--- title: 3 Reasons to Break Free From Flux-Cored Wire in Welding description: Learn three compelling reasons why it might be time to bid farewell to flux-cored wire and embrace solid wire for your welding processes. image: https://blog.daihen-usa.com/hubfs/1-Blog/featured-flux-cored-wire.webp --- [![OTC Daihen Inc.](https://www.daihen-usa.com/wp-content/uploads/2022/05/logo.png)](https://www.daihen-usa.com/) [OTC DAIHEN](https://www.daihen-usa.com) ## Primary Menu - Technologies - [![Synchro-Feed-Evolution-menu](https://www.daihen-usa.com/wp-content/uploads/2024/01/Synchro-Feed-Evolution-menu.webp)Synchro Feed Evolution Ultra Low Spatter Welding](https://www.daihen-usa.com/low-spatter-synchro-feed-evolution/) - [![ultra-low-spatter-menu](https://www.daihen-usa.com/wp-content/uploads/2024/01/ultra-low-spatter-menu.png)Plasma Jet TIG High Jet Stream Flow](https://www.daihen-usa.com/plasma-jet-tig-welder/) - [Support](https://www.daihen-usa.com/support/) - [![emergency](https://www.daihen-usa.com/wp-content/uploads/2022/07/emergency.png)Emergency Support](https://www.daihen-usa.com/support/#emergency) - [![support](https://www.daihen-usa.com/wp-content/uploads/2022/07/support.png)Service](https://www.daihen-usa.com/support/#spareparts) - [![rma](https://www.daihen-usa.com/wp-content/uploads/2022/07/rma.png)In-House Repair](https://www.daihen-usa.com/support/#techsupport) - [![parts](https://www.daihen-usa.com/wp-content/uploads/2022/07/parts.png)Parts](https://www.daihen-usa.com/support/#inhouserepair) - [Training](https://www.daihen-usa.com/training/) - [![register-menuicon](https://www.daihen-usa.com/wp-content/uploads/2022/07/register-menuicon.png)Register](https://www.daihen-usa.com/training/#register) - [![class-menuicon](https://www.daihen-usa.com/wp-content/uploads/2022/07/class-menuicon.png)Class Offering](https://www.daihen-usa.com/training/#courseoverview) - [![faq-menuicon](https://www.daihen-usa.com/wp-content/uploads/2022/07/faq-menuicon.png)Training FAQs](https://www.daihen-usa.com/training/#trainingfaqs) - [Resources](https://www.daihen-usa.com/resources/) - [![manuals](https://www.daihen-usa.com/wp-content/uploads/2022/07/manuals.png)Product Manuals](https://www.daihen-usa.com/product-manuals-otc-daihen/) - [![buyers-guide](https://www.daihen-usa.com/wp-content/uploads/2022/07/buyers-guide.png)Buyer’s Guides & Videos](https://www.daihen-usa.com/buyers-guides-videos/) - [![industry-articles](https://www.daihen-usa.com/wp-content/uploads/2022/07/industry-articles.png)Industry Articles](https://blog.daihen-usa.com/?__hstc=51647990.76b0b6a765e9ea5764d9133abef56596.1646249670674.1652379522534.1659373989410.28&__hssc=51647990.1.1659373989410&__hsfp=2776171110) - [![weld-spatter](https://www.daihen-usa.com/wp-content/uploads/2022/07/weld-spatter.png)Weld Spatter 101](https://www.daihen-usa.com/weld-spatter/) - [![warranty](https://www.daihen-usa.com/wp-content/uploads/2022/07/warranty.png)Warranty Info](https://www.daihen-usa.com/resources/warranty-info/) - [![older-model-charts](https://www.daihen-usa.com/wp-content/uploads/2022/07/older-model-charts.png)Reference Charts](https://www.daihen-usa.com/reference-charts/) - [![cost](https://www.daihen-usa.com/wp-content/uploads/2022/07/cost.png)Welding Cost Analysis](https://info.daihen-usa.com/welding-cost-analysis?__hstc=51647990.76b0b6a765e9ea5764d9133abef56596.1646249670674.1652379522534.1659373989410.28&__hssc=51647990.1.1659373989410&__hsfp=2776171110) - [![newsletter](https://www.daihen-usa.com/wp-content/uploads/2022/07/newsletter.png)Get My Free Newsletter](https://info.daihen-usa.com/welding-automation-newsletter?