Welding Wires

Novak Wires offers a diverse range of welding wires tailored to meet the specific needs of various industries. Our product portfolio includes:

MIG WIRES

MIG wire, also known as Metal Inert Gas wire or Gas Metal Arc Welding (GMAW) wire, is a type of consumable welding electrode used in the MIG welding process. MIG welding is a popular welding technique that involves the use of an electric arc to melt and join metals together. Here’s some key information about MIG wire:

Composition: MIG wire is typically made of a solid metal wire or a metal wire with a flux core. The choice of wire composition depends on the specific welding application and the type of metals being joined. Common materials for MIG wire include mild steel, stainless steel, aluminum, and various alloy metals.
Diameter: MIG wires come in various diameters, typically ranging from 0.80 mm to 1.20 mm or even larger(up to 2.00mm). The wire diameter is chosen based on the thickness of the metals being welded and the desired welding parameters.
Shielding Gas: In MIG welding, a shielding gas is used to protect the weld pool from atmospheric contamination, such as oxygen and nitrogen, which can lead to poor-quality welds. Common shielding gases include carbon dioxide (CO2), argon (Ar), helium (He), or a mixture of these gases, depending on the materials and welding process used.
Wire Feed: MIG welding machines have a wire feeding mechanism that continuously feeds the MIG wire through the welding torch to maintain a consistent arc.
Applications: MIG welding with the appropriate MIG wire is used for a wide range of applications, including automotive repair, metal fabrication, construction, and manufacturing. It is versatile and can be used to weld various metals, from thin sheet metal to thick structural components.
Advantages: MIG welding with the right wire offers advantages such as high welding speeds, good weld bead appearance, minimal spatter, and ease of use. It’s suitable for both beginner and experienced welders.
Setup: Proper setup of the welding machine, wire feed speed, voltage, and gas flow rate is crucial to achieve high-quality welds. Welding parameters may vary depending on the specific MIG wire and metal being used.

In summary, MIG wire is an essential component in the MIG welding process, allowing for the fusion of metals with the help of an electric arc and a shielding gas. The choice of MIG wire and welding parameters depends on the specific welding application and the materials involved.

TIG WIRES

TIG wire, also known as Tungsten Inert Gas welding wire, is a type of welding consumable used in the TIG welding process. TIG welding is a welding technique that uses a non-consumable tungsten electrode to create an electric arc for welding. TIG welding is often used for precise and high-quality welds on a variety of materials, including metals like steel, stainless steel, aluminum, and copper. Here are some key points about TIG wire:

Composition: TIG welding wire is typically made of the same material as the base metal being welded. For example, if you are welding stainless steel, you would use stainless steel TIG wire. This ensures compatibility and helps maintain the integrity of the weld.
Filler Material: TIG welding often requires the use of filler material, which is fed into the weld pool manually as needed to provide additional material for the weld. The filler wire can come in various diameters and compositions to suit the specific welding application.
Sizes: TIG welding wire comes in various diameters, ranging from very thin wires for delicate work to thicker wires for heavier welding jobs. The choice of wire diameter depends on the material thickness and the desired weld characteristics.
Inert Gas Shielding: In TIG welding, an inert gas, such as argon or helium, is used to shield the weld area from atmospheric contamination. This inert gas prevents oxidation and ensures a clean and strong weld.
Manual Control: TIG welding requires a high level of skill and control by the welder. The welder must manually control the arc length, filler wire feed, and travel speed to produce high-quality welds.
Applications: TIG welding is commonly used in applications where precision and control are essential, such as aerospace, automotive, and high-purity welding applications in industries like food processing and pharmaceuticals.

TIG welding is known for its ability to produce clean, precise, and aesthetically pleasing welds, making it a preferred choice for industries and applications that require high-quality welding. The choice of TIG wire and the welding parameters depend on the specific materials and welding requirements of the job.

SAW WIRES

Submerged Arc Welding (SAW) is a welding process that uses a continuously fed electrode wire to join two pieces of metal. The welding wire used in SAW is a critical component of the process, as it plays a significant role in producing high-quality welds. Here’s some information about submerged arc welding wires:

Composition: Submerged arc welding wires are typically made of mild steel, low alloy steel, or stainless steel, depending on the application and the type of material being welded. The choice of wire composition is essential to match the properties of the base metal.
Wire Diameter: The diameter of the welding wire can vary depending on the welding application, but common diameters range from 2.0 mm to 4.0 mm. The choice of wire diameter depends on factors such as the welding current, the joint configuration, and the thickness of the base metal.
Wire Feed Mechanism: SAW uses a continuous wire feed mechanism to deliver the welding wire to the joint. The wire is fed through a contact tube, which conducts the welding current to the wire and forms the arc when it contacts the workpiece.
Controlled Environment: Submerged arc welding is called “submerged” because the arc and the weld pool are shielded by a layer of granular flux. This flux layer prevents atmospheric contamination of the weld and provides protection against oxidation and other defects. The flux also influences the chemistry and mechanical properties of the weld.
Specialized Alloys: In some cases, specialized submerged arc welding wires with specific alloying elements are used for applications where high strength, corrosion resistance, or other specific properties are required. For example, for welding stainless steel, a stainless steel submerged arc welding wire would be used.
Wire Packaging: Submerged arc welding wires are typically packaged on large spools or coils to ensure continuous welding without frequent interruptions for wire changes.
Welding Process Variations: Submerged arc welding can be adapted for various welding processes, such as single-wire, twin-wire, and tandem welding, depending on the application’s requirements and the desired welding speed and quality.
Advantages: SAW is known for its high deposition rates, excellent weld quality, and deep penetration capabilities, making it suitable for welding thick materials and for applications where productivity is crucial, such as in the fabrication of large structures and pipelines.
Applications: Submerged arc welding is commonly used in various industries, including shipbuilding, construction, pressure vessel fabrication, and the manufacturing of heavy machinery and equipment.

Selecting the appropriate submerged arc welding wire and flux combination is crucial to achieving the desired weld quality and meeting specific welding requirements. Welding parameters, such as voltage, current, and travel speed, should also be carefully controlled to ensure a successful weld.