Systems and methods for tubular welding wire

Abstract

A submerged arc welding (SAW) wire includes a metal sheath surrounding a granular core. The metal sheath includes at least approximately 0.6% manganese by weight and at least approximately 0.05% silicon by weight, and the granular core includes less than 2% manganese by weight and less than 2% silicon by weight. Further, the granular core does not include components that provide shielding gas during SAW.

1 . A submerged arc welding (SAW) wire, comprising:
 a metal sheath surrounding a granular core, wherein the metal sheath comprises at least approximately 0.6% manganese by weight and at least approximately 0.05% silicon by weight, and wherein the granular core comprises less than 2% manganese by weight and less than 2% silicon by weight, wherein the granular core does not include components that provide shielding gas during SAW.   
     
     
         2 . The SAW wire of  claim 1 , wherein the metal sheath comprises at least approximately 0.1% silicon by weight. 
     
     
         3 . The SAW wire of  claim 1 , wherein the metal sheath comprises between approximately 0.2% and approximately 0.3% silicon by weight. 
     
     
         4 . The SAW wire of  claim 1 , wherein the metal sheath comprises between approximately 0.25% and approximately 0.75% silicon by weight. 
     
     
         5 . The SAW wire of  claim 1 , wherein the metal sheath comprises less than approximately 1.8% manganese by weight. 
     
     
         6 . The SAW wire of  claim 1 , wherein the metal sheath comprises between approximately 0.8% and approximately 2% manganese by weight. 
     
     
         7 . The SAW wire of  claim 1 , wherein the metal sheath comprises between approximately 0.9% and approximately 1.1% manganese by weight. 
     
     
         8 . The SAW wire of  claim 1 , wherein the metal sheath comprises less than approximately 0.1% carbon by weight. 
     
     
         9 . The SAW wire of  claim 1 , wherein the granular core comprises less than 1% manganese by weight and less than 1% silicon by weight. 
     
     
         10 . The SAW wire of  claim 1 , wherein the granular core comprises less than 0.5% manganese by weight and less than 0.5% silicon by weight. 
     
     
         11 . The SAW wire of  claim 1 , wherein the granular core comprises less than 0.05% manganese by weight and less than 0.05% silicon by weight. 
     
     
         12 . The SAW wire of  claim 1 , wherein the SAW wire is configured for use in conjunction with a SAW flux that provides shielding gas near a weld pool during SAW. 
     
     
         13 . A submerged arc welding (SAW) system, comprising:
 a welding wire feeder that supplies a SAW wire to a SAW torch to form a weld pool on the surface of a workpiece during SAW, wherein the SAW wire comprises a metal sheath surrounding a granular core, wherein the metal sheath comprises at least approximately 0.6% manganese by weight and at least approximately 0.05% silicon by weight, and wherein the granular core comprises less than 2% manganese by weight and less than 2% silicon by weight; and   a flux delivery component that delivers a SAW flux to the surface of the workpiece, wherein the SAW flux provides at least a portion of the atmosphere near the weld pool during SAW.   
     
     
         14 . The SAW system of  claim 13 , wherein the metallic sheath comprises less than approximately 2% manganese by weight and less than approximately 0.75% silicon by weight. 
     
     
         15 . The SAW system of  claim 13 , wherein the metal sheath comprises between approximately 0.2% and approximately 0.3% silicon by weight and between approximately 0.9% and approximately 1.1% manganese by weight. 
     
     
         16 . The SAW system of  claim 13 , wherein the granular core comprises less than 1% manganese by weight and comprises less than 1% silicon by weight. 
     
     
         17 . The SAW system of  claim 13 , wherein the granular core comprises less than 0.05% manganese by weight and comprises less than 0.01% silicon by weight. 
     
     
         18 . A method of submerged arc welding (SAW), comprising:
 feeding a SAW wire to a SAW torch near a workpiece, wherein the SAW wire comprises a metal sheath surrounding a granular core, wherein the metal sheath comprises at least approximately 0.6% manganese by weight and at least approximately 0.05% silicon by weight, and wherein the granular core comprises less than 2% manganese by weight and less than 2% silicon by weight;   establishing an arc between the SAW wire and the workpiece to form a weld pool; and   providing a SAW flux that submerges the weld pool and provides at least a portion of the atmosphere near the weld pool.   
     
     
         19 . The method of  claim 18 , wherein the metal sheath comprises between approximately 0.2% and approximately 0.3% silicon by weight and between approximately 0.9% and approximately 1.1% manganese by weight. 
     
     
         20 . The method of  claim 20 , wherein the granular core comprises less than 1% manganese by weight and comprises less than 1% silicon by weight.