ITW Megafil cored wires
Gas-shielded cored wires were mainly developed for welding structural steels and thick materials. They offer greater process reliability than solid wires, have a higher deposition rate and can be used in constrained positions. All these advantages lead to a higher production rate than with solid wire or manual metal arc welding with fewer defects in the weld seam.
Production
The unique production technology used by ITW Welding to manufacture the seamless MEGAFIL® cored wire offers valuable product benefits to the end user. The manufacturing process is structured as follows: Strip is formed into a tube, HF-welded and then drawn to the cored diameter. In the next step, the tube is filled with agglomerated powder using a vibration system. The wire is then annealed, drawn to the final diameter and coated with copper. Finally, the wire is precisely wound onto different spool sizes in layers. The result is a completely closed cored wire with an extremely dry powder core that does not absorb any moisture during storage or the welding process.
Approvals
Seamless MEGAFIL® cored wires are available for most steel grades with a wide range of approvals from companies such as ABS, DNV, LR and TÜV. The wire can be ordered with a 3.1 certificate listing the actual chemical composition and mechanical properties of the batch supplied.
Brands from ITW
We can offer you not only cored wire from ITW, but also filler metals from the Hobart and Elga brands.
All advantages at a glance
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Higher deposition rate due to increased welding parameters
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Greater process reliability, can be used in constrained positions and produces fewer defects in the weld seam
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Avoidance of hydrogen-induced cracking . The hydrogen content in the weld metal, tested according to EN and AWS, is less than 4 ml/100 g Typical values are less than 3 ml/100 g
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No special storage precautions are necessary. Can be stored indefinitely like solid wire. No risk of moisture absorption
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No re-drying required, even after storage in a damp environment
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Resistant to moisture absorption even after removal from the pack, e.g. when attached to wire feed unit
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No flaws in the filling - therefore reliable weld metal properties
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Copper coating for optimum welding current transfer between contact tip and wire and to minimize contact tip wear
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Excellent wire feeding properties and swirl-free entry into the contact tip thanks to carefully controlled dimensions, cast and helix. Ideal for robot welding
Frequently asked questions to ITW Megafil cored wires
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