FabCOR 86R Metal-Cored Wire: The Complete Guide to Settings, Deposition Rate & Applications

What Is FabCOR 86R? A Metal-Cored Wire Built for Production

Every fabrication shop has one: a spool that sits in the consumables cage because nobody on the floor is sure what it does. If that spool says FabCOR 86R, you are looking at one of the most productive wires a heavy-fabrication shop can load into a MIG gun. FabCOR is a registered trademark of Hobart Brothers Company of Troy, Ohio, and 86R is the flagship of their gas-shielded metal-cored line.

Here is the precise definition. FabCOR 86R is a gas-shielded, metal-powder metal-cored wire, which places it under the metal-cored arc welding process known as MCAW, or GMAW-C. It is not a solid wire and it is not a flux-cored wire. Its major classification is AWS A5.18: E70C-6M H4, and it also carries the European classification EN ISO 17632-A: T 46 3 M M21 2 H5 / M20 2 H5.

Reading the E70C-6M H4 Label

That string of characters tells you almost everything about the wire’s capability:

• E — electrode.
• 70 — minimum tensile strength of 70,000 psi.
• C — composite (metal-cored) electrode, the giveaway that this is not solid wire.
• 6 — the specific chemistry and usability designator.
• M — designed to run on a mixed shielding gas (M21 or M20).
• H4 — diffusible hydrogen limited to 4 mL per 100 g of weld metal.

For a full breakdown of how wire composition drives behaviour, see our guide to what MIG welding wire is made of.

Where Does FabCOR 86R Fit?

A metal-cored wire is a tubular sheath packed with metallic powder instead of flux. That design is the whole point: the filled core carries alloys, arc stabilizers and deoxidizers, while the steel sheath carries the current. The result is a spray-transfer arc that behaves more like solid wire for penetration and bead appearance, yet deposits far more metal per unit of time. Because there is no flux, there is also no slag to chip and virtually none of the silica-island cleanup that plagues solid-wire work. If you are more familiar with the opposite end of the wire spectrum, our explainer on whether flux core is the same as MIG clears up the confusion.

Where FabCOR 86R Is Used

FabCOR 86R is built for non-alloyed and fine-grain steels, and it handles both single-pass and multi-pass welds. Weld position is listed as flat and horizontal for spray transfer, which is exactly where production welding lives. It has even been tested to the AWS D1.8 seismic provisions for demand-critical welds, a credential that matters on structural work.

Typical applications include:

• Storage vessels and pressure-related fabrication
• Steel structures and general heavy fabrication
• Earthmoving and heavy equipment
• Rail cars and shipbuilding
• Automatic, mechanized and robotic welding cells

Mechanised and robotic users get the biggest lift, since the wire’s smooth arc and consistent feed suit automated motion. Our page on robotic submerged arc welding shows how high-deposition automation is reshaping heavy-duty work, and the same logic applies here. The wire’s steady arc also eases the load on your contact tip, though tip wear still drives most feed problems.

So who should consider FabCOR 86R? High-volume shops welding thick steel in the flat and horizontal position, especially those running automated or robotic cells. It is not the answer for vertical-up out-of-position work or windy outdoor sites, where solid wire and flux-cored wire still own the day. If you are still sharpening the fundamentals, our welding practice guide is a solid companion. In the sections ahead we cover the MCAW process, shielding gas and settings, deposition rates, technique, troubleshooting, and the 2025 recall, so you can decide whether this wire earns a permanent place on your machine.

How Metal-Cored Wire Works: The MCAW Process Explained

Solid MIG wire is a homogeneous rod of steel. Metal-cored wire is not. Picture a steel tube — seamless or formed and seamed — wrapped around a powder fill of iron, alloying elements, and deoxidizers. That one detail explains nearly everything about how FabCOR 86R behaves at the arc, before you touch a single setting.

Inside the Wire: Sheath Plus Metal Powder

Cut a length of metal-cored wire and you find a hollow shell packed with granular metal. The sheath carries most of the current and forms the bulk of the deposit. The powder core tunes chemistry, scavenges oxygen, and stabilizes the arc. Crucially, there is no mineral flux in that core — no limestone, no rutile, no fluorides. That is the fork in the road between this and gasless MIG welding, which relies on a tubular wire full of the slag-forming minerals metal-cored avoids.

The result is a filler metal that feeds like solid wire and deposits like a cored product. The declared chemistry for FabCOR 86R shows what the powder is doing: carbon around 0.03, manganese 1.44, silicon 0.67, sulfur 0.015, and phosphorus 0.008. Those deoxidizers and alloys were metered into a powder, not melted into a billet.

