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Wire & Welding Products

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We offer MIG & TIG welding wires, welding electrodes, brazing & Filler rod and wire and solders made from copper, stainless steel, aluminum, plus cobalt, silver and tin & lead. Available in diameters ranging from 1/16” to ¼”, these welding products are offered in a variety of lengths and forms, including custom cut-to-length, spools, coils, and wire basket spools. All welding products conform to or exceed the specifications of organizations such as American Welding Society (AWS), American Bureau of Shipping (ABS), and Bureau Veritas (BV).

In addition to custom welding products, we also offer a standard range of mild steel welding wire used as a welding consumable in a range of applications ranging from garage welding to various demanding welding environments. This welding wire is a copper-coated mild steel wire that produces welds with excellent radiographic and mechanical properties. Supplied in various diameters in cut to length rod (Flag Tagged), spools, coils, or drums. The spooled items providing excellent feeding in semiautomatic plus automatic production welding. All our products can be delivered in customized KANBAN and Just-In-Time (JIT) programs. Expedited delivery is available too.

We also offer some Resistance welding products such as copper spot welding tips and copper alloy resistance wheels and other items.





Specifications  · Mild Steel Welding Wire  · Various Processes  · Welding Processes

Specifications

Wire Form & Uses

A wire is a single, usually cylindrical, string of metal. Wires are used to bear mechanical loads and to carry electricity and telecommunications signals. Wire is commonly formed by drawing the metal through a hole in a die or draw plate. Standard sizes are determined by various wire gauges. The term wire is also used more loosely to refer to a bundle of such strands, as in 'multistranded wire', which is more correctly termed a wire rope in mechanics, or a cable in electricity.

Wire has many uses. It forms the raw material of many important manufacturers, such as the wire-net industry, wire-cloth making and wire-rope spinning, in which it occupies a place analogous to a textile fiber. Wire-cloth of all degrees of strength and fineness of mesh is used for sifting and screening machinery, for draining paper pulp, for window screens, and for many other purposes. Vast quantities of aluminum, copper, nickel and steel wire are employed for telephone and data wires and cables, and as conductors in electric power transmission, and heating. It is in no less demand for fencing, and much is consumed in the construction of suspension bridges, and cages, etc. In the manufacture of stringed musical instruments and scientific instruments wire is again largely used. Among its other sources of consumption it is sufficient to mention pin and hair-pin making, the needle and fish-hook industries, nail, peg and rivet making, and carding machinery; indeed there are few industries into which it does not enter.

Not all metals and metallic alloys possess the physical properties necessary to make useful wire. The metals must in the first place be ductile and strong in tension, the quality on which the utility of wire principally depends. The metals suitable for wire, possessing almost equal ductility, are platinum, silver, iron, copper, aluminum and gold; and it is only from these and certain of their alloys with other metals, principally brass and bronze, that wire is prepared. By careful treatment extremely thin wire can be produced. Special purpose wire is however made from other metals (e.g. tungsten wire for light bulb and vacuum tube filaments, because of its high melting temperature). Copper wires are also plated with other metals, such as tin, nickel, and silver to handle different temperatures, provide lubrication, and provide easier stripping of rubber from copper.

Wire Gauges

All wire gauges are available.

Welding Wire Products

Aluminum Alloy Wire and Electrodes
Chrome Alloy Wire and Electrodes
Cobalt and Tungsten Rod and Electrodes
Copper Alloy rod and wire
Copper and Copper Free MIG/TIG Wire
Low fuming and Nickel Silver Brazing Wire and Rod
Mild Steel Welding Wire
Silver and Silver alloy MIG & TIG
Stainless and Nickel MIG/TIG Wire and Electrodes

Available Diameters

1/16" to 1/4"
(Smaller can be made on request and if quantities are large enough for our production run.)

