Systems and methods for welding electrodes

Abstract

The invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FACW). In one embodiment, a tubular welding wire includes a sheath and a core, and the core comprises a rare earth silicide component (cerium, lanthanum, or a combination thereof). The core may also comprise an organic stabilizer component, a carbon component, and an agglomerate. The organic stabilizer component may comprise an organic molecule or organic polymer bound to one or more Group I or Group II metals. The carbon component may comprise graphite, graphene, carbon black, lamp black, carbon nanotubes, diamond, or a combination thereof. The agglomerate may comprise oxides of one or more Group I or Group II metals, titanium, and manganese.

1 . A tubular welding wire, comprising:
 a metallic sheath disposed around a granular core, wherein the granular core comprises a rare earth silicide component, and wherein the rare earth silicide comprises cerium, lanthanum, or a combination thereof.   
     
     
         2 . The tubular welding wire of  claim 1 , wherein the rare earth component comprises between approximately 0.1% and approximately 5% of the tubular welding wire by weight. 
     
     
         3 . The tubular welding wire of  claim 1 , wherein the granular core further, comprises:
 an organic stabilizer component comprising one or more organic molecules or organic polymers bound to one or more Group I or Group II metals;   a carbon component comprising graphite, graphene, carbon black, lamp black, carbon nanotubes, diamond, or a combination thereof; and   an agglomerate comprising oxides of one or more Group I or Group II metals, titanium, and manganese.   
     
     
         4 . The tubular welding wire of  claim 1 , wherein the tubular welding wire is configured for welding coated metal workpieces, wherein the tubular welding wire is configured to provide a weld having a porosity less than approximately 0.25 inches per inch of the weld at travel speeds greater than approximately 30 inches per minute. 
     
     
         5 . The tubular welding wire of  claim 4 , wherein the porosity is less than approximately 0.10 inches per 1 inch of the weld. 
     
     
         6 . The tubular welding wire of  claim 4 , wherein the weld has a Charpy-V-Notch toughness greater than approximately 20 ft. lbs. at approximately −40° F. and greater than approximately 30 ft. lbs. at approximately −30° F. 
     
     
         7 . The tubular welding wire of  claim 1 , wherein the granular core further comprises a potassium source. 
     
     
         8 . The tubular welding wire of  claim 7 , wherein the potassium source includes potassium silicate, potassium titanate, potassium alginate, potassium carbonate, potassium fluoride, potassium phosphate, potassium sulfide, potassium hydroxide, potassium oxide, potassium permanganate, potassium silicofluoride, potassium feldspar, potassium molybdates, or a combination thereof. 
     
     
         9 . The tubular welding wire of  claim 7 , wherein the potassium source includes potassium alginate. 
     
     
         10 . The tubular welding wire of  claim 3 , wherein the tubular welding wire comprises between approximately 0.01% and approximately 5% organic stabilizer component by weight.