Why No Slag Changes Everything at the Arc

Flux-cored wire uses flux to protect the puddle. Metal-cored wire uses shielding gas from the outside. Because the core produces no slag, there is nothing to chip, wire-brush, or grind between passes. You can stack beads almost as fast as you can travel, a genuine difference on multi-pass work. The trade-off is that the shielding comes from the torch, not the wire, so coverage must stay intact.

This doubles as a quick diagnostic. A genuine FabCOR 86R deposit leaves essentially no slag. If a spool starts laying down glassy islands, something is wrong — a fact that mattered in a 2025 recall, where a bad batch was flagged precisely because it produced slag it should not have.

Current Density: The Engine Behind the Deposition Rate

Here is what matters most for productivity. Deposition rate is driven by current density — amps per unit of cross-sectional area. A solid wire carries current through its full diameter, so the whole conductor limits the amps you can push before resistance heating and burn-back bite. A cored wire splits the job: the thin sheath conducts, while the powder core carries almost no current. Force the same amperage through a smaller metal area and the melt-off rate climbs — which is why a cored wire can out-deposit a solid wire of similar diameter, as Hobart notes in its write-up on metal-cored wire in robotic welding.

Spray Transfer and a Shallow, Wide Penetration Profile

Because the current density is high and the arc is stable, metal-cored wire runs in spray-transfer mode at typical settings. Droplets detach smoothly and axially instead of globbing. The practical signature is a broad, slightly shallow penetration profile and a nicely wetting, low-crown bead. Deep penetrating fingers are rare; instead you get consistent fusion across the joint — ideal when you are filling wide bevels on heavy steel.

If you have followed how polarity shapes an arc in TIG polarity selection, you already understand why a stable spray arc matters. Smooth transfer means less spatter and more heat going into melting wire rather than throwing metal.

Low Hydrogen by Design

FabCOR 86R is classified H4, meaning diffusible hydrogen is limited to 4 ml per 100 g of weld metal; typical measured values run 1.8 to 2.8 ml/100 g. There is no flux to absorb moisture and release it into the puddle, so the deposit stays dry. That matters on restrained joints, thick sections, and higher-strength steels where hydrogen cracking hides until it lets go. The wire still needs dry storage, but the chemistry starts you clean.

So before the dials and gas: a cored wire is a thin conductive sheath around an inert powder, running a spray arc with no slag and low hydrogen. Every setting in the next section exists to feed that behavior.

Shielding Gas, Polarity, and Machine Settings for FabCOR 86R

FabCOR 86R is forgiving, but it still lives inside a defined operating envelope. Nail the gas, polarity, and voltage and it runs smooth, nearly spatter-free, and fast. Miss them and you will blame the wire when the machine is the real problem. Here is the window you need to stay in.

Shielding Gas: Argon-Rich Mixes Only

Metal-cored wire is not self-shielded, so you always run a gas. FabCOR 86R is built for two families of argon-rich mixes:

• 75-95% Argon / balance CO2 — the workhorse range for carbon steel.
• 95% Argon / 5% Oxygen — a slightly more fluid puddle and a flatter bead.

Flow rate runs 35-50 cfh (17-24 l/min). Too little and you lose the shielding umbrella over the puddle; too much and turbulence pulls air into the arc.

More argon buys you a more stable arc, a quieter puddle, and less spatter. More CO2 runs hotter and wetter, drives penetration deeper, and needs more voltage. That is why a 90% Ar/10% CO2 mix typically takes 1-3 volts less than 75% Ar/25% CO2 at the same wire feed speed. When in doubt, start at 75% Ar/25% CO2 for flat and horizontal thick work and step toward higher argon for thinner metal and out-of-position passes. Set your trim once, then leave it alone.

Polarity: DCEP, Every Time

FabCOR 86R runs on Direct Current Electrode Positive (DCEP) — torch positive, work lead negative. That is the same polarity family as conventional solid-wire MIG and most gas-shielded flux-cored wires. Reverse the leads and the arc misbehaves badly. If the naming confuses you, our guide to TIG welding polarity explains DCEN, DCEP, and AC, while polarity for flux core welding shows why self-shielded wires prefer DCEN instead.

CV vs Pulsed MIG: The Wire Handles Both

FabCOR 86R is designed to run on constant voltage (CV) and pulsed power sources. CV is the set-and-go standby: voltage controls arc length, wire feed speed (WFS) controls amperage, and you tune the two against each other. Pulsed MIG alternates between a high peak current and a low background current many times a second, cutting average heat input and delivering spray-like droplets with far less spatter.

