. Common to the complete Elgacore

programme is a deposited metal hydrogen level below 5ml/100g.

All Elga rutile wires produce high quality root beads on ceramic backing.

Basic flux cored wires are not used to any great extent due to their comparatively

limited welding characteristics and consequent lack of welder friendliness.

Within these limitations however basic wires offer good low temperature fracture

toughness and good crack resistance under conditions of high restraint, e.g. fillet

welds in thick material.

Elga metal cored wires

Metal cored wires contain little or no flux and so produce only a very small

amount of slag, similar to that from a solid wire. The core is composed mainly

of metal powder which in turn contributes to increased productivity. The deposition

efficiency is 96%, against 86% for a rutile flux cored wire, resulting in a

higher deposition rate.

Metal cored wires give very good penetration, similar to solid wire, but with the

added advantage of a wider penetration profile. The combination of these two

factors reduces the risk of lack of fusion and root defects. Today´s wires can be

used for plate thicknesses down to 2-3 mm and, together with the advantages

previously mentioned, has led to them replacing solid wire in many applications.

Metal cored wires permit a significantly higher travel speed, minimal spatter

and less stop/start problems.

This wire type has limited positional operability since it lacks a supporting

slag. In the spray transfer mode the wire is suitable for applications in the flat

and horizontal positions. In the short arc mode it can also be used vertically up,

which is a widely used method for the root bead in single sided welding without

ceramic backing.

Metal cored wires are used extensively in mechanised and robotic applications

but recent years have also seen their increasing use for manual welding, as an

alternative to both solid and rutile flux cored wires.

Elga - For improved profitability

Problem-free production with Elga cored wires

· Exceptionally good wire feeding due to extremely clean surface

· Reliable batch-to-batch consistency

· Weld with a stable, smooth arc

· Negligible spatter = little or no post- weld dressing

· High deposition rates

· Comprehensive range