Available Sizes

Coils
Custom Cut-To-Length (with or without Flag-Tags)
Drums
Spools
Wire Baskets

Logistics Services

Bar Coding
Blanket Orders with Scheduled Releases
JIT (Just In Time) Delivery
KANBAN
Lean Manufacturing services
Shipping Logistics
Special Packaging with printing and point of sale
Trucking
Warehousing Services

Compliances

ABS (American Bureau of Shipping)
AWS (American Welding Society)
BV (Bureau Veritas)
CWB (Canadian Welding Bureau)
DB (Deutsche Bahn)
LLOYD's (Register of Shipping)
RINA (Registro Italiano Navale)
TUV (VdTUV-Merkblatt)

Order Quantity

We offer various quantity breaks and this is dependant on materials and packaging.

Typical Lead Time

Expedited service is available
Production orders are generally 8-12 weeks and dependant of capacity
Stocking programs with scheduled releases


Mild Steel Welding Wire

Available Diameters

0.023" or 0.58mm
0.030" or 0.76mm
0.035" or 0.89mm
0.040" or 1.02mm
0.045" or 1.14mm
0.0625" or 1.59mm

Available Sizes

1 lb and 5 lb spools
33 - 40 lb / 15 - 18 Kg Wire Basket or plastic spools
36" cut lengths or custom lengths
550 lb / 250 Kg Drums

Applications

Construction
Industrial Manufacturing
Pipe Welding
Structural Steel Welding
Vessel Welding


Various Processes
Brazing is a metal-joining process whereby a filler metal is heated above and distributed between two or more close-fitting parts by capillary action. The filler metal is brought slightly above its melting (Liquidus) temperature while protected by a suitable atmosphere, usually a flux. It then flows over the base metal (known as wetting) and is then cooled to join the workpieces together. It is similar to soldering, except the temperatures used to melt the filler metal is above 450 °C (842 °F), or, as traditionally defined in the United States, above 800 °F (427 °C).

Filler materials: A variety of alloys are used as filler metals for brazing depending on the intended use or application method. In general, braze alloys are made up of 3 or more metals to form an alloy with the desired properties. The filler metal for a particular application is chosen based on its ability to: wet the base metals, withstand the service conditions required, and melt at a lower temperature than the base metals or at a very specific temperature.

Braze alloy is generally available as rod, ribbon, powder, paste, cream, wire and preforms (such as stamped washers). Depending on the application, the filler material can be pre-placed at the desired location or applied during the heating cycle. For manual brazing, wire and rod forms are generally used, as they are the easiest to apply while heating. In the case of furnace brazing, alloy is usually placed beforehand since the process is usually highly automated. Some of the more common types of filler metals used are:
  • Aluminum-silicon
  • Copper
  • Copper-phosphorus
  • Copper-zinc (Low-fuming (RBCuZn-C), Nickel Silver (RBCuZn-D), Phosphor bronzes (ERCuSn-A), Silicon bronze (ERCuSi-A), Aluminum Bronzes (ERCuAl-A) and various other filler metals)
  • Gold-silver
  • Nickel alloy
  • Silver & Silver alloys (BCuP & Bag series of silver brazing alloys or filler metals)
  • Amorphous brazing foil using nickel, iron, copper, silicon, boron, phosphorus, etc.
There are many heating methods available to accomplish brazing operations. The most important factor in choosing a heating method is achieving efficient transfer of heat throughout the joint and doing so within the heat capacity of the individual base metals used. The geometry of the braze joint is also a crucial factor to consider, as is the rate and volume of production required. The easiest way to categorize brazing methods is to group them by heating method. Here are some of the most common:
  • Torch brazing
  • Furnace brazing
  • Induction brazing
  • Dip brazing
  • Resistance brazing
  • Infrared brazing
  • Blanket brazing
  • Electron beam and laser brazing
  • Braze welding
Soldering is a process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, the filler metal having a relatively low melting point. Soft soldering is characterized by the melting point of the filler metal, which is below 400 °C (752 °F). The filler metal used in the process is called solder.