__hstc=51647990.76b0b6a765e9ea5764d9133abef56596.1646249670674.1652379522534.1659373989410.28&__hssc=51647990.1.1659373989410&__hsfp=2776171110) - [Blog](https://blog.daihen-usa.com/) - [About OTC DAIHEN](https://www.daihen-usa.com/about-otc-daihen/) - [![about](https://www.daihen-usa.com/wp-content/uploads/2022/07/about.png)About Us](https://www.daihen-usa.com/about-otc-daihen/) - [![team](https://www.daihen-usa.com/wp-content/uploads/2022/07/team.png)Meet The Team](https://www.daihen-usa.com/meet-the-team/) - [![faq](https://www.daihen-usa.com/wp-content/uploads/2022/07/faq.png)FAQs](https://www.daihen-usa.com/faqs/) - - Search Search - [Contact Us](https://www.daihen-usa.com/contact/) - [Solutions ▼](https://www.daihen-usa.com/support/) - [Robotic Welding Cells](https://www.daihen-usa.com/robotic-welding-cells/) - [Welding Robots](https://www.daihen-usa.com/arc-welding-robots/) - [Welding Power Sources](https://www.daihen-usa.com/welding-power-sources/) - [COMPANY](https://www.daihen-usa.com/about-otc-daihen/) - [TRAINING](https://www.daihen-usa.com/training/) - [SUPPORT](https://www.daihen-usa.com/support/) - [![LinkedIn logo](https://blog.daihen-usa.com/hs-fs/hubfs/otc-linkedin.png?width=18&height=18&name=otc-linkedin.png)](https://www.linkedin.com/company/otc-daihen-inc.) - [![Youtube logo](https://blog.daihen-usa.com/hs-fs/hubfs/otc-youtube.png?width=26&height=26&name=otc-youtube.png)](https://www.youtube.com/user/OTCDaihen) [![OTC DAIHEN Logo](https://blog.daihen-usa.com/hubfs/Logos/daihen-logo-hs-white.png "OTC DAIHEN Logo")](https://www.daihen-usa.com/) - [ROBOTIC WELDING](https://www.daihen-usa.com/robotic-welding/) - [Robotic Welding Cells](https://www.daihen-usa.com/robotic-welding-cells/) - [ECO-ARCs](https://www.daihen-usa.com/eco-arc-series/) - [PT ARCs & SERVO ARCs](https://www.daihen-usa.com/pt-servo-arc/) - [DT-ARCs](https://www.daihen-usa.com/dt-arc-series/) - [ROTA-ARCs](https://www.daihen-usa.com/rota-arc-series/) - [TRI-ARCs](https://www.daihen-usa.com/tri-arc/) - [ED-ARCs](https://www.daihen-usa.com/ed-arc-series/) - [Ready-To-Ship Systems](https://www.daihen-usa.com/pre-engineered-robotic-welding-cells/) - [Arc Welding Robots](https://www.daihen-usa.com/arc-welding-robots/) - [6-Axis Robots](https://www.daihen-usa.com/6-axis-robots/) - [7-Axis Robots](https://www.daihen-usa.com/7-axis-robots/) - [Robot Accessories](https://www.daihen-usa.com/robot-accessories/) - [Robot Controllers](https://www.daihen-usa.com/robot-controllers/) - [Robot Positioner](https://www.daihen-usa.com/robot-positioner/) - [Robotic Sensors](https://www.daihen-usa.com/robotic-sensors/) - [Welding Cobots](https://www.daihen-usa.com/integration/welding-cobots/) - [WELDING POWER SOURCES](https://www.daihen-usa.com/welding-power-sources/) - [Welbee Power Sources](https://www.daihen-usa.com/welbee-power-sources/) - [Welding Torches & Wire Feeders](https://www.daihen-usa.com/welding-torches-and-wire-feeders/) - WELDING TECHNOLOGY - [Synchro Feed Evolution](https://www.daihen-usa.com/low-spatter-synchro-feed-evolution/) - [Plasma Jet TIG Welder](https://www.daihen-usa.com/plasma-jet-tig-welder/) - MORE THAN WELDING - [Material Handling Robots](https://www.daihen-usa.com/material-handling/) - [Plasma Cutting](https://www.daihen-usa.com/plasma-cutting/) - [Finishing