What to Consider When Choosing Solid or Flux Cored Wire

Welding Wire

While deciding on whether to use solid or flux cored wire, there are certain factors that you should consider. And, the factors to take into consideration are:


You must consider the location where you will be welding when you select which method of welding you will use. Gas shielded flux cored wire or solid wire welding cannot be done in windy locations, as exposure of the shielding gas to wind can cause the integrity of the weld to be compromised. The loss of shielding gas will cause the weld to become porous.

Self-shielded flux core wire welding can be done outdoors, even if it is windy. You do not require any shields to protect the shielding gases, as the burning flux generates the shielding gases. And, since the self-shielding flux core wire does not need external shielding gas, it is portable compared to solid wire. This is especially beneficial in the case of agricultural applications and also for the purpose of welding thick materials that are 16-gauge and more.


The appearance of the weld is also an important aspect. If you’re welding materials that are less than 3/16-inches to thin sheet metals, solid wire produces a weld that has a clean look. This is why professionals working with thinner materials or automotive specialists who work with bodywork tend to prefer solid wire for their jobs.

Type of Applications, Parameter Settings and Thickness

Most often, amateur welders use a common combination of wire and shielding gas for varied applications. Most commonly a 0.035 diameter wire is used with 25% carbon dioxide and 75% argon as shielding gas. However, when you are welding a thicker material, you must consider the weld wire diameter and the power source output, as using a low amperage with the 0.035 diameter wire may not produce a high-quality weld. Using a very small wire for thick applications or misapplication of solid wire may not provide proper penetration in the case of thicker materials.

Using flux cored wire can help to improve productivity although it is more expensive, as it can handle the welding of materials that are dirty having oil, mill scale or rust. Although the materials would need to be cleaned to prepare them for welding, flux cored wires contain deoxidising elements which trap the contaminants in the weld pool and prevent weld problems. The flux coated wire also increases the penetration and offers a better rate of deposition than solid wire. Although the cost of materials for flux coated wire is more, the production time is reduced significantly.

So, addressing the question of which wire is a better option, both wires have different properties and each works better for specific applications. Both types of wires produce high-quality welds when applied properly and within proper parameters. While solid wire penetrates deeply and does not produce much spatter, flux cored wire produces a larger ball type of transfer with low levels of spatter. Both the methods are equally easy to use and are suitable for various applications. The solid wire may be much better on thinner materials, as there is no production of slag and it can be painted immediately and also the weld bead is more aesthetic. Finally, the choice of wire really depends on the application and your welding requirement.

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