Pure titanium and titanium alloys have been used in various fields such as aerospace industry, automotive industry, bio-materials, and welding materials because of their high specific strength, excellent corrosion resistance and non-toxic to human body. Among these applications, titanium welding materials are growing with the development of the industries connected with ship and marine plants. However, high cost of titanium welding materials can be the problem for practical applications. The rising cost of the titanium alloy materials is mainly due to the high cost of raw materials, complex manufacturing process, high manufacturing cost as well as small quantity batch production. In this study, flux cored wire (FCW) of titanium was suggested to solve the problems of the high cost and small quantity batch production. The flux cored wire (FCW) of titanium can be designed for single or multiple pass welds on many grades of titanium alloys. Also, the development of flux cored wire (FCW) that has the merit of conventional arc welding and solid wire is being studied.

The purpose of the study is to design the optimum drawing process for manufacturing FCAW (flux cored arc welding) Ti wires. In this study, as-received Ti sheets were characterized and then designed three types of tubes were designed. The number of ten dies with different diameters was designed for the Geleji equation by considering the yield stress. EBSD analysis was carried out to characterize the deformation twins during plastic working, and heat treatment at different temperatures were preformed to remove the deformation twins.

From the FE-simulations which were carried out to compare the strain rate of three of tubes, it was found that butt type and overlap type tubes with lower strain rate ate more deformable than welded tube. Drawing test was carried out to analysis the effect of flux fractions (50%, 70% and 90%) of butt and overlap type’s tubes. The wall thickness of final tubes was decreased and the flux was well distributed with increasing flux fraction from 50 to 90%.