Generation4™ Welding Wire suitable for various Joint Styles, Welding Types and Welding Processes for your next project
CWI Generation4™ Welding Wire is designed for use in many different welding processes. The three most common types of Welding used with our Stainless Steel and Nickel Welding alloys are Tungsten Inert Gas (TIG), Metal Inert Gas (MIG) and Submerged-Arc Welding (SAW).
To ensure that you select the proper welding consumable alloy to work with your welding process, a brief description of each process is listed below.
Tungsten Inert Gas (TIG) Welding
Highly Skilled Welding for Aesthetic Applications
Also known as Gas Tungsten Arc Welding (GTAW), TIG Welding uses a tungsten electrode, a filler metal and an inert shielding gas (such as argon or helium) during the welding process. This method requires a highly skilled welder, as the manual technique requires two hands to utilize the equipment and apply the filler metal to create the weld joint.
TIG Welding is typically used with stainless steels and non-ferrous metals, on thinner section of metal, and provides the welder greater control over the properties of the weld versus other similar processes. It has the disadvantage of being relatively slow due to its complexity and multi part process.
Metal Inert Gas (MIG) Welding
Simple Welding Process for Industrial Applications
Also known as Gas Metal Arc Welding (GMAW), the MIG Welding process employs a welding gun, a power supply, an electrode (alloy wire) and a shielding gas. The welding procedure is uncomplicated, with the welding gun bringing all the required components (power, filler metal, shielding gas) together at the weld point.
Compared to other methods, training for MIG Welding requires less time to develop a usable skill level in the field. It is the preferred welding method in most industrial applications and can be easily adapted to automation if required. Issues with dross and porosity of welds can affect the quality of the finished welds, so additional scrutiny of materials and cleanliness is required.
Submerged Arc (SAW) Welding
Automated Welding Method Offering a High Deposition Rate
Often called Sub-Arc Welding, the SAW Welding process is primarily an automated method of welding that isolates the arc zone below (sub) the surface of a molten flux, eliminating atmospheric contamination. The process uses a continuous feed of consumable welding wire in either a single or multiple wire/alloy combination.
SAW has the advantage of a high deposition rate and deep weld penetration, making for a high ft/min welding rate. It also allows for single pass welds with thicker material. SAW is limited by the plane of the welding operation (straight welds are preferred) and can result in the need for an added slag removal step.
Below is a list of the wire diameters that we have stocked for each of the welding types we support. As a manufacturer, we can always provide customized solutions for your particular welding applications.
Wire Diameters by Welding Type
| MIG (GMAW) Diameters | TIG (GTAW) Diameters | SUB ARC (SAW) Diameters | |||
|---|---|---|---|---|---|
| Imperial in. | Metric mm | Imperial in. | Metric mm | Imperial in. | Metric mm |
| 0.023 | 0.6 | 1/16 | 1.6 | 5/64 | 2 |
| 0.030 | 0.8 | 3/32 | 2.4 | 3/32 | 2.4 |
| 0.035 | 0.9 | 1/8 | 3.2 | 1/8 | 3.2 |
| 0.045 | 1.14 | 5/32 | 4.0 | 5/32 | 4.0 |
| 0.047 | 1.2 | 3/16 | 4.8 | ||
| 1/16 | 1.6 |
Recommended Welding Procedures
CWI Generation4™ Stainless Steel and Nickel Welding Wire alloys can be used with many different joint styles and welding processes. Once the weld joint style, the filler material, and the process has been identified, a proper welding procedure can be identified. The welding procedure chosen for Stainless Steel and Nickel Welding depends upon the process to be used as well as the size and alloy of the actual consumable.
The charts below provide detailed information on the voltage, amperage (current), and gas (atmosphere) to be used in TIG (Tungsten Inert Gas), MIG (Metal Inert Gas), and SAW (Submerged-Arc Welding) Welding processes for the general alloys that we provide:
Recommended Welding Procedures for Gen 4 Stainless Steel Welding Wire
| Process | Diameter of Wire | Voltage (V) | Amperage (A) | Gas | |
|---|---|---|---|---|---|
| TIG | 0.035" | 0.9 mm | 12-15 | 60-90 | 100% Argon |
| 0.045" | 1.1 mm | 13-16 | 80-110 | 100% Argon | |
| 1/16" | 1.6 mm | 14-18 | 90-130 | 100% Argon | |
| 3/32" | 2.4 mm | 15-20 | 120-175 | 100% Argon | |
| 1/8" | 3.2 mm | 15-20 | 150-220 | 100% Argon | |
| MIG | 0.030" | 0.8mm | 24-28 | 140-180 | 99% Argon + 1% Oxygen -or- 97% Argon + 3% CO2 |
| 0.035" | 0.9mm | 26-29 | 160-210 | 99% Argon + 1% Oxygen -or- 97% Argon + 3% CO2 | |
| 0.045" | 1.1mm | 28-32 | 180-250 | 99% Argon + 1% Oxygen -or- 97% Argon + 3% CO2 | |
| SAW | 0.0625" | 1.6mm | 29-33 | 200-280 | Suitable Flux may be used |
| 3/32" | 2.4mm | 28-30 | 275-350 | Suitable Flux may be used | |
| 1/8" | 3.2mm | 29-32 | 350-450 | Suitable Flux may be used | |
| 5/32" | 4.0mm | 30-33 | 450-550 | Suitable Flux may be used |
Recommended Welding Procedures for Gen 4 Stainless Nickel Welding Wire
| Process | Diameter of Wire | Voltage (V) | Amperage (A) | Gas | |
|---|---|---|---|---|---|
| TIG | 0.035" | 0.9 mm | 12-15 | 60-90 | 100% Argon |
| 0.045" | 1.1 mm | 13-16 | 80-110 | 100% Argon | |
| 1/16" | 1.6 mm | 14-18 | 90-130 | 100% Argon | |
| 3/32" | 2.4 mm | 15-20 | 120-175 | 100% Argon | |
| 1/8" | 3.2 mm | 15-20 | 150-220 | 100% Argon | |
| MIG | 0.035" | 0.9mm | 26-29 | 150-190 | 75% Argon + 25% Helium |
| 0.045" | 1.2mm | 28-32 | 180-220 | 75% Argon + 25% Helium | |
| 1/16" | 1.6mm | 29-33 | 200-250 | 75% Argon + 25% Helium | |
| SAW | 3/32" | 2.4mm | 28-30 | 375-350 | Suitable Flux may be used |
| 1/8" | 3.2mm | 29-32 | 350-450 | Suitable Flux may be used | |
| 5/32" | 4.0mm | 30-33 | 400-550 | Suitable Flux may be used |