Der beste Schweißdraht: Rutil-Fülldraht, Metallpulver- Fülldraht oder Massivdraht?
Die Wahl des richtigen Schweißdrahtes ist ein entscheidender Aspekt eines jeden Schweißprojekts. Die verschiedene Arten von Schweißdrähten haben unterschiedliche Eigenschaften, die sie für bestimmte Anwendungen geeignet machen. In diesem umfassenden Blog vergleichen wir drei gängige Schweißdrahttypen: Rutil-Fülldraht, Metallpulver-Fülldraht und Massivdraht. Wir erörtern ihre Vor- und Nachteile sowie ihre Anwendungsbereiche, damit Sie eine fundierte Entscheidung für Ihr spezifisches Projekt treffen können.
Folded cored wires are produced by folding a metal strip and filling it with flux, after which it is tightly folded. The folded cored wires are not completely closed, allowing moisture to enter the filling. This moisture absorption can lead to porosities and cracks in the weld. Additionally, the mechanical properties are often lower than those of seamless cored wires.
Seamless cored wires are produced by filling a seamless tube with metal or rutile powder. The tube is then drawn to the desired diameter. Because the wire is completely closed, the chance of porosities and cracks due to moisture absorption is minimal. This is the reason Certilas has only CEWELD seamless cored wires in it’s productrange.
Metal cored Wire
GMAW (C)
Metal cored welding wire contains metal powder in the core, which contributes to the mechanical properties of the weld metal. This type of wire typically requires external gas shielding, such as CO₂ or a mixture of argon and CO₂.
"Metal cored welding wires offer high efficiency, resulting in more efficient welding and higher productivity," says Roel Litjens, Welding Technologist at Certilas. "Increased tensile strength and toughness are achieved thanks to the metal powder and other alloying elements in the core," adds Roel.
Metal cored welding wires create welds with minimal porosity, improving the durability and strength of the weld. This makes them particularly suitable for heavy and critical applications such as shipbuilding, offshore applications, and pressure vessels.
Rutile flux-cored Wire
FCAW
Rutile flux cored welding wire contains a core of rutile (titanium dioxide) and other minerals. This type of welding wire can be used with shielding gas but can also be used without gas shielding.
" Rutile flux cored wire is suitable for welding in various positions, especially vertical up," explains Roel Litjens. The arc is more stable and produces less spatter, resulting in a cleaner weld. The slag is easy to remove, saving time in cleaning the weld.
"Less spatter means less cleaning after welding, what is saving time and costs," adds Roel.
The high deposition rate increases welding productivity, providing an economic advantage. In general, rutile flux cored wire has lower tensile strength and toughness compared to metal cored welding wire, making it less suitable for critical applications requiring high strength and durability.
Solid Wire
GMAW
Solid welding wire is a completely solid wire without the addition of powder. This type of wire is used for MIG/MAG welding (Metal Inert Gas / Metal Active Gas) and requires shielding gas such as argon, CO₂, or a mixture thereof. Roel says: "Solid welding wires produce welds with good mechanical properties, but the chance of lack of fusions is higher."
In general, solid wires are cheaper than cored wires due to the simpler production process. Solid wire produces less welding fumes and vapors, promoting a healthier work environment. The use of clean materials is preferred to avoid imperfections such as porosities. "For positional welding, solid wires are less suitable than cored wires due to the lower efficiency compared to cored wires," says Roel. "This significantly increases production costs," he adds.
Die Wahl zwischen Schlacke führendem Fülldraht, Metallpulver Fülldraht und Massivdraht hängt stark von den spezifischen Anforderungen des Projekts ab, z. B. von den mechanischen Eigenschaften, der Schweißqualität, den Kosten und den Umweltfaktoren. Die Wahl des richtigen Schweißdrahtes auf der Grundlage der spezifischen Anforderungen des Projekts kann die Effizienz, Qualität und Haltbarkeit der Schweißnaht erheblich verbessern.
Wie Roel Litjens betont: „Die Wahl des richtigen Schweißdrahtes ist nicht nur eine finanzielle, sondern auch eine technische Entscheidung“. Oft wird bei der Wahl der Schweißzusatzwerkstoffe gespart, aber das ist nur ein kleiner Teil der gesamten Schweißkosten, wie wir in unserem Blog „Führt nahtloser Fülldraht zu höherer Qualität und geringeren Schweißkosten im Schiffbau?“ ausführlich erörtert haben:
