5 Best Flux Core Wire For Beginner & Experienced Welders

Are you an experienced or novice welder looking for flux cored wire which is easy to use, cheaper, gives high quality and clean weld but couldn’t find the right one? Opened tens of tabs on your favorite browser and spent many hours in research & reading reviews but couldn’t make a decision?
Then you are at the right place. We have done a lot of research and created our top 5 best flux cored wire of 2020 review and buyer guide. For each flux cored wire we have mentioned the features in brief, pros & cons, and most frequently asked questions.

Top 5 Flux Core Wire To Consider In 2020

5. Blue Demon E71T

This made in USA Blue Demon E71TT is one of the best flux cored wire for welding all carbon steels. It used to weld 16 gauge through 0.5” steel with different welding methods such as lap, butt and fillet.

Feature Weight: 10 Pounds Spool Dimension: 9 x 9 x 3 inches Size: 0.035 inch Packaged Quantity: 1 View on Amazon

• This is a self shielding flux cored wire that doesn’t need shielding gas.
• Can be used in multi pass operations.
• It is used for butt and lap methods of welding on galvanized sheets.
• Also can used to repair automobile, roofing sheet metals.
• Some other welding applications of Blue Demon E71T are: Ornamental iron, general fabrication, farm implements and prefabricated building.

Pros:

• After a wire brush it has a perfect bead.
• It runs smoothly
• Minimal slag and removes easily
• Minimal splatter
• Pass bend test
• Value for money

Cons:

• It can not used on aluminium to weld
• Can be smokey

It can weld in all positions such as flat, horizontal, vertical and overhead. Also can easily weld carbon & galvanized steel and other varieties of metals except aluminium. It does a great job with an affordable cost as compared to the expensive brands. According to buyers from different marketplaces this is the best flux core wire for sheet metal.

Q&A

Q-In which country Blue Demon E71T Flux cored wire is manufactured?
This is made in the USA and you can find this on the label of each product.
Q-What is the weight of the roll?
It depends on the spool you want to purchase. The available spools are 1#,2#,10# or 33#.
Q- What is the dimension of the spindle hole?
It has a 2” spindle hole which fits into most of the welder cases.
Q- Can it be used for multi pass welding?
Yes, it has a limited multipass.
Q- Can it be used on mig welder?
Yes, it is designed for it. You can put it in and start welding without any gas.

 4. Hobart H222106-R19 Carbon Steel Welding Wire

The Hobart E71T-11 flux cored welding wire is a choice of professionals. This carbon steel welding wire is compatible to weld galvanized or thin gauge mild steels. Proudly it is manufactured in the USA.

Feature Weight: 2 Pounds Spool Dimension: 3.8 x 3.7 x 1.8 inches Size: 0.030 inch and 0.035 inch Packaged Quantity: 1 View on Amazon

• It can be used for both single and multi pass welds.
• It operates only on straight polarity i.e. Direct Current Electrode Negativity (DCEN).
• It operates without gas because it is a self shield welding wire.
• It is designed for mig welders, so you can easily put it in and start welding.
• To weld light structural, prefabricated constructions, machinery part fabrication we can use this flux core wire.
• Other applications of this welding wire are: general fabrication, short assemblies, tanks and railroad car repairs.

Pros:

• Less Splatter
• Better penetration and flow
• Super hard after it has cooled
• Clean welds
• Value for money

Cons:

• Smokes a lot which makes it hard to see during extended welds.
• Small spool of weight only 2lb.

The Hobart model flux core wire comes with a very affordable price with a great quality. This gasless welding wire is good to use for carbon steel as well as it has other applications on different fabrication work, short assemblies, light structural etc. It comes with a small spool roll so it is recommended to use for short welding projects where you need less flux core wire.It comes with both the 0.030 inch and 0.035 inch in sizes with the spool dimension 3.8×3.7×1.8 inches and 4x4x2 inches respectively. 

Q&A

Q- Is it a Direct Current Electrode Positive (DCEP) or Direct Current Electrode Negative (DCEN) welding wire?
This self shield flux core wire is DCEN.
Q- What is the carbon content in this wire?
It has the carbon in the form of Calcium Carbonate and Lithium Carbonate format. You can find details by reading the Hobart safety data sheet. Use this link to read it.
Q- What is the dimension of the center hole?
The 10 pound spool has a 2 inch center hole where the 2 pound spool has a smaller center hole.

3. Blue Demon 308LFC-O Stainless Steel Gasless Welding Wire

Another Blue Demon flux core welding wire has taken a place in our best flux cored wire list. Like other Blue Demon products this one is also made in the USA.

Feature Weight: 0.16 Ounces Dimension: 4 x 4 x 2 inches Size: 0.035 inch Packaged Quantity: 1 View on Amazon

• This flux cored wire is a self shield gasless welding wire.
• Suitable for stainless steel welding.
• Comes in various sizes including 0.035 inches in diameter.
• It operates in Direct Current Electrode Positive (DCEP) straight polarity only.
• All 300 series stainless steel including 308L can be weld by using this flux core welding wire.
• 430 stainless steel can also be weld by using it.
• It can be used for both single and multi pass welding operations.
• With a proper MIG setting it can even weld cast iron.

