Although it is widely acknowledged in the industry that droplet transfer modes determine welding quality, inconsistent process results still occur even when the transfer mode of welding materials is fixed. For instance, flux-cored wires differ from welding electrodes. Commercially available products feature non-axial repelled globular transfer, yet they deliver varying welding performance under different operators and working conditions. Since flux-cored wires perform optimally within a specific current range, the selection of droplet transfer modes becomes particularly critical and worthy of attention.

      Without a full understanding of the properties of flux-cored wires, it is impossible to select the proper droplet transfer mode, which will inevitably lead to unsatisfactory welding quality such as severe spatter and poor weld appearance.

      Taking E501T-1 flux-cored wire as the research object, this paper correlates the selection and characteristics of droplet transfer modes, analyzes their relationship with welding performance, and demonstrates the necessity of proper mode selection through typical application cases. This research possesses practical value and reference significance for promoting technological progress and enhancing product competitiveness of enterprises.