- Carbon steel flux core wire welding is one of the most common flux core welding types used in industrial applications. The flux core wire is constructed of low alloy steel wire with a core which consists of several elements that differ slightly between flux wire manufacturers, although the final welding gas shield is carbon dioxide. Carbon steel flux core wire produces slag which can be minimized over the course of time with practice.
- Low alloy flux core wire is used primarily for welding general purpose steel with low carbon content, such as one might find in reinforcing bars or in some automotive parts. Low alloy flux core wire is formulated to be used either as carbon dioxide shielded or carbon dioxide and argon shielded welding material. Maximum carbon content for welding steel with low alloy flux core wire is .30 percent.
- Stainless steel flux core wire is utilized regularly in automotive applications such as in exhaust system repair due to the material's ability to successfully combine high carbon content steel with stainless steel as well as its resistance to corrosion. Some industrial types of stainless steel flux core wire require an initial weld with a special pre-treatment before welding the part to produce an efficient, high-quality weld.
- Cast iron flux core welding involves the joining of ductile cast iron to itself or to mild steels. It is particularly useful in the repair of cast iron industrial components. Because the metal is deposited more quickly than with carbon or stainless steel, the temperatures reached during welding are much lower, which prevents warping or expansion of the cast iron while the weld is being produced.