Out-of-position work rules out straight spray transfer. Narrow the voltage window, lower the arc, and run either short-circuit or pulsed spray transfer. Pulsed is the smoother option overhead and on vertical-up joints.

A Representative Starting Point for 0.045 in Wire

The numbers below are typical starting points drawn from the FabCOR 86R data sheet.

These are flat and horizontal numbers. For a 90% Ar/10% CO2 mix, subtract 1-3 volts. To scale up, larger diameters (1/16 in and 3/32 in) run far more amperage and deposit more metal at the same WFS, so dial the voltage up with them and let the machine’s duty cycle guide how hard you push.

Set Your CTWD Before You Blame the Voltage

Contact tip to work distance (CTWD) has a bigger effect on this wire than most people expect. Target roughly 1/2 in to 3/4 in (13-19 mm) for 0.045 in wire. Stretch it longer and you lose voltage at the arc, flatten the bead, and risk lack of fusion. Push it too short and you fry tips and spatter the nozzle. Keep the tip clean and replace it when the bore wears oval — our contact tip welding guide covers wear and troubleshooting in detail.

Deposition Rate and Efficiency: The Productivity Case for FabCOR 86R

Why do fabricators reach for FabCOR 86R instead of a cheaper solid wire? The answer comes down to one question: how much weld metal can you lay down per hour, and how much of it actually stays as weld? Hobart rates this wire for deposition in excess of 20 lb/hr (about 9 kg/hr) with efficiencies of 95% and greater. Those two numbers are the entire productivity story.

Higher deposition translates directly into higher travel speeds and a lower overall cost per weld. To understand why, separate three terms that people often blur together.

Melt-Off Rate vs. Deposition Rate vs. Operating Factor

Melt-off rate is how fast the wire is consumed at the arc. Deposition rate is how much of that melted wire actually lands in the joint as usable weld metal instead of flying off as spatter or fume. Operating factor is the share of paid time the arc is actually lit. High deposition is great, but when you spend half the day chipping slag and grinding spatter, operating factor collapses and real output follows.

Metal-cored wire attacks all three at once. Current travels through a thin outer sheath rather than the full cross-section, so current density at the arc is higher. That lets the wire melt faster at the same amperage, depositing more metal per amp than solid wire ever will.

Typical Deposition Across Diameters and Amperages

Exact numbers depend on your gas, CTWD, and machine, but the table below shows the ballpark once the settings are dialed in. The manufacturer’s FabCOR 86R data sheet is the final word for any single diameter.

Notice where the bigger diameters land. From 1/16 in up, you are comfortably past the 20 lb/hr mark, and even 0.045 in beats most comparable solid wires at the same current.

From Deposition to Travel Speed and Cost Per Foot

Deposition only matters if it reaches your bottom line. More metal per hour means you can move the torch faster along the same joint, so each weld takes fewer minutes. Divide the total cost of a weld by its length and labor is almost always the biggest slice, not wire. Faster travel with high deposition cuts that slice directly, which is why higher deposition lowers cost per weld, not just cost per pound.

The Labor Math: Fewer Passes, Less Cleanup

The efficiency number matters as much as the deposition number. FabCOR 86R leaves virtually no slag coverage, so multi-pass work proceeds without deslagging between passes. On heavy sections that removes a chipping and brushing step from every pass. Low spatter and smoke cut post-weld cleaning and keep operators happier. The same discipline that trims cleanup also sharpens bead appearance, so our guide to good and bad MIG welds is a useful reference.

Built for Robots and High-Volume Cells

Automation is where these gains compound, because robots never pause and operating factor stays high. FabCOR 86R comes in 0.035, 0.045, 0.052, 1/16, 5/64, and 3/32 in diameters on 33/44 lb spools, 60 lb coils, or 750/900 lb X-Pak drums. The drum packaging is the point: it feeds straight and consistent for long stretches, so a cell keeps running instead of stopping for spool changes. Hobart notes metal-cored wire excels in robotic welding applications, and it pairs naturally with high-deposition processes like robotic submerged arc welding. A clean contact tip and feed path keep that advantage intact.

Welding Technique: CTWD, Travel Speed, and Bead Shape

Settings get you in the ballpark; technique decides whether FabCOR 86R lays down a clean bead or a mess. Metal-cored wire is sensitive to distance and angle, and once you master the three variables that matter — stickout, travel angle, and arc position — it becomes one of the easiest wires in the shop to run.

