Processes and consumables for carbon steel -- Pros and cons

[calweld]

We've had plenty of threads and posts dealing with the correct use and application of the various processes and filler material in SS and aluminum, there really hasn't been much talk about the same in carbon steel.

I have noticed in the past a lot of confusion about the various processes, and where each is appropriate.

For the purposes of this discussion, I would like to use these definitions:

MIG -- hard wire, gas shield
Dual shield -- gas shielded, flux cored wire
SMAW -- stick
Flux core -- innershield or equivalent

I believe dualshield is technically a MIG process, but it's different enough I think it should be considered a process in itself, at least for this thread.

We have welders here from all experience and educational backgrounds, it would be interesting to hear everybody's views on what process they like to use and in what situations, and what processes won't be used in certain applications. It would be very educational, and very interesting, to see how we all either line up or disagree about the different methods of welding things.

[Fat-Fab.com]

We've had plenty of threads and posts dealing with the correct use and application of the various processes and filler material in SS and aluminum, there really hasn't been much talk about the same in carbon steel.

I have noticed in the past a lot of confusion about the various processes, and where each is appropriate.

For the purposes of this discussion, I would like to use these definitions:

MIG -- hard wire, gas shield
Dual shield -- gas shielded, flux cored wire
SMAW -- stick
Flux core -- innershield or equivalent

I believe dualshield is technically a MIG process, but it's different enough I think it should be considered a process in itself, at least for this thread.

We have welders here from all experience and educational backgrounds, it would be interesting to hear everybody's views on what process they like to use and in what situations, and what processes won't be used in certain applications. It would be very educational, and very interesting, to see how we all either line up or disagree about the different methods of welding things.







When ever I can I use a wire feed type process. Be it FCAW or shop based GMAW and DS.
Much of my work is field work and it is simply faster and cheeper for the customer for me to drag out for SMAW to make a half a dozen welds, than it is to set-up my ln-25.
In my case all of my equipment is set up for portability, I do not have a dedicated set of shop machines. (see signiture sorry for the size I can't seem to change it) so the same will hold true one or two welds and I use SMAW.



For me anything over ¼” is plate and falls under my 1” unlimited structural certification SMAW FCAW as such both processes can accomplish the same end. So for me time is the ultimate deciding factor.

All of the processes mentioned SMAW FCAW GMAW (duel shield) Have a place and a time to be used I reach for the hard wire when welding thin sheet steel under the ¼” threshold. I find the FCAW 5/64” Coreshield 8 the wire of choice for ¼” and up. Fast deposition easy slag removal and excellent charppy impact.

When we turn to pipe (ASME) we open up a whole new can, and I’ll let that for the boys from the patch.

[calweld]

Seems like we have a related thread, this is a good time to get this one going.

I agree with FatFab, anything more than a few welds, the feeder comes out. Normally on the truck I keep two feeders, one set up with .045 NR-211 or 21B for the lighter stuff and one set up with .068 NR 232 for the heavy stuff. Doesn't really take any more time setting up than doing it with stick.

My preferred process is actually dualshield, unfortunately being portable and outside I can't always control the wind. When practical on the bigger jobs I will, though, even going to the point of stringing tarps. The deposition rate can't be beat, especially out-of-position, I had a job I posted on the Hobart board last year where I bypassed the contactor on my feeder and was running the stuff at 500 amps.

[Fat-Fab.com]

anything more than a few welds, the feeder comes out. Normally on the truck I keep two feeders, one set up with .045 NR-211 or 21B for the lighter stuff and one set up with .068 NR 232 for the heavy stuff. Doesn't really take any more time setting up than doing it with stick.



I too have two feeders set up on my truch a LN-25 with core8 5/64" and a Redy-Welder (spool gun) with nr211 .035"

TJ

[stick man]

wire vs stick would have to agree ever sense I got a LN25 have been spoiled using the wire, normally keep outtershield E71 t-1 in the feeder but on windy days still have to go with the old trusty 7018 what is a good self shield wire all the ones Ive tried end up looking like crap. And how do you convince the customer that if using the right wire it is as good as stick, Ive got one that will flat tell you they don't wont any of thier repairs done with wire. calweld what was that wire you were telling me about for AR and T1 lost the paper I wrote it on and can't rember the thread. "hope you do".

[calweld]

For T-1 I use Trimark991, there are also some 110 series wires that work good.

AR plate I always use a 70,000 tensile material, never the high tensile stuff. Outershield or 7018 is ideal.

[calweld]

Depending on what you're welding, ESAB Coreshield 8, Hobart 21B, or Lincoln NR211 are the easiest to learn how to use, flux core with no gas. NR 232 takes a little more practice, plus a lot of bad words:o

[stick man]

thanks for rembering taking that info to the truck right now so it don't get lost. I was thinking the outtershield was ok for AR atleast I have done it before and never had any come backs but never tried wire for T-1 always used 11018 stick rod,

[Sberry]

I use solid wire in the shop and chuck a couple sticks in for portable work, for me it isn't worth the effort to carry more stuff. A lot of my shop work is out of position, but general and light anyway. It doesn't make sense or save cost to add different processes.

[Darmik]

I carry 3 feeders
1 has Hobart Fabco XL 71 Flux core .045 and 1 roll 1/16" Gas C02 and 1 roll gasless
1 has Solid wire 70s -6 .045 gas C-25
1 has spool gun .035 5356 and 2 rolls of 4043
and the tig , stick and Oxy/fuel


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