81933B - Hobart Megafil 819R 1/16-inch Seamless Flux-Cored Wire 35lb

Technical Overview of Hobart Megafil 819R

The Hobart Megafil 819R is a premium, seamless, rutile flux-cored wire designed for the welding of high-strength, low-alloy steels. Engineered with Hobart's proprietary seamless manufacturing technology, this wire features a hermetically sealed copper-coated sheath that completely protects the internal flux core from the atmosphere. This design results in extremely low diffusible hydrogen levels (typically less than 3ml/100g), making it an exceptional choice for critical applications where resistance to hydrogen-induced cracking is paramount. The 1/16-inch diameter and 35lb spool configuration are optimized for heavy industrial fabrication environments utilizing automated or semi-automatic welding systems.

Metallurgically, the Megafil 819R is classified under AWS A5.29 as E81T1-Ni1M-J H4. It is formulated with approximately 1% Nickel, providing superior impact toughness at low temperatures, specifically maintaining Charpy V-Notch properties down to -60°C (-76°F). This makes the wire particularly suitable for offshore structures, pipelines, and heavy equipment operating in arctic or sub-zero environments. The wire requires a shielding gas mixture of Argon and CO2 (M21), which supports a stable spray-like transfer, deep penetration, and excellent sidewall fusion.

The copper coating on the Megafil 819R not only prevents rusting during storage but also enhances electrical conductivity at the contact tip. This results in consistent arc ignition and stability, reducing micro-arcing within the torch liner and extending the life of consumables. The seamless nature of the wire also provides rigidity and column strength similar to solid wires, ensuring precise feedability over long distances, which is critical for robotic applications. By eliminating the seam found in traditional folded wires, Hobart ensures that the flux remains unexposed to ambient humidity, removing the need for specialized conditioning or heated storage in many environments.