Solutions](https://www.daihen-usa.com/finishing-solutions/) - [Assembly](https://www.daihen-usa.com/assembly/) - [RESOURCES](https://www.daihen-usa.com/resources/) - [Blog](https://blog.daihen-usa.com) - [ROI Calculator](https://www.daihen-usa.com/roi-calculator/) - [Subscribe to eNewsletter](https://info.daihen-usa.com/welding-automation-newsletter) - [Product Manuals](https://www.daihen-usa.com/product-manuals-otc-daihen/) - [Reference Charts](https://www.daihen-usa.com/reference-charts/) - [Warranty Info](https://www.daihen-usa.com/resources/warranty-info/) - [Welding Spatter 101](https://www.daihen-usa.com/weld-spatter/) - [Weld Sample Request](https://share.hsforms.com/1988748/29c25b01-8865-4d13-bee7-8571813f5ca5?__hstc=22325028.9076249f07035e1b31fa84fd446fe84d.1709088700121.1709585640965.1709640284848.14&__hssc=22325028.10.1709640284848&__hsfp=2434429739) - [CONTACT US](https://www.daihen-usa.com/contact/) - [Contact Your Rep](https://www.daihen-usa.com/meet-the-team/) - [Ask the Automation Expert](https://info.daihen-usa.com/welding-automation-e-hotline) # 3 Reasons to Break Free From Flux-Cored Wire in Welding Posted by [OTC DAIHEN](https://blog.daihen-usa.com/author/otc-daihen) on May 2, 2024 - [Tweet](https://twitter.com/share) ![featured-flux-cored-wire](https://blog.daihen-usa.com/hs-fs/hubfs/1-Blog/featured-flux-cored-wire.webp?width=1200&height=630&name=featured-flux-cored-wire.webp) As welding technology advances, it's becoming increasingly clear that flux-cored wire might not always be the best option. In this article, we'll explore three compelling reasons why it might be time to bid farewell to flux-cored wire and embrace solid wire for your welding processes. ## Three Reasons to Bid Farewell to Flux-Cored Wire in Welding ### 1. Flux-Cored Wire Is More Expensive When it comes to the bottom line, cost considerations are paramount. Solid wire typically has a lower price point than flux-cored wire. A quick comparison online reveals that solid wire ranges from $3.5 to $4.5 per pound, while flux-cored wire can cost anywhere from $7 to $10 per pound. This substantial cost differential can impact your budget, especially for high-volume welding operations. ### 2. Solid Wire Produces a Higher Quality Weld in Most Situations The quality of the weld is non-negotiable in any welding application. Take a look at the image showcasing![Image showcasing the differences between a weld with flux-cored wire (left side of the image) and a weld with 0.035” solid wire (right side of the image)](https://blog.daihen-usa.com/hs-fs/hubfs/weld%20copy.webp?width=317&height=341&name=weld%20copy.webp) the differences between a weld with flux-cored wire (left side of the image) and a weld with 0.035” solid wire (right side of the image).  Notice the distinct differences: the flux-cored weld (left) exhibits a lack of penetration, a small slag inclusion and a less desirable profile, whereas the solid wire weld (right) demonstrates deep penetration and a superior weld profile. Ideally, a weld will have a flat, uniform and consistent profile. One advantage of Flux-Cored Arc Welding (FCAW) is the slag produced when welding vertically or overhead. The slag covering supports the weld puddle for vertical and overhead welds. If welds are made in the flat or horizontal position, weld quality is typically much better with solid wire. ### 3. Flux-Cored Wire Creates Potential Working Hazards Beyond the weld itself, the working environment is another critical consideration. The flux coating on flux-cored wire produces substantial amounts of smoke and fumes during the welding process, leading to a potentially hazardous work environment. On the other hand, solid wire, especially when paired with a high Argon shielding gas, generates significantly less smoke and fumes, thereby promoting a safer and healthier workplace for welders. In the end, solid wire emerges as the clear winner in terms of cost-effectiveness, weld quality and fume control in welding.  ## The Power Source Can Support a Switch in Welding Wire Oftentimes, expensive flux-cored wire is used because it has a wider range of operating parameters and is more forgiving for operators. However, a switch in welding equipment can [cut costs in many ways](https://blog.daihen-usa.com/how-investing-in-an-advanced-welding-power-source-can-cut-costs), including the kind and amount of wire and gas used.![Welbee II](https://blog.daihen-usa.com/hs-fs/hubfs/welbee-1.webp?width=174&height=236&name=welbee-1.webp) For example, the[OTC DAIHEN Welbee II welding power source](https://www.daihen-usa.com/welbee-power-sources/) has technology that allows standard wires to weld with the same appeal as the more expensive wires and gas combinations. There is no need to purchase the more expensive welding wires or gases for these machines. Also, the Welbee II creates minimal spatter, which equals minimal wasted wire and less post-weld cleanup, including labor and grinding materials. Want more information on Welbee power sources? Learn more in the [Welbee II Welding Power Source Buyer's Guide and Comparison Chart](https://blog.daihen-usa.com/the-welbee-ii-welding-power-source-buyers-guide-comparison-chart). *OTC DAIHEN is your one-stop welding system supplier. We produce everything you need — welder, robot, torch, wire feeder and all the know-how to put it together and apply it to your toughest welding challenges.* *[![New call-to-action](https://no-cache.hubspot.com/cta/default/1988748/94b8b247-0841-4296-97e1-51c2b8c91a74.png)](https://cta-redirect.hubspot.com/cta/redirect/1988748/94b8b247-0841-4296-97e1-51c2b8c91a74)* Topics: [Robotic Welding](https://blog.daihen-usa.com/topic/robotic-welding), [Manual Welding](https://blog.daihen-usa.com/topic/manual-welding) ### **Subscribe!** Get **Keeping It Clean**, a monthly enewsletter with all the latest in welding and robotic automation. # 3 Reasons to Break Free From Flux-Cored Wire in Welding Posted by [OTC DAIHEN](https://blog.daihen-usa.com/author/otc-daihen) on May 2, 2024 - [Tweet](https://twitter.com/share) ![featured-flux-cored-wire](https://blog.daihen-usa.com/hs-fs/hubfs/1-Blog/featured-flux-cored-wire.webp?width=1200&height=630&name=featured-flux-cored-wire.webp) As welding technology advances, it's becoming increasingly clear that flux-cored wire might not always be the best option. In this article, we'll explore three compelling reasons why it might be time to bid farewell to flux-cored wire and embrace solid wire for your welding processes. ## Three Reasons to Bid Farewell to Flux-Cored Wire in Welding ### 1. Flux-Cored Wire Is More Expensive When it comes to the bottom line, cost considerations are paramount. Solid wire typically has a lower price point than flux-cored wire. A quick comparison online reveals that solid wire ranges from $3.5 to $4.5 per pound, while flux-cored wire can cost anywhere from $7 to $10 per pound. This substantial cost differential can impact your budget, especially for high-volume welding operations. ### 2. Solid Wire Produces a Higher