Soldering is distinguished from brazing by use of a lower melting-temperature filler metal; it is distinguished from welding by the base metals not being melted during the joining process. In a soldering process, heat is applied to the parts to be joined, causing the solder to melt and be drawn into the joint by capillary action and to bond to the materials to be joined by wetting action. After the metal cools, the resulting joints are not as strong as the base metal, but have adequate strength, electrical conductivity, and water-tightness for many uses. Soldering is an ancient technique mentioned in the Bible and there is evidence that it was employed up to 5000 years ago in Mesopotamia.

Soldering Applications
One of the most frequent applications of soldering is assembling electronic components to printed circuit boards (PCBs). Another common application is making permanent but reversible connections between copper pipes in plumbing systems. Joints in sheet metal objects such as food cans, roof flashing, rain gutters and automobile radiators have also historically been soldered, and occasionally still are. Jewelry components are assembled and repaired by soldering. Small mechanical parts are often soldered as well. Soldering is also used to join lead came and copper foil in stained glass work. Soldering can also be used as a semi-permanent patch for a leak in a container or cooking vessel.

One guideline to consider when soldering is that, since soldering temperatures are so low, a soldered joint has limited service at elevated temperatures. Solders generally do not have much strength, so the process should not be used for load-bearing members.

Some examples of solder types and their applications include tin-lead (general purpose), tin-zinc for joining Aluminium, lead-silver for strength at higher than room temperature, cadmium-silver for strength at high temperatures, zinc-aluminum for aluminum and corrosion resistance, and tin-silver and tin-bismuth for electronics.

Soldering filler materials are available in many different alloys for differing applications. In electronics assembly, the alloy of 63% tin and 37% lead (a eutectic alloy) or 60/40, which is almost identical in performance has been the alloys of choice. Other alloys are used for plumbing, mechanical assembly, and other applications.

These formulations have several advantages for soldering; chief among these is the coincidence of the Liquidus and Solidus temperatures, i.e. the absence of a plastic phase. This allows for quicker wetting as the solder heats up, and quicker setup as the solder cools. A non-eutectic formulation must remain still as the temperature drops through the Liquidus and Solidus temperatures. Any differential movement during the plastic phase may result in cracks, giving an unreliable joint. Common solder alloys are mixtures of tin and lead, respectively:
  • 63/37: melts at 183 °C (361 °F) (eutectic: the only mixture that melts at a point, instead of over a range)
  • 60/40: melts between 183–190 °C (361–374 °F)
  • 50/50: melts between 185–215 °C (365–419 °F)
Lead-free solders are suggested anywhere young children may come into contact with (since young children are likely to place things into their mouths), or for outdoor use where rain and other precipitation may wash the lead into the groundwater.

Lead-free solder alloys melt around 250 °C (482 °F), depending on their composition.

For environmental reasons, 'no-lead' solders are becoming more widely used. Unfortunately most 'no-lead' solders are not eutectic formulations, making it more difficult to create reliable joints with them.

Other common solders include low-temperature formulations (often containing bismuth), which are often used to join previously-soldered assemblies without un-soldering earlier connections, and high-temperature formulations (usually containing silver) which are used for high-temperature operation or for first assembly of items which must not become unsoldered during subsequent operations.

Alloying silver with other metals changes the melting point, adhesion and wetting characteristics, and tensile strength. Of all the brazing alloys, the silver solders have the greatest strength and the broadest applications.

Specialty alloys are available with properties such as higher strength, better electrical conductivity and higher corrosion resistance.



Welding Processes
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the workpieces to form a bond between them, without melting the workpieces.

Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be done in many different environments, including open air, under water and in outer space. Regardless of location, however, welding remains dangerous, and precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light.

Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had used for centuries to join iron and steel by heating and hammering them. Arc welding and oxyfuel welding were among the first processes to develop late in the century, and resistance welding followed soon after. Welding technology advanced quickly during the early 20th century as World War I and World War II drove the demand for reliable and inexpensive joining methods. Following the wars, several modern welding techniques were developed, including manual methods like shielded metal arc welding, now one of the most popular welding methods, as well as semi-automatic and automatic processes such as gas metal arc welding, submerged arc welding, flux-cored arc welding and electroslag welding. Developments continued with the invention of laser beam welding and electron beam welding in the latter half of the century. Today, the science continues to advance. Robot welding is becoming more commonplace in industrial settings, and researchers continue to develop new welding methods and gain greater understanding of weld quality and properties.

Arc Welding
These processes use a welding power supply to create and maintain an electric arc between an electrode and the base material to melt metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and filler material is sometimes used as well.

Gas Welding
The most common gas welding process is oxyfuel welding, also known as oxyacetylene welding. It is one of the oldest and most versatile welding processes, but in recent years it has become less popular in industrial applications. It is still widely used for welding pipes and tubes, as well as repair work.

The equipment is relatively inexpensive and simple, generally employing the combustion of acetylene in oxygen to produce a welding flame temperature of about 3100 °C. The flame, since it is less concentrated than an electric arc, causes slower weld cooling, which can lead to greater residual stresses and weld distortion, though it eases the welding of high alloy steels. A similar process, generally called oxyfuel cutting, is used to cut metals.

Resistance Welding
Resistance welding involves the generation of heat by passing current through the resistance caused by the contact between two or more metal surfaces. Small pools of molten metal are formed at the weld area as high current (1000–100,000 A) is passed through the metal. In general, resistance welding methods are efficient and cause little pollution, but their applications are somewhat limited and the equipment cost can be high.

Spot welding is a popular resistance welding method used to join overlapping metal sheets of up to 3 mm thick. Two electrodes are simultaneously used to clamp the metal sheets together and to pass current through the sheets. The advantages of the method include efficient energy use, limited workpiece deformation, high production rates, easy automation, and no required filler materials. Weld strength is significantly lower than with other welding methods, making the process suitable for only certain applications. It is used extensively in the automotive industry—ordinary cars can have several thousand spot welds made by industrial robots. A specialized process, called shot welding, can be used to spot weld stainless steel.

Like spot welding, seam welding relies on two electrodes to apply pressure and current to join metal sheets. However, instead of pointed electrodes, wheel-shaped electrodes roll along and often feed the workpiece, making it possible to make long continuous welds. In the past, this process was used in the manufacture of beverage cans, but now its uses are more limited. Other resistance welding methods include butt welding, flash welding, projection welding, and upset welding.



 MORE IMAGES 

·  1 lb Plastic Spool

·  11 lb Plastic Spool

·  30 lb Plastic Spool

·  30 lb Wire Basket

·  550 lb Pack

·  Brass Wire for Redrawing

·  Brazing Filler Metal Coils and Spools

·  Copper Coated Mild Steel ER-70S-6 Wire On Wire Spools

·  ER70S6 Cu Coated Steel Welding Wire - Plastic Spool Adapter

·  ER70S6 Welding Wire On Steel Spool With Insert

·  Galvanized Steel Wire In Process

·  Galvanizing and Drawing Line

·  HR Clean and Coat - Acid Phosphate Borax

·  Low Fuming Brazing Rods

·  Stainless Wire for Redrawing

·  Steel Wire Drawing

·  Straight Cut-to-length Wire

·  Straight Cut to Length Wire

·  Straight Wire Cut to Length

·  Welding Rod and Wire

·  Welding Wire Drum

·  Welding Wire Spool w. Plastic Wrap

·  Wire Coils

·  Wire Drawing Line

·  Wire Processing


 DOWNLOADS 

Conversions of Fraction to Decimal
(PDF, 36KB)

Hardness Conversion Table
(PDF, 55KB)

Metal Weight Conversion Table
(PDF, 29KB)

Wire Gauge Chart
(PDF, 33KB)

Common Metric Equivalents
(PDF, 39KB)


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