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Flux Cored Arc Welding!
Learning Center
FCAW Welding
Welding
Introduction to Welding
History of Welding
Art of Welding
Flux core arc welding was introduced in the 1950s. Technically the
introduction of this process was not new. It was just a new type of an
electrode that can be used on a MIG welding machine. Flux cored arc
welding is a process similar to MIG welding. Both processes using
continues wire feeds, and similar equipment. The power supply for a
FCAW, and a MIG welder, are the same machine. They are both
considered semi automatic processes, and have a very high production
rate.
Welding Processes
Stick Welding
MIG Welding
Flux Cored Arc Welding
TIG Welding
The main difference between flux cored arc welding and MIG welding is
the way the electrode is shielded from the air. Flux cored arc welding just
like the name implies, has a hollow wire with flux in the center, similar to
the candy called pixy sticks. Just as the name states, a Flux Core. The
main difference between MIG welding and flux core arc welding is, FCAW
gets its shielding from the flux core, and this allows the operator to weld
outdoors where it is windy. Its like a SMAW welding electrode turned
inside out! MIG welding gets its shielding from a bottle of gas which has
serious draw backs, when welding outdoors, or in drafty conditions.
Welder Certifications
Welding Certification
3G SMAW
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6G Pipe SMAW
3G MIG Welding
3G FCAW
Welder Resources
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Weld ability of Metals
The
Welding
Business
Owners Handbook Review Welding with flux core electrodes has some serious cons when it comes to the weld ability of metals. So far, FCAW has
The Fabricator!
been perfected on most carbon steels, cast iron, nickel based alloys, and some stainless steels. Unfortunately most
non ferrous exotic metals cannot be welded and that includes aluminum. On the upside for most hobbyists the flux core
electrode may be an excellent choice for general garage work, because if used in a MIG welder there is no shielding
gas required on some electrodes.
The main difference between FCAW, and a MIG welders are, flux cored arc welding power supplies are available with,
much, more, power! Basically they are an extremely powerful MIG welder! Some flux core arc welders come with the
capabilities of running over an extremely hot, 1000 plus amps! That is where they leave MIG welding in the dust for
production.
CO2 by itself produces the deepest penetrating weld but has some draw backs. The mechanical properties of the weld
are not the best due to fact the flux in the wire reacts with the shielding gas. Others draw backs are, it produces a lot of
spatter, and the arc is stiff and not as stable as it can be.
Argon by itself will also weld with a flux cored electrode, but just like CO2, it reacts not favorable with the flux. Both
Argon and Carbon dioxide can make a decent looking weld if used by themselves. What the weld looks like verses the
actually quality of the weld are two different stories.
The most common gasses used for dual shield FCAW are a mixture of Carbon Dioxide and Argon or Argon and
Oxygen. The most popular is C25 / 25% Carbon Dioxide and 75% Argon. This gas produces a stable arc, less spatter,
and allows more of a spray transfer of metal. I recently used this mixture when taking my 3G flux cored arc welding
certification. In some other cases a mixture of Argon and Oxygen may be used. Oxygen in small percentages stabilizes
the weld arc and improves the mechanical properties of the weld.
Ultimately if using dual shield its always best to read the electrodes manufactures recommendations or ask you
gas supplier for the proper gas.
As with most electrodes there is a standard classification code or designation code, on the spool they come on. To
understand the classifications better it is important to know some basics about where the classification codes are
different.
A somewhat common flux cored welding electrode is the E71T 1. As with all electrodes the numbers and letters all
mean something. There identifications are as follows.
E Stands for electrode.
7 Stands for the minimum amount of tensile strength. In this case it is 70,000
lbs of tensile strength per square inch of weld. The way this number is figured is
by adding four zeros to the number.
1 Stands for the position that this electrode can be welded in. There are only
two designations and they are 0 for flat and horizontal welding, then there is
1 for all position welding.
T Stands for a tubular electrode. When T is used it is always assumed it is
a flux cored electrode.
1 The last is the shielding flux type designations.
As a note with all flux cored electrodes they need to be stored in a dry place. Otherwise the may pick up moisture and
this will cause major weld defects.
FCAW is very similar to MIG welding when it comes to welding techniques! The main difference is how the puddle looks
and the fact that welds are covered in flux much like stick welding.
The first thing to consider is if you need to weld back hand or fore hand. Either technique can be used for any position
and remember these are just guidelines!
Back hand welding is when the handle of the welder is dragged like a Stick
welder. The back hand technique is common for flux core welding in the flat
and horizontal positions. The only other time you may want to consider the
back hand technique is when welding in the 4G position. The reason for this
is to avoid getting spatter on yourself. I tried welding a grove weld in the
overhead position using the fore hand technique and quickly got burned by a
few sparks that got inside my leather. The picture on the left shows the
spatter the nozzle got from welding in the overhead position, this is typical,
and unavoidable. The down side of back hand welding is that the weld puddle
is a little harder to see.Also when welding overhead the machine set-up must
be perfect! If you are less experienced you may find you weld wonders off of
the weld joint without knowing it. You typically focus on the weld puddle size
behind the crater just like stick welding. This method produces a very deep
penetrating, high, and narrow weld.
This picture is a weld I did in the 4G position, even though the back hand
technique produces a high weld, they look pretty much like it was welded in
the flat position. The fore hand method is when the welding handle is pushed
in the direction of the travel. This method is typically used on thinner metals,
in the vertical up, and for overhead fillet welds (4F). The fore hand method
also work well in the flat or horizontal position. This method of travel makes
seeing the weld puddle easy. This allows you to see the weld joint easier and
the chances of wandering off of the joint are not very likely. The down side of
this technique is spatter can sometimes become excessive if the travel angle
is not right.
When it comes to flux core welding techniques there are no simple answers. Most of the techniques are the same as
with all welding processes. For instance the whip of the weld, doing circles, and weave techniques used for wider
welds. When it comes to doing wider weave welds, it is the least common. Most flux core electrodes are typically
designed for stringer beads. Many times on wider welds the flux will peel off by itself without chipping. The pictures
below are the cap of a 3G weld done using dual shielding, C25 gas, and E71T-1. All it takes is just a tap with a
chipping hammer and the flux just drops to the floor!
The angles to weld in different positions are similar to MIG welding! What changes when using flux core welding is a
combination of many different factors like, electrode types, flux types, shielding gas (if any), and the thickness of the
metal welded! It comes down to practicing with a specific type of electrode, on the same thickness of metal, by using a
trial and error method. What works with one electrode type and metal thickness, may not work with another. I have
personally found that welding overhead requires a perfect angle, and a precisely set-up machine in order to get the job
done. The overhead angle is about 10 degrees, no matter if the method is fore hand or back hand. Otherwise it will
seem like it is impossible to get a good weld. All of the other positions are not as critical when it comes to travel angle.
Just like any other welding process it is best to take a piece of scrap metal similar to the piece to be welded and do a
quick practice run before welding!
The Conclusion
The reality of flux core arc welding is using a typical MIG welding machine and mostly the same equipment, with a few
small exceptions! Although they are considered two different types of welding processes, it is only the electrode type,
and shielding type, that separate them. Learning and understanding flux core welding is about learning to use a
different type of electrode in a MIG welding machine. That is all there really is to flux core arc welding.