Quality Weld in Most Situations The quality of the weld is non-negotiable in any welding application. Take a look at the image showcasing![Image showcasing the differences between a weld with flux-cored wire (left side of the image) and a weld with 0.035” solid wire (right side of the image)](https://blog.daihen-usa.com/hs-fs/hubfs/weld%20copy.webp?width=317&height=341&name=weld%20copy.webp) the differences between a weld with flux-cored wire (left side of the image) and a weld with 0.035” solid wire (right side of the image).  Notice the distinct differences: the flux-cored weld (left) exhibits a lack of penetration, a small slag inclusion and a less desirable profile, whereas the solid wire weld (right) demonstrates deep penetration and a superior weld profile. Ideally, a weld will have a flat, uniform and consistent profile. One advantage of Flux-Cored Arc Welding (FCAW) is the slag produced when welding vertically or overhead. The slag covering supports the weld puddle for vertical and overhead welds. If welds are made in the flat or horizontal position, weld quality is typically much better with solid wire. ### 3. Flux-Cored Wire Creates Potential Working Hazards Beyond the weld itself, the working environment is another critical consideration. The flux coating on flux-cored wire produces substantial amounts of smoke and fumes during the welding process, leading to a potentially hazardous work environment. On the other hand, solid wire, especially when paired with a high Argon shielding gas, generates significantly less smoke and fumes, thereby promoting a safer and healthier workplace for welders. In the end, solid wire emerges as the clear winner in terms of cost-effectiveness, weld quality and fume control in welding.  ## The Power Source Can Support a Switch in Welding Wire Oftentimes, expensive flux-cored wire is used because it has a wider range of operating parameters and is more forgiving for operators. However, a switch in welding equipment can [cut costs in many ways](https://blog.daihen-usa.com/how-investing-in-an-advanced-welding-power-source-can-cut-costs), including the kind and amount of wire and gas used.![Welbee II](https://blog.daihen-usa.com/hs-fs/hubfs/welbee-1.webp?width=174&height=236&name=welbee-1.webp) For example, the[OTC DAIHEN Welbee II welding power source](https://www.daihen-usa.com/welbee-power-sources/) has technology that allows standard wires to weld with the same appeal as the more expensive wires and gas combinations. There is no need to purchase the more expensive welding wires or gases for these machines. Also, the Welbee II creates minimal spatter, which equals minimal wasted wire and less post-weld cleanup, including labor and grinding materials. Want more information on Welbee power sources? Learn more in the [Welbee II Welding Power Source Buyer's Guide and Comparison Chart](https://blog.daihen-usa.com/the-welbee-ii-welding-power-source-buyers-guide-comparison-chart). *OTC DAIHEN is your one-stop welding system supplier. We produce everything you need — welder, robot, torch, wire feeder and all the know-how to put it together and apply it to your toughest welding challenges.