Flux Cored Welding Wire Production Line
flux core wire welding machine (11)(1)
flux core wire machine
flux-cored wire welding(1)(1)
flux core wire welder (8)(1)
flux cored welding wire

Flux Cored Welding Wire Production Line

A flux-cored wire production line is a set of automated industrial equipment designed to process steel strip and flux powder into the final wire product. The core manufacturing process involves progressively roll-forming the steel strip into a "U" shape, filling it with flux powder, closing it into a tubular form, and subsequently reducing its diameter through multiple drawing passes to achieve the desired finished wire size.

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Product Introduction

Flux-cored wires are primarily divided into two types: seamed and seamless, with the core difference in their production lines lying in the post-seaming treatment:

Seamed flux-cored wire: This is the most common type. After the steel strip is joined, a longitudinal seam remains, and the production line does not include a welding process.

Seamless flux-cored wire: After joining the steel strip, an additional in-line welding step (such as high-frequency or laser welding) is added to seal the seam, resulting in a seamless tubular wire. Seamless wires effectively prevent moisture absorption of the flux powder and are suitable for higher-demand welding applications. However, their production technology is more complex and the manufacturing cost is higher.

Process flow:

1. Steel Strip Pre-treatment Unit Function: Uncoils, cleans, and dries the raw steel strip.

Key Equipment: Uncoiler, ultrasonic cleaning unit, drying unit.

Process Objective: To remove oil and contaminants from the steel strip surface, ensuring the quality of subsequent forming and welding operations.

2. Forming and Powder Filling Unit Function: Forms the steel strip by rolling and fills it with powder. Key Equipment: Forming machine (including multiple sets of rollers), powder hopper, and powder feeder. Process Objective: To gradually press a flat steel strip into a U-shape using multiple rolling passes while simultaneously filling it with powder precisely and uniformly.

3. Seam-Closing and Preliminary Diameter-Reduction Unit Function: Closes the U-shaped steel strip to encase the flux powder and performs preliminary drawing to reduce the diameter. Key Equipment: Seam-closing unit, rough wire-drawing machine (or integrated wire-rolling unit). Process Objective: To close the open U-shaped steel strip into a tubular shape, thereby securing the flux powder inside. Subsequently, wire drawing is used to reduce the wire diameter and increase the compaction density of the flux powder.

4.Precision Drawing and Post-Processing Unit

Function: To draw the welding wire to its final diameter and perform surface treatment. Key Equipment: Precision drawing unit (multi-pass wire drawing machine), chemical plating/cleaning system, and oiling unit. Process Objective: To precisely process the welding wire to the required specifications (e.g., Φ1.2 mm) through multi-pass drawing. Cleaning and oiling are performed to enhance surface cleanliness and improve wire-feeding performance during subsequent use.

5. Layer Winding and Packaging Equipment Function: To wind the finished welding wire onto spools and seal the packaging. Key Equipment: Precision layer-winding machine (including tensioning device and wire-traversing mechanism), take-up stand, and vacuum packaging equipment. Process Objective: To achieve neat winding and moisture-proof sealing of the welding wire, facilitating storage and transportation.

Overview of Key Technical Parameters

Parameter Category	Typical Range/Specifications
Raw material specifications
Steel strip width	8 - 20 mm	Different production lines have different compatibility ranges; the common range is 10–16 mm.
Steel strip thickness	0.25 - 1.5 mm	Carbon steel is typically 0.5–1.0 mm thick, while stainless steel can be as thin as 0.25–0.3 mm.
Forming machine parameters
Forming diameter (initial)	Φ3.2 - 6.0 mm	Initial diameter after rolling by the forming machine
Number of main rolls	10 - 12 pairs (adjustable)	The common configuration is 10 to 12 pairs of main rolls. Some production lines also use more sets of rolls.
Roll dimensions	Φ160 mm ± 6mm	Standard main roll diameter
Powder filling rate	10% - 60% adjustable	The common range is 15-50%, and for carbon steel, it is usually 15-25%.
Filler rate error	≤ ±1% (typically ±0.5%)	The high-precision production line can be controlled within ±0.2%.
Wire Drawing Machine Parameters
Number of drawing heads	8 - 16	Number of drawing passes/block for wire drawing machines
Wire-drawing drum diameter	350 /500 mm	Standard wire drawing drum specification
Finished welding wire specifications
Finished wire diameter	0.8 - 5.0 mm	The most common sizes are Φ1.2 mm and Φ1.6 mm.
Speed and Production Capacity
Forming speed	60 - 100 m/min	Linear speed during the forming stage
Wire drawing speed	160 - 1000 m/min
Annual production capacity	1,000 - 3,000 tons per year
Power and energy consumption
Total equipment power	11 kW - Hundreds of kW
Unit power rating	2.2 - 11 kW (Main Motor)
Electricity consumption per tonne	Approximately 130 kWh per tonne
Equipment Dimensions and Weight
Total length of the production line	36 - 39 m
Footprint area	1.5米 × 39m
gross weight of equipment	20,000 kg

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Packing & Delivery

2025-08-221730127571

Why Choose Us?

* Our Machines use cutting-edge technology to deliver high-quality results.
* The company is guided by market competition and gives full play to the overall advantages of both parties.
* We always firmly believe that innovation is the way to achieve success, integrity is the foundation of a hundred years of
business, we wholeheartedly provide you with reliable quality products and satisfactory service, welcome the new and old customers from all walks of life to patronize and guide!
* We have a strong focus on innovation, constantly seeking to improve our Straight Line Drawing Machines.
* Our company is based on a rigorous and realistic scientific attitude with unswerving professionalism.
* We are constantly innovating and improving our Machines to meet changing customer needs.
* In the course of the company's operation, it has always been adhering to the corporate mission of 'pursuing excellent quality and creating greater value for customers' and actively participating in market competition.

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