Sheathed welding wire

Abstract

Provided is a welding wire and method for manufacturing a welding wire providing for quality welds on 300 series stainless steel and similar materials. A metal powder core is encapsulated in a metal sheath. The metal sheath composition comprising up to about 6% nickel, by weight, and may correspond to a series 400 stainless steel. A combination of the metal sheath and the metal powder core provides an overall alloy content of a series 300 stainless steel.

1 - 25 . (canceled) 
     
     
         26 . A welding wire, comprising:
 a metal sheath comprising a 430 stainless steel; and   a core encapsulated by the sheath, an alloyed combination of the metal sheath and the core comprising a 309 stainless steel.   
     
     
         27 . The welding wire of  claim 26 , wherein the sheath comprises between about 16 and 18% chromium and up to about 0.75% nickel, all by weight. 
     
     
         28 . The welding wire of  claim 26 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight. 
     
     
         29 . The welding wire of  claim 26 , wherein the alloyed combination comprises less than about 0.12% carbon. 
     
     
         30 . The welding wire of  claim 26 , wherein the alloyed combination comprises between about 0.65 and 1% silicon, by weight. 
     
     
         31 . The welding wire of  claim 26 , comprising an outer diameter equal to or less than approximately 0.0625 inches. 
     
     
         32 . The welding wire of  claim 26 , comprising an outer diameter of between approximately 0.035 inches and 0.045 inches. 
     
     
         33 . A welding wire, comprising:
 a metal sheath comprising a 439 stainless steel; and   a core encapsulated by the sheath, an alloyed combination of the metal sheath and the core comprising a 309 stainless steel.   
     
     
         34 . The welding wire of  claim 33 , wherein the sheath comprises between about 17 and 19% chromium and up to about 0.5% nickel, all by weight. 
     
     
         35 . The welding wire of  claim 33 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight. 
     
     
         36 . The welding wire of  claim 33 , wherein the alloyed combination comprises less than about 0.12% carbon. 
     
     
         37 . The welding wire of  claim 33 , wherein the alloyed combination comprises between about 0.65 and 1% silicon, by weight. 
     
     
         38 . The welding wire of  claim 33 , comprising an outer diameter equal to or less than approximately 0.0625 inches. 
     
     
         39 . A method of manufacturing a welding wire, comprising:
 cupping a metal sheath strip comprising a 430 or 439 stainless steel;   disposing a metal core material on the metal sheath, a combination of the metal sheath and the metal core material comprising an overall alloy content of series 309 stainless steel;   closing the metal sheath about the metal core material to form a wire;   reducing a diameter of the wire; and   baking the wire.   
     
     
         40 . The method of  claim 39 , wherein the sheath comprises between about 16 and 18% chromium and up to about 0.75% nickel, all by weight. 
     
     
         41 . The method of  claim 40 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight. 
     
     
         42 . The method of  claim 39 , wherein the sheath comprises between about 17 and 19% chromium and up to about 0.5% nickel, all by weight. 
     
     
         43 . The method of  claim 42 , wherein the alloyed combination of the metal sheath and the core comprises between about 23 and 25% chromium and between about 12 and 14% nickel, all by weight. 
     
     
         44 . The method of  claim 39 , wherein the alloyed combination comprises less than about 0.12% carbon. 
     
     
         45 . The method of  claim 39 , wherein baking the wire comprises baking at a temperature between about 600° F. and 700° F.