* *[![New call-to-action](https://no-cache.hubspot.com/cta/default/1988748/94b8b247-0841-4296-97e1-51c2b8c91a74.png)](https://cta-redirect.hubspot.com/cta/redirect/1988748/94b8b247-0841-4296-97e1-51c2b8c91a74)* Topics: [Robotic Welding](https://blog.daihen-usa.com/topic/robotic-welding), [Manual Welding](https://blog.daihen-usa.com/topic/manual-welding) ### Browse by Categories - [Buyers Guides (5)](https://blog.daihen-usa.com/topic/buyers-guides) - [Customer Success (12)](https://blog.daihen-usa.com/topic/customer-success) - [Manual Welding (44)](https://blog.daihen-usa.com/topic/manual-welding) - [Manufacturing Systems (10)](https://blog.daihen-usa.com/topic/manufacturing-systems) - [OTC DAIHEN News (7)](https://blog.daihen-usa.com/topic/otc-daihen-news) --- ## Keeping It Clean Newsletter Join thousands of others who receive this monthly enewsletter with all the latest in welding and robotic automation. [![Get My Free Newsletter](https://no-cache.hubspot.com/cta/default/1988748/fbed1512-d020-443e-a435-c7792b156f66.png)](https://cta-redirect.hubspot.com/cta/redirect/1988748/fbed1512-d020-443e-a435-c7792b156f66) ![](https://blog.daihen-usa.com/hs-fs/hubfs/daihen_footer_logo.png?width=158&height=76&name=daihen_footer_logo.png) 1400 Blauser Dr Tipp City, OH 45371 Phone: [(937) 667-0800](tel:9376670800) Fax: (937) 667-0885 [Robotic Welding Cells](https://www.daihen-usa.com/robotic-welding-cells/) [ECO-ARCs](https://www.daihen-usa.com/eco-arc-series/) [PT-ARCs & SERVO-ARCs](https://www.daihen-usa.com/pt-servo-arc/) [DT-ARCs](https://www.daihen-usa.com/dt-arc-series/) [ROTA-ARCs](https://www.daihen-usa.com/rota-arc-series/) [TRI-ARCs](https://www.daihen-usa.com/tri-arc/) [ED-ARCs](https://www.daihen-usa.com/ed-arc-series/) [Arc Welding Robots](https://www.daihen-usa.com/arc-welding-robots/) [6-Axis Robots](https://www.daihen-usa.com/6-axis-robots/) [7-Axis Robots](https://www.daihen-usa.com/7-axis-robots/) [Robot Controllers](https://www.daihen-usa.com/robot-controllers/) [Robot Positioners](https://www.daihen-usa.com/robot-positioner/) [Robot Sensors](https://www.daihen-usa.com/robotic-sensors/) [Welding Power Sources](https://www.daihen-usa.com/welding-power-sources/) [Welbee Power Sources](https://www.daihen-usa.com/welbee-power-sources/) [Welding Torches & Wire Feeders](https://www.daihen-usa.com/welding-torches-and-wire-feeders/) [Frequently Asked Questions](https://www.daihen-usa.com/faqs/) [Support](https://www.daihen-usa.com/support/) [Training](https://www.daihen-usa.com/training/) [Resource Center](https://www.daihen-usa.com/resources/) [About OTC DAIHEN](https://www.daihen-usa.com/about-otc-daihen/) [Contact Us](https://www.daihen-usa.com/contact/) [Careers](https://www.daihen-usa.com/careers/) [Become a Distributor](https://www.daihen-usa.com/become-a-distributor/) Copyright © 2024 OTC DAIHEN. | [Privacy Policy](https://www.daihen-usa.com/privacy-policy/) | Web Design by [Marketing Essentials](https://mktgessentials.com/) ```json { "@context" : "http://schema.org", "@type" : "Organization", "logo" : "https://www.daihen-usa.com/wp-content/uploads/2022/05/logo.png", "name" : "OTC DAIHEN", "url" : "https://www.daihen-usa.com" } ``` ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "OTC DAIHEN", "url" : "https://blog.daihen-usa.com/author/otc-daihen" }, "dateModified" : "2024-05-02T13:01:40.957Z", "datePublished" : "2024-05-02T13:01:40.000Z", "headline" : "3 Reasons to Break Free From Flux-Cored Wire in Welding", "image" : [ "https://blog.daihen-usa.com/hubfs/1-Blog/featured-flux-cored-wire.webp" ], "mainEntityOfPage" : { "@id" : "https://blog.daihen-usa.com/3-reasons-to-break-free-from-flux-cored-wire-in-welding", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://blog.daihen-usa.com/hubfs/daihen-logo-hs-01.png" }, "name" : "OTC DAIHEN Inc." } } ```