CTWD: The Single Most Powerful Control

Contact tip to work distance (CTWD), or stickout, is the one lever a welder can pull to change amperage without touching the machine. Because metal-cored wire is resistance-heated, CTWD strongly controls current and deposition: shortening the stickout raises amperage at a given wire-feed speed, while lengthening it lowers amperage and cools the puddle. Push the tip closer and the arc bites harder with deeper penetration; pull it back for a wider, shallower bead.

For 0.045 in wire, most flat and horizontal work runs best with a CTWD of roughly 1/2 to 3/4 in (13–19 mm), held steady as you travel. A wandering stickout causes amperage swings, an unstable arc, and defects like undercut and lack of fusion. Think of stickout as a trim knob for amperage, not a cosmetic detail. If you keep burning through contact tips, stickout is often the culprit as much as wear — our guide to contact tip selection and maintenance covers the full checklist.

Travel Speed, Angle, and Bead Shape

Travel speed partners with CTWD. For 0.045 in wire, typical flat and horizontal ranges span roughly 27–36 V and 200–400 A at increasing wire-feed speeds, so match your travel to the deposition rate. Too slow and the broad, flat metal-cored bead piles up and crowns; too fast and you thin the bead and invite undercut.

Hold a travel angle of about 5–15 degrees, dragging (backhand) or pushing slightly depending on position. Keep the work angle square to the joint. What you will notice immediately is the bead profile: metal-cored wire produces a broad, flat bead with a low crown and shallow penetration compared with solid wire, whose finger-like penetration runs deeper. That flat face covers gaps well, but it also means you cannot rely on deep root fusion — component fit-up does part of the work. Our guide to reading good and bad MIG welds helps you judge profile on the fly.

Feed Consistency and Arc Position

Keep the wire feed smooth and the arc riding the leading edge of the puddle. That single habit stabilizes transfer and eliminates undercut and lack-of-fusion defects, while steady feeding extends contact tip and liner life. In robotic cells, the same rule governs programming: consistent CTWD and lead-edge arc placement matter more than fancy motion, which is why metal-cored wire excels in robotic applications. If the arc starts climbing the puddle instead of leading it, your travel is too slow or your stickout too long — correct one variable at a time. Shops chasing higher deposition can study how robotic high-deposition welding manages wire and travel control.

Out-of-Position Limits and Joint Prep

Here is the hard rule: conventional spray transfer with metal-cored wire belongs to flat and horizontal positions only. Try to run spray out of position and the puddle sags, the arc destabilizes, and you get poor fusion. Vertical and overhead work demands short-circuit or pulsed spray transfer instead, which give you puddle control the molten spray never will. Building that hand skill takes deliberate hours — see our guide to building real welding skills.

Fit-up matters because of that shallow penetration. Bevel thick plate, leave a small root gap, and keep surfaces clean. On heavy plate, a 60-degree included bevel with a 1/16 to 1/8 in root face gives the shallow-penetrating arc enough land to fuse without burning through. Run a hot root pass that fuses the land fully, then fill passes at your travel speed sweet spot, watching that each bead ties into the toe of the last.

FabCOR 86R vs Solid MIG Wire vs Flux-Cored: Which Should You Use?

Three wire processes dominate shop-floor steel welding: solid GMAW wire, gas-shielded metal-cored wire like FabCOR 86R, and flux-cored wire — both gas-shielded (FCAW-G) and self-shielded (FCAW-S). They share feeders, guns, and power sources, but the arc physics differ enough to reshape your whole day. Metal-cored wire combines the high deposition of flux-cored wire with the high efficiency and no-slag nature of solid wire, which explains why it lands firmly in the middle of the productivity curve.

Unsure whether flux-cored even counts as MIG? This guide on is flux core the same as MIG clears that up in a few minutes.

Head-to-Head Comparison

Those numbers trace back to chemistry and shielding method. FabCOR 86R runs on 75% Ar/25% CO₂ and delivers roughly 476 MPa yield, 558 MPa tensile, 30% elongation, and about 101 J impact at −30 °C. Those are genuine structural mechanicals, not just fast-and-loose numbers. The FabCOR 86R data sheet spells out the full ranges.

Metal-cored wins on productivity and cleanliness. It lays down metal fast, leaves no slag to chip, and keeps spatter low, so bead appearance stays tidy and cleanup drops to a quick wire brush. The trade-off is real: metal-cored wire needs clean, consistent gas shielding, decent fit-up, and cleaner plate than flux-cored will forgive. Blow your shielding and you get porosity immediately.

Hydrogen is the quiet differentiator. FabCOR 86R is H4 classified, with diffusible hydrogen around 1.8–2.8 ml/100 g typical, which lowers the risk of hydrogen-induced cracking compared with non-H-classified consumables. On thick, restrained, or high-strength steel, that one number can matter more than raw deposition rate.

