The invention provides a novel process for a formula of a 
slag-free flux-cored wire, and relates to a 
welding material. The manufacturing method adds the combination of 
molybdenum powder, 
nickel powder and 
rare earth silicon to a formula of raw materials, eliminates mineral 
powder in a common formula, and optimizes the proportion of various types of 
metal powder in the formula. According to the formula, the 
welding material comprises the following components: 4 to 8 parts of micro carbon ferrochromium, 12 to 18 parts of low carbon 
ferromanganese, 56 to 67 parts of 
iron powder, 2 to 6 parts of 
molybdenum powder, 0.1 to 0.4 part of ferroboron, 2 to 5 parts of 
rare earth silicon, 1 to 3 parts of 
ferrosilicon, 2 to 3 parts of 
ferrotitanium, 2 to 3 parts of 
sodium fluoride, 3 to 7 parts of ferroaluminum, 1 to 3 parts of aluminum to 
magnesium powder and 4 to 8 parts of 
nickel powder. The invention improves the 
toughness, strength and anti-fatigue performance of 
welding seams and thins welding-seam grains by adding the combination of 
molybdenum powder, 
nickel powder and 
rare earth silicon into the raw materials of the formula, eliminating the mineral powder in the common formula, and optimizing the proportion of various types of 
metal powder in the formula. Meanwhile, slagging on the surfaces of the welding seams is avoided, and welding efficiency is raised by 20 percent compared with 
slag-type processes.