Tubular wires made from copper coated strip

Abstract

The present disclosure relates to a method for producing a tubular welding electrode comprising the steps of providing a strip of copper-coated steel material having a length and first and second surfaces, wherein at least the first surface of the strip is at least substantially coated with a copper alloy, forming the strip into a “U” shape along the length, filling the “U” shape of the strip with a granular powder flux, and mechanically closing the “U” shape to form a sheath of copper-coated steel material that substantially encases the granular powder flux, thus forming a tubular welding electrode.

1 . A tubular welding electrode having a length comprising:
 a granular core extending substantially along the length of the electrode; and   a steel sheath extending substantially along the length of the electrode and substantially encasing the granular core;   wherein the steel sheath has an inner and an outer surface;   wherein the steel sheath has and opposing radial ends that extend substantially along the length of the electrode;   wherein the opposing radial ends of the steel sheath are joined via a seam extending substantially along the length of the electrode; and   wherein the outer surface of the steel sheath is at least substantially coated with copper or a copper alloy prior to joining the opposing radial ends of the steel sheath.   
     
     
         2 . The tubular welding electrode of  claim 1 , wherein the seam is a butt or overlap seam. 
     
     
         3 . The tubular welding electrode of  claim 1 , wherein the granular core is a granular powder flux fill core. 
     
     
         4 . The tubular welding electrode of  claim 1 , wherein the granular core is a granular metal core. 
     
     
         5 . The tubular welding electrode of  claim 1 , wherein the copper or copper alloy is plated onto the outer surface of the steel sheath. 
     
     
         6 . The tubular welding electrode of  claim 1 , wherein both the inner and outer surfaces of the steel sheath are at least substantially coated with copper or a copper alloy. 
     
     
         7 . A tubular welding electrode having a length comprising:
 a granular core extending substantially along the length of the electrode; and   a steel sheath extending substantially along the length of the electrode and substantially encasing the granular core;   wherein the steel sheath has an inner and an outer surface, and   wherein the inner surface of the steel sheath is at least substantially coated with copper or a copper alloy.   
     
     
         8 . The tubular welding electrode of  claim 7 , wherein the granular core is a granular powder flux fill core. 
     
     
         9 . The tubular welding electrode of  claim 7 , wherein the granular core is a granular metal core. 
     
     
         10 . The tubular welding electrode of  claim 7 , wherein the copper or copper alloy is plated onto the inner surface of the steel sheath. 
     
     
         11 . The tubular welding electrode of  claim 7 , wherein both the inner and outer surfaces of the steel sheath are at least substantially coated with copper or a copper alloy. 
     
     
         12 . A method for producing a tubular welding electrode comprising:
 a. providing a strip of copper-coated steel material having a length and first and second surfaces, wherein at least the first surface of the strip is at least substantially coated with copper or a copper alloy;   b. forming the strip into a “U” shape along the length;   c. filling the “U” shape of the strip with a granular flux; and   d. mechanically closing the “U” shape to form a sheath of copper-coated steel material that substantially encases the granular flux, thus forming a tubular welding electrode.   
     
     
         13 . The method of  claim 12 , wherein the mechanical closing involves forming a butt or overlap seam. 
     
     
         14 . The method of  claim 12 , wherein the copper or copper alloy is plated onto the strip of steel material. 
     
     
         15 . The method of  claim 12 , further comprising a step e) of drawing the tubular welding electrode to a desired diameter. 
     
     
         16 . The method of  claim 12 , wherein the second surface is not coated with copper or a copper alloy and during step b) the first surface of the strip is located on the inside of the “U” shape. 
     
     
         17 . The method of  claim 12 , wherein the second surface is not coated with copper or a copper alloy and during step b) the first surface of the strip is located on the outside of the “U” shape. 
     
     
         18 . The method of  claim 12 , wherein the second surface of the strip is at least substantially coated with copper or a copper alloy. 
     
     
         19 - 24 . (canceled)