Solid wire is the simplicity champion. It is the cheapest per pound, the easiest to run, and the best out-of-position choice for thin material. It is also the slowest of the three. Composition matters here, as this breakdown of what MIG welding wire is made of explains.

Flux-cored is the field survivor. Self-shielded FCAW-S shrugs off wind and surface contamination and needs no gas, which is why it owns outdoor structural and pipeline repair. In exchange you chip slag between passes, breathe more fume, and accept a process that is a little less efficient on clean, fit-up-friendly plate. If you want the gasless version specifically, start with this gasless MIG welding guide.

Fume deserves its own line. Both metal-cored and flux-cored wires generate more fume than solid wire, and any chromium-bearing steel falls under OSHA’s hexavalent chromium rules. Good airflow and the right protective eyewear for welding are non-negotiable for any of the three.

Decision Matrix

• Heavy equipment, thick plate, indoors, clean steel: metal-cored, FabCOR 86R or similar H4 wire.
• Thin sheet, tight fit-up, vertical-down work: solid MIG wire.
• Outdoors, windy, rusty or painted steel, field repair: flux-cored, especially self-shielded.
• Maximum deposition on a fixed robot cell: step up to robotic submerged arc welding.

Where FabCOR 86R Is Overkill

Not every job earns the upgrade. If you weld a few hours a week, run thin sheet, or your machine lacks the duty cycle for continuous production, solid wire is simpler and cheaper. Metal-cored rewards volume: it wants a steady gas supply, consistent travel speed, and a setup like the one outlined in this guide to planning welding facilities. Think of it as a production tool, not a weekend upgrade.

Common Mistakes and How to Troubleshoot Defects

Even with a high-deposition wire like FabCOR 86R, small setup errors can create defects that waste time and compromise quality. The key to fast repairs is knowing what to look for and correcting the root cause instead of chasing symptoms. Most problems trace back to a few variables: gas coverage, voltage, travel speed, and wire feeding. Fix those and the defect usually disappears. By applying the tips below and referencing proven resources such as Good and Bad MIG Welds: How to Tell the Difference, you can keep your welds clean and consistent.

Excessive Spatter

Heavy spatter is often the first sign of an unbalanced arc. High spatter can trace to shielding gas mix, voltage or arc length, or CTWD being too long. For higher CO2 mixes (75% Ar/25% CO2), voltages must be increased 1-3 V versus 90% Ar/10% CO2 to maintain arc length. Check your contact tip for wear, shorten your stickout, and verify your machine settings against the FabCOR 86R data sheet for your material thickness. A worn tip and a long stickout are the two quickest fixes, so rule them out first.

Porosity

Pinholes in your bead usually mean poor shielding. Common causes include low gas flow, drafts, surface contamination, or a damaged gun liner. When working in a shop, review your Welding Facilities layout to block wind and maintain proper airflow. Always clean mill scale, oil, or rust before welding, and confirm gas coverage with a test bead. If pinholes appear only at the start of a weld, the issue is often gas pre-flow rather than flow rate.

Lack of Fusion

A weld that sits on top of the joint with no root tie-in is a safety risk. This defect often stems from travel speed too high, wrong gun angle, or insufficient amperage. For manual work, build your control through regular welding practice, and inspect critical joints against the acceptance criteria in AWS D1.8/D1.8M. In robotic cells, under-cut and lack of fusion can be caused by poor seam tracking and inconsistent wire payout, which X-Pak drums are designed to reduce.

Undercut, Convexity, and Cold Lap

Undercut often comes from too much voltage or travel speed, while excessive convexity or cold lap can be caused by low travel speed or improper gun work. To avoid these flaws, study the differences covered in Overlap Welding Defect and Overlapping Welding. Make small, incremental changes to voltage and travel speed rather than large corrections. Change one variable at a time and run a test coupon before committing to a full pass.

Poor Wire Feeding, Birdnesting, and Burnback

Feeding issues can ruin productivity faster than most defects. Check drive rolls, liner condition, and Quick Connect Welding Leads for kinks or loose connections. Burnback, where the wire fuses to the contact tip, is often caused by a short stickout or slow wire feed recovery. For new operators, the How to Use a Wire Welder guide is a solid starting point. If you run automated cells, also consider the benefits outlined in Robotic Submerged Arc Welding.

