The Truth About Deposition Rates: CEWELD Ultra Clean III (Uncoppered Wire) vs Metal cored (MCAW).
In a welding world where 80% of welding costs are determined by the number of melted kilograms per hour, many contradictory things are claimed by welding specialists. How do I speed up my welding process, reduce my costs, and improve quality? Does the metalcored welding wire really have 20% more deposition and does the wire pay for itself? In this blog we give you answers on all these questions
CURRENT DENSITY
Many discussions are held and welding specialists contradict each other repeatedly. The fact is that the seller of filler materials always shows only what suits them best and often leaves out essential matters. The theory states that the current density of the metal cored wire is higher and for that reason shows a higher yield and deposition. This theory is partially correct but in practice, it holds little water because the metal cored wire also has its limitations and in the case of a 1.2 mm wire, it cannot be loaded higher than 300 Amps because then we will experience "snowballing" of the arc and generate small spatters next to the weld and undercut.
CEWELD Ultra Clean III vs MCAW: Key Performance Differences
Most companies weld the 1.2 mm metal cored wire around 280 amps and find this very pleasant to weld because this type of wire from 200 to 290 amps does not really have a globular area compared to solid welding wire. However, if we compare this with the Ultra Clean III 1.0 mm at the same current, we achieve over 30% more kilograms per hour with significantly less slag on the weld and a much higher travel speed. Moreover, the welder enjoys 80% less welding smoke and a beautiful weld without undercut and weld spatter with higher notch impact values.
WHICH DIAMETER SHOULD I USE?
In the table below, we can see that the Ultra Clean III in 1.0 mm offers the highest deposition up to 300 amperes. The 1.2 mm only offers a higher deposition if we can apply at least 325 amperes to the workpiece.
Deposition, Ultra Clean III versus metaal gevulde draad
Ultra Clean III is a low-speed drawn welding wire to prevent cracks and unevenness on the wire surface and has a much larger cast and smaller helix than you are used to from other welding wires. Ultra Clean III is not coated with a copper layer but with a new industrial lubricant that reduces friction resistance in the liner by 55% and ensures unprecedented arc stability. Metallurgically, Ultra Clean III is a cleaner form of the AWS A 5.18: ER 70S-6 where the copper is limited to the lowest possible values and the nominal composition guarantees a higher yield strength of at least 460 MPa.
Beautifully clean welds with virtually no post-processing required.
Using Ultra Clean III 1.0 mm at 220 Amps (4.7 kg/h).
Welding with silicates, which requires post-processing.
The best metal-cored wire on the market, 1.2 mm at 280 Amps (4.7 kg/h).
✔ 30% higher deposition rate than metal-cored wire
✔ Over 100 Joules at -50°C
✔ Suitable for offshore applications at -40°C, even down to -60°C
✔ Significantly reduced silicates
✔ Highly suitable for multi-layer welding, such as in the 3D WAAM process, where clean welds are essential
✔ Deeper penetration in fillet welds, with strong positive sidewall fusion
✔ No wire twist, wire exits the contact tip straight every time
✔ Excellent performance on weld primer with M24 gas
✔ 55% less resistance in torch and liner
✔ 80% less welding fume
✔ No harmful copper fumes for the welder
✔ Completely spatter-free
✔ Lower hydrogen content in the deposited weld metal
✔ Reduced material and overall welding costs
| a-height of 4 mm in PB position | MCAW | Ultra Clean III |
| Recommended current and wire diameter | 285 amp | 1,2mm | 238 amp | 1,0mm |
| Recommended wire feed speed | 9,47 mtr/min | 12,8 mtr/min |
| Recommended travel speed | 45 cm/min | 45 cm/min |
| Deposition in kg/hr | 4,7 kg | 4,7 kg |
| Price per kg welding wire | €4,50/kg | €2,50/kg |
| Required kg welding wire for an a4 | 0,19 kg | 0,18 kg |
| Welding wire costs per meter corner weld a4 | €0,86 | €0,45 |
| Savings on welding wire costs | - | 47% |
Spits
Hull weight ~300 Ton
Orion
Hull weight ~900 Ton
Queen marry 2
Hull weight ~76.000 Ton
Pioneering spirit
Hull weight ~192.000 Ton