Pros:

• Little Slag
• Clean Weld
• Minimal Spatter
• Smooth and consistent weld
• Great penetration
• Easy to use

Cons:

• The spool is not good

This blue demon flux core wire is one of the best welding wires because it can weld stainless steel without gas. It uses AWS A5.22 welding Current Direct Current Electrode Positive. Some users have tried to weld cast iron and it works perfectly. Due to the stainless steel flux core the weld does not rust or corrode. It comes with three different spools i.e. 1#, 10# and 25#, hence the weight and dimension of the product differs based on the spool type.

Q&A

Q- What is the proper MIG setting to use this welding wire effectively?
Many customers have issues to set the mig properly for first 2 to 3 uses and start complaining about the welding wire is good. If the mig is set to fast with maximum power and DCEP, then it works perfect with this welding wire. 
Q- Can I use shielding gas to weld with this welding wire?
Yes you can use shielding gas if you need a wider bead and more stable arc. If you are doing a sound welding work then shielding gas is not required.
Q- Should I use 120 volt or 240 volt welders?
This wire runs well on 75 to 100 amps on reverse polarity. Both 120V and 240V mig machines can produce the required amperage.
Q- Can I polish this weld and is it rust free?
Yes this stainless steel flux core welding is rust free. It gives a clean weld but to get a perfect finish it needs grinding, sanding and polishing.

2. Forney 42300 Flux Core Mig Wire

This made in USA Forney 42300 E71T-GS flux core wire is a self shield welding wire which doesn’t need gas. It works well on dirty, rusty and painted materials.

Feature Weight: 2 Pounds Dimension: 1 x 4 x 4 inches Size: 0.030 inch Packaged Quantity: 1 View on Amazon

• 
  This MIG wire is ideal to weld mild steel.
• It can weld in all positions.
• Its high travel speed makes it the best welding wire for single pass welding applications.
• It operates in DCEN straight polarity.
• This wire has a tensile strength of 79,000 psi.
• It produces less spatter. Further, if you need to reduce spatter then it is recommended to use Argon/CO2 mix.
• It can be used for outdoor welding as it doesn’t require shielding gas.
• It can easily weld 18 gauge or more thicker steel, so you do not need to use other welding wires for thick steel applications.
• Few of the popular applications of this mig welding wire are: mechanical repairs, assembly welding, automotives, tanks, railroad repairs and other light work needed to do around the house.
• It can even consider as the best.

Pros:

• Welds thicker mild steel.
• Very affordable price.
• Arcs well
• It has a good penetration with less splatter
• Little slag to clean
• Easy to use
• Gives a finished well look weld
• Smooth & consistent weld
• It comes with a 90 days warranty against manufacturing defects

Cons:

• Plastic spool which broke easily

If you are using Forney 42300 welding wire then you don’t need to clean up the metal because it can weld rusty, dirty and painted materials. I would say this is the best feature of this welding wire. It can be used for both single and multi pass weldings & welds in F,H,V,OH all directions. Welding with gas includes risks of porosity because the blowing wind takes the gas away, as this welding wire doesn’t require gas so it is recommended to use in outdoor windy conditions. You don’t need other wires to weld thicker mild steels because this is the best flux-cored wire for mild steel.

Q&A part

Q- Can it be used in a 125 ampere welder?
Yes, this mig flux cored wire can easily be used with a 125 amp welder.
Q- Can it be used with different manufactured welders such as Hobart,Miller or Harbor?
Any welder comes with a 75 amp DCEN straight polarity this welding wire will work. It is considered the best flux cored wire for harbor freight welder.
Q- Can I use it for soldering of electronic items?
No you can’t because it is made for MIG welders only.
Q- What is the tensile strength of this welding wire?
As compared to other flux core wires it has the highest tensile strength of 79,000 psi.

1. INETUB BA71TGS Carbon Steel Gasless Flux Cored Welding Wire

In this curated list we have placed INETUB BA71TGS at the #1 for various reasons which you will see soon. This is the best brand among other flux cored wire companies out there in the market.

Feature Weight: 2.2 Pounds Dimension: 3.9 x 1.9 x 3.9 inches Size: 0.030 inch and 0.035 inch Packaged Quantity: 1 View on Amazon

• It defines AWS E71T-GS alloy.
• It is a self shield gasless flux cored wire ideal to weld in outdoor windy conditions.
• This easy to use welding wire has high feedability and provides smooth arc action.
• It can weld in all basic welding positions.
• It supports both single and multi pass welding.
• This wire is best to weld carbon manganese and thin carbon steels.
• Another great feature of this welding wire is, it can weld zinc and galvanized coated plates without cleaning up the metals.
• This wire needs to be used on DCEN straight polarity.
• There are many applications including tanks, boilers, automobile body parts, construction works and large thickness steel structures.