Burn-Through and Heat Control on Thin Sections

On thin gauge material, excess heat can cause burn-through in seconds. To manage it, reduce amperage and voltage, increase travel speed, use a tighter weave or stringer, and consider a slight push angle to flatten the arc. For applications where heat input is critical, review process fundamentals in Is Flux Core the Same as MIG? and Polarity for Flux Core Welding. Always prioritize safety with proper Protective Eyewear for Welding and follow OSHA welding safety guidance. When in doubt, clamp a heat sink or backing bar behind the joint to pull heat away.

By correcting these common errors at the source, FabCOR 86R will deliver its full productivity gains without sacrificing the clean, consistent beads your shop relies on. For more defect-specific advice, explore Metal Rolling and Welding or Can You Weld Hardened Steel? as you scale to more demanding jobs.

Safety, Fume Control, Storage, and the 2025 FabCOR 86R Recall

Metal-cored wire is a productivity tool, but it is still an open-arc process that throws a lot of fume. Treating safety as an afterthought is how shops collect citations and welders collect long-term health problems.

What’s Actually in Welding Fume

Welding fume is a cocktail of fine metal oxides, fluorides, and gases. With FabCOR 86R, a mild-steel metal-cored wire, the main metals are iron, manganese, and small amounts of silicon. Manganese is the one to watch. NIOSH sets its recommended exposure limit for manganese compounds and fume at 1 mg/m³ as an 8-hour TWA, with a short-term exposure limit of 3 mg/m³. Prolonged manganese fume exposure can cause Parkinson’s-like symptoms.

OSHA’s permissible exposure limit (PEL) for total welding fume — particulates not otherwise regulated — is 15 mg/m³. ACGIH recommends a tighter 5 mg/m³ for iron, mild-steel, and aluminum welding fume. NIOSH goes further and recommends keeping welding fumes at the lowest feasible concentration because it treats welding fume as a suspected occupational carcinogen. You can read the details in OSHA’s welding safety fact sheet.

Hexavalent chromium, Cr(VI), is a separate concern. It forms during hot work on chromium-bearing metals like stainless steel. OSHA’s PEL for Cr(VI) is 5 µg/m³ as an 8-hour TWA, with an action level of 2.5 µg/m³. FabCOR 86R is a mild-steel wire, so it isn’t a chromium source on its own — but the base metal drives fume chemistry. Weld stainless with any wire and Cr(VI) is back on the table.

Ventilation, Respirators, and PPE

The best control is source capture, not dilution. Local exhaust ventilation (LEV) at the arc, fume extraction guns, and properly positioned hoods pull fume away before it reaches your breathing zone. Getting the layout right up front matters — a solid welding facilities setup guide covers airflow, hood placement, and machine spacing.

Personal protective equipment is the last line of defense, not the first. That means a properly shaded helmet, safety glasses with side shields under the hood (protective eyewear for welding), leather gloves, a flame-resistant jacket, and closed-toe boots. When LEV can’t keep exposure under the limit — confined spaces, heavy manganese, or stainless — strap on a half-mask respirator with P100 filters or a powered air-purifying respirator (PAPR).

Fume exposure isn’t only a long-term concern. If you are welding while pregnant, treat ventilation and respiratory protection as non-negotiable and talk to a doctor about the specific metals involved.

Storing Metal-Cored Wire

Metal-cored wire likes dry, stable conditions. Keep spools sealed until use, off concrete floors, and inside a dry cabinet or their original packaging. Damp wire causes porosity and unstable arcs, and it wastes the smooth deposition you switched to metal-cored wire for in the first place. Rotate stock first-in, first-out so old lots don’t sit for months.

The July 2025 FabCOR 86R Recall

On July 7, 2025, Hobart Filler Metals voluntarily recalled FabCOR 86R Lot K61310, produced the week of April 21, 2025, under part numbers S249412-029 and S249412-044. During manufacturing, flux from another product was inadvertently introduced into the batch, which is not supposed to be there.

Because metal-cored wire runs without a flux core, the tell-tale sign was a slag layer forming over the bead — something this wire should never produce. Hobart replaced affected product at no cost through authorized distributors. If you have spools from that lot, stop welding, quarantine them, and contact your distributor. You can confirm the affected part numbers in the official recall notice.

Practical Tips, Best-Fit Applications, and a Buying Decision Checklist

Everything in this guide comes down to one question: can FabCOR 86R make your shop faster, cleaner, and more profitable? For the right work, yes. Here is how to set it up, where it wins, and how to decide.

