The family of Cored Wire products includes two main categories: flux cored wire and alloy core injection rod. Flux Cored Wire (FCW) is used in arc welding (FCAW) and performance surface treatments of steel (ie. hard facing). Alloy cored wire, commonly known as ‘Injection Rod’ is used in molten metal processing. Yoder is a supplier of tooling and equipment, understanding the unique requirements of each application.
Flux Cored Wire
Flux cored wire is produced with either a lap or butt seam, to retain the flux material within the tube. Powdered flux is metered into the roll forming process, after which the tube is drawn down to the final wire diameter and recoiled, typically at speeds ranging from 200 to 500 FPM. Yoder provides roll forming machinery and tooling that is integrated to the FCW production system. Recently, Yoder has partnered with Lamnea Bruk, Sweden, to supply the roll forming equipment and form tooling which is integrated to their FCW Production system. Depending on the frequency of product changes, the FCW machinery can be setup cantilevered, for quick tooling changeover, or between housings, depending on the customer’s needs.
Yoder’s M-1 ½-S roll forming machine produces FCW product, at high speed. The integral gear box and roll stand design makes for a compact, modular machine, easily integrated to an FCW Production system. This specialized version of the popular M-1 ½ includes additional features unique to the requirements of manufacturing flux cored wire.
Yoder’s QVW-150S pull-thru design, can be retrofitted to replace competitor’s forming machinery, and has the benefit of common tooling sizes with the M-1 ½-S machine, adding flexibility into the production environment.
Alloy Cored Wire
For the molten metal treatment of iron, steel and non-ferrous alloys, cored wire ‘injection rod’ is used to adjust the balance of alloying elements at hot mills and foundries. Within the processing of forming cored wire, the alloys are introduced to the roll former either a powder flux, much like the manufacture of weld wire, or a solid core. The alloy is metered into the roll forming machine. After the alloy is introduced, the thin metal ‘jacket’ is roll formed around the alloy, mechanically closed with a lockseam, sized down to finish diameter, then oscillate recoiled on a mandrel. In application, the finished cored wire product must be precision fed into the molten metal so the desired amount of alloy element(s) added. The jacket roll formed over the core serves as a carrier, to transport the alloy into the molten material, so it is not lost in the surface slag.
Yoder provides specialized roll forming machines and tooling, designed for alloy Cored Wire production. Like the flux cored wire solutions, both rafted and non-rafted systems are available, tailored to customers needs. Recently, we have designed and built tooling that can accommodate both powder and solid alloy fed into the jacket. This development provides customers the flexibility of their manufacturing environment so they do not need to dedicate roll forming systems to separate products.