Metal cored wires were first developed in 1973 by Airco.  However, it wasn’t until recently that they have been perfected for widespread use.  They are now rapidly becoming an industry favorite for a wide variety of reasons and applications. 

Metal cored electrodes are identified as a composite tubular filler metal electrode consisting of a metal sheath and a core of various powdered materials, producing no more than silicon islands on the face of a weld bead.  (Standard Welding Terms and Definitions.  AWS A3.0:2001)

Their popularity is growing because first and foremost, they are very cost-effective.  The cost of labor is the highest single factor influencing the bottom line in any welding operation.  Deposition rates are 15 to 30% higher than solid wire resulting in the same percentage of increase in travel speeds.  These factors quickly increase the profit margin.

Steve Barhorst, Tubular Wire Marketing Manager at ITW Hobart Brothers Company indicates, “Switching to metal cored wire can save $100 to $200 for every 100 pounds of weld metal deposited.  The productivity increase from using metal cored wire quickly outweighs the increased cost of the consumables.”   

Low spatter, exceptionally clean weld beads, and slag-free welds dramatically reduce clean-up time and result in enhanced weld appearance.  This unique wire is highly resistant to undercut, even at higher current settings.  Arc characteristics improve while fume levels decrease.  Metal cored wires have better wetting action and better sidewall fusion than solid wire.  They can be used in a variety of welding positions 

Metal cored wires are being used in structural and fabrication applications, rail car construction, chemical and food service industries, automotive exhaust fabricators, shipyards, offshore platforms, pressure vessels, general plate fabrication, agricultural equipment, and others in a wide variety of semi-automatic, automatic, and robotic applications.  They are in compliance with most recognized standards including the American Welding Society, American Petroleum Institute, American Bureau of Shipping, Lloyds Register of Shipping, American Society of Mechanical Engineers, along with industry-specific standards such as Ford, General Motors, and Chrysler.