A Step-by-Step Setup Checklist

1. Verify classification and lot. Confirm the spool or drum is marked AWS A5.18 E70C-6M H4 and check the lot number against your supplier’s recall notices. Non-conforming lots often reveal themselves through unexpected slag formation during the first pass.
2. Choose your gas. Use a 75–95% argon/CO₂ blend for spray transfer on carbon steel. Don’t reach for 100% CO₂ if you want the smooth metal-cored bead this wire is designed to deliver.
3. Set wire-feed speed and voltage. Start around 350–450 ipm at 26–30 volts for 1/16-inch wire, then fine-tune by watching the arc and bead.
4. Set CTWD. Hold 3/4 to 1 inch of stick-out. Too short burns the tip; too long loses the transfer and causes spatter.
5. Test on scrap. Run a bead on matching plate before you touch a real part.
6. Dial in travel speed. Match travel to the puddle so the toes wet out without undercut or overlap. If the edges start rolling over, you are traveling too slow. See our guide to the overlap welding defect.
7. Inspect the first pass. Look for a flat, slightly convex bead with tight ripples and no silica islands.

Where FabCOR 86R Shines — and Where It Doesn’t

The wire is a strong match for long, straight, high-deposition welds on non-alloyed and fine-grain steels in flat and horizontal positions. Best-fit applications include:

• Structural steel and heavy fabrication with long, straight seams
• Storage tanks and pressure-vessel shell courses
• Railcars and earthmoving equipment
• Robotic welding cells running continuous production

It is a poor fit for outdoor, windy sites, very out-of-position thin work, and dirty or heavily rusty steel. In those situations reach for self-shielded flux-cored or stick, which shrug off wind and contamination. If gasless is your only route, our gasless MIG welding guide covers the alternatives.

Storage, Handling, and Spool Selection

Store wire in a dry, enclosed environment in its original, intact packaging. Re-drying is not recommended — once moisture and contaminants get in, performance suffers. For robotic or high-volume cells, choose the X-Pak 750/900 lb drum, because straight payout improves seam tracking and extends tip and liner life. Smaller spools suit bench work and short runs. Keep spare contact tips on hand and inspect liners regularly.

Cost-Justification Checklist

Before you commit a cell to the wire, run the numbers:

1. Does the job involve long, straight welds you can run continuously?
2. Are your materials clean, non-alloyed, or fine-grain steel?
3. Can you cut grinding and rework from silica and spatter?
4. Will higher deposition let you finish sooner or win more work?
5. Is your gas supply set up for argon/CO₂ blends?
6. Have you compared cost per linear foot of weld, not cost per pound?

Operator Appeal and Reducing Rework

Welders adopt a wire when it makes their day easier, and FabCOR 86R’s smooth arc, low spatter, and minimal cleanup do exactly that. Train your team on the settings above, let them prove the wire on scrap, and standardize the procedure so everyone starts from the same baseline. Encourage deliberate welding practice on the new wire before it goes into production. Fewer defects mean less rework, and that is where the real savings live.

The Buying Decision in One Line

If your work is long, straight, high-deposition welding on clean carbon steel — especially in flat and horizontal positions or a robotic cell — FabCOR 86R will pay for itself. If your jobs are short, badly fit-up, windy, or dirty, stick with a process built for those conditions. Match the wire to the work, and the productivity gains arrive on their own.

Conclusion: Is FabCOR 86R Worth It for Your Shop?

Here is the honest bottom line. FabCOR 86R is AWS A5.18 E70C-6M H4, a gas-shielded metal-cored wire run on DCEP for non-alloyed and fine-grain steels. What it buys you is real: deposition rates above 20 lb/hr, 95%+ efficiency, virtually no slag, and noticeably less spatter and smoke than solid wire. You trade a little of the simplicity you get with plain MIG, and in return you get faster travel, less grinding, and a lower cost per finished part, especially on flat and horizontal production welds and on automated or robotic cells.

That trade only pays off when the wire fits the job. Metal-cored 86R shines on long, straight, high-volume joints where you can hold a steady contact-tip-to-work distance and let the arc run. On thin sheet, out-of-position gymnastics, or one-off repair work, solid wire or flux-cored may still be the smarter call. Match the consumable to the work, not the other way around.

Key Settings and Safety Reminders

Before you spool up, lock in the fundamentals: DCEP polarity, the shielding gas your procedure calls for, and a CTWD you can actually hold. If polarity and gas always trip you up, our guide to DCEN vs DCEP for flux core clarifies the direction current flows and why it matters.

Two reminders never change no matter how clean the wire runs:

• Local exhaust ventilation and proper PPE are mandatory. A low-fume consumable reduces smoke; it does not remove the hazard. OSHA’s welding safety fact sheet covers the ventilation basics every shop needs.
• Always confirm the current standard version. Check AWS A5.18/A5.18M and verify that your shielding gas and wire lot match your written procedure qualification, not just a date stamp on the box.