Pros:

• Higher deposit rate
• Minimal spatter
• Fast freezing salg and it can be easily removed
• The bead appearance is good
• In windy conditions it gives porosity free weld
• Smooth to use
• Deep penetration
• Best value for money

Cons:

• Its bit smoky
• Weak spool

The INETUB BA71TGS is one of the best MIG gasless flux cored wire to weld various metals in all welding positions at extreme outdoor conditions. It can weld thick metals and zinc coated metals without requiring any clean up prior to the welding task. 90% buyers have given it a 5 star review in different marketplaces. It has more tensile strength of 82,700 psi more than Forney 42300. This is manufactured in Italy by using the state of the art technology with the finest quality material by keeping the american standard.

Q&A

Q- Can it weld stainless steel?
No, it can weld only carbon steel.
Q- How much stick out tip and inclination of the torch is recommended?
In between 0.59 to 0.98 inches of stick out and 30 degrees of the inclination of the torch with the welding plane is recommended.
Q- What is the maximum and minimum thickness of the metal it can weld?
Maximum 0.157” and minimum 0.039” in single pass welding.
Q- Where is it manufactured and does it come with a warranty?
It is manufactured in Italy with finest quality material by keeping the american standard. It doesn’t have any warranty but the quality of the product is so high that you don’t even need a warranty.
Q- What is the carbon percentage containing this welding wire?
The carbon percentage is 0.18% in weight percent.

Things to consider while buying a flux core wire

There are few aspects that need to be considered before buying a flux core wire. In the marketplace there are many brands and quality of welding wires and it is difficult to choose the right one. To help you on this we have already listed top 5 flux core wires but to help you further in making the right decision we have prepared the below buying guidelines.

Type of flux core wire

The first question you should ask to yourself is the type of flux core you want to buy. Most of the wires are self shielding gasless, like the top 5 flux core wires we have mentioned above. Some flux core wires require gas to give you porosity free and less spatter weld while welding outside in windy environments.

Material

Here need to consider two things: the material you want to weld and the material in which the flux core wire is made of. Most of the flux core wire is made of mild steel and carbon steel which works on DCEP and DCEN straight polarity. Some wires only weld stainless steel not other materials such as aluminium or carbon steel. So you need to check the specification of the welding wire or to speak with the manufacturer.

Wire Size (0.30 vs 0.35 flux core wire)

The size of the wire depends on the diameter of the welder, nozzle tip and feed wheel. However, these can be adjusted but the welder amperage and the plate you are welding mostly define the size of the wire. The thinner the welding plate is the smaller the wire diameter required, similarly the lower the welder amperage the smaller the wire size.
It’s really important to consider the welder you have and the material thickness on which you are planning to weld.

Spool Size & Strength

It’s really important to consider the spool your welder can accommodate and the spindle hole size. Another factor is the amount welding you need to do. These two factors define the reel you will buy. Generally the bigger spools cost less, but if you need the wire for a small welding project then its unnecessary to buy a bigger reel.

Application

The material you will be welding and the environment in which you will weld determines the welding wire you need to spend money on. Keep in mind that you are buying stainless steel wire for welding stainless steel plates, and steel wire to weld steel plates. Some flux wire can weld only clean materials and some can weld zinc coated, dirt, rusty and painted materials. You need to take extra care especially when you are welding stainless steel.
Apart from the above points we also need to consider cost, warranty, durability, polarity, single or multi pass,welding direction, stability while buying a flux cored welding wire.

Benefits of the Best Flux Core Wire

As we know the best output we get from the best product. Especially in welding where you need to weld different plates to create a structure which we will use everyday so it’s important to use the best flux core wire to create a durable weld. Below are the benefits we will get from best flux core welding wires

• Clean and durable welding
• Deep penetration and smooth to use
• Easy to remove slag
• Minimal spatter emission
• Single and multi pass use
• Easy and porosity free weld in outdoor windy environment
• Fast and well look finished weld 

How to use Best Flux Core Wire

The best thing about these wires is they are self shielding and don’t need shielding gas to weld. They can weld carbon steel and stainless steel by using a mig welder. It’s very simple to use, put the wire in a mig welder, set up the wire speed and volt of the welder and you are all set to start your welding. In case if you don’t know the proper settings required for your welding wire then we would suggest to test with a quick weld with the standard settings and adjust the welder knobs until you get the desired result. Please check quick demo video on using of flux core wire

Conclusion

In this article we have presented the top 5 flux core wire and buying guidelines to help you in your buying decision. According to us the INETUB is the best gasless flux cored welding wire you should go for. It has the highest positive rating in different marketplaces and is affordable.If you need a versatile flux core wire at a cheaper rate then you should go for Blue Demon products.
Hope our article has helped you a bit in your buying process of flux core wire. If you liked our article then do share with your colleagues and comment below which flux core wire you are going to purchase.
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