A Word for Beginners and Veterans Alike

If you are new to wire welding, do not rush the switch. Get comfortable running a bead, then dial in stickout and gas flow slowly. If metal-cored feels twitchy at first, that is usually a CTWD or travel-speed issue, not a bad spool. Our contact tip guide helps here, since a worn tip quietly wrecks bead quality.

For experienced fabricators, the move is an audit. Walk your high-volume weld schedule and flag every joint that runs flat or horizontal for long stretches. Those are your conversion candidates. Test the wire there, compare cycle times and cleanup hours against solid wire, and let the numbers decide. Chances are good the spools sitting idle in your cage have been the answer all along.

Frequently Asked Questions

Is FabCOR 86R a flux-cored wire?

No. FabCOR 86R is a gas-shielded metal-cored (metal-powder) wire, classified AWS A5.18 E70C-6M H4, so it produces virtually no slag. Flux-cored wires contain mineral flux that forms a slag layer you must remove between passes.

What polarity and shielding gas does FabCOR 86R use?

It runs on Direct Current Electrode Positive (DCEP) with a shielding gas of 75-95% argon balanced with CO2, or 95% argon and 5% oxygen, at roughly 35-50 cfh (17-24 l/min).

What is the AWS classification of FabCOR 86R?

FabCOR 86R is classified AWS A5.18: E70C-6M H4, equivalent to EN ISO 17632-A: T 46 3 M M21 2 H5. The H4 designation caps diffusible hydrogen at 4 ml per 100 g of weld metal.

Can FabCOR 86R be used for out-of-position welding?

Its spray-transfer mode is intended for flat and horizontal positions. For vertical or overhead work you must switch to pulsed spray or short-circuit transfer and adjust the procedure accordingly, so check your WPS before running out of position.

How much does FabCOR 86R improve deposition versus solid wire?

It delivers deposition rates in excess of 20 lb/hr with efficiencies of 95% or greater, and generally beats solid wire at the same amperage. The bigger win is often the elimination of deslagging and reduced cleaning between passes.

What diameters and packages is FabCOR 86R sold in?

It is available in 0.035, 0.045, 0.052, 1/16, 5/64 and 3/32 inch diameters, on 33 or 44 lb spools, 60 lb coils, or 750/900 lb X-Pak drums designed for robotic and high-volume welding.

Was FabCOR 86R recalled?

Yes. On July 7, 2025 Hobart Filler Metals recalled Lot K61310 (manufactured the week of April 21, 2025; part numbers S249412-029 and S249412-044) because flux from another product was introduced during manufacturing. Affected wire was replaced at no cost through distributors.

How do I know if I have a bad or non-conforming lot of FabCOR 86R?

Metal-cored wire should leave virtually no slag. If you see a slag layer forming on the bead, that is a strong visual signal of a non-conforming lot, and you should stop use and contact your distributor with the lot number.

Is FabCOR 86R the same as FabCOR Edge XP?

No. They are distinct Hobart metal-cored products. FabCOR Edge XP is a premium wire formulated to address silicon-island formation and distribution on scale-free base metal, while 86R is the established high-deposition general workhorse classified E70C-6M H4.

Do I need special ventilation to weld with metal-cored wire?

Yes. All welding generates fume containing metals such as iron, manganese and, with chromium-bearing metals, hexavalent chromium, which OSHA limits to 5 ug/m3 as an 8-hour TWA. Use local exhaust ventilation or fume-extraction guns and add respiratory protection when engineering controls are not enough.

Authoritative Sources & Further Reading

• https://www.hobartbrothers.com/news-events/metal-cored-wire-excels-on-robotic-welding-applications-improves-productivity
• https://pdiimages.praxair.com/PDIB2CImages/product-pdf/Fabcor86R_Data_Sheet.pdf
• https://app.aws.org/mwf/attachments/97/104097/Fabcor86R.pdf
• https://millerweldslatam.com/wp-content/uploads/2021/05/fabcor-86r-aws-d1-8-hobart-miller-welds-min.pdf
• https://www.hobartbrothers.com/products/metal-cored-wires-gas
• https://www.osha.gov/sites/default/files/publications/OSHA_FS-3647_WELDING.pdf
• https://www.osha.gov/hexavalent-chromium
• https://www.cdc.gov/niosh/chemicals/pel88/pell-pages/welding.html
• https://pubs.aws.org/Download_PDFS/D1.8-D1.8M-2021-FinalWeb-PV.pdf
• https://webstore.ansi.org/standards/aws/awsd18m2025
• https://www.airgas.com/medias/Hobart-Bros-FabCOR-Recall.pdf