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Flux cored arc welding (FCAW) is a welding process that uses a continuous tubular wire filled with flux. There are two types - gas shielded and self-shielded. Gas shielded wires provide better shielding and higher welding speeds than self-shielded wires. Rutile flux cored wires can be used in all positions and have low spatter, while basic flux cored wires are best for flat positions due to their slag. Metal cored wires have very high deposition rates. FCAW offers advantages over solid wire and SMAW, including faster welding and enhanced performance from core materials.
Flux cored arc welding (FCAW) is a welding process that uses a continuous tubular wire filled with flux. There are two types - gas shielded and self-shielded. Gas shielded wires provide better shielding and higher welding speeds than self-shielded wires. Rutile flux cored wires can be used in all positions and have low spatter, while basic flux cored wires are best for flat positions due to their slag. Metal cored wires have very high deposition rates. FCAW offers advantages over solid wire and SMAW, including faster welding and enhanced performance from core materials.
Flux cored arc welding (FCAW) is a welding process that uses a continuous tubular wire filled with flux. There are two types - gas shielded and self-shielded. Gas shielded wires provide better shielding and higher welding speeds than self-shielded wires. Rutile flux cored wires can be used in all positions and have low spatter, while basic flux cored wires are best for flat positions due to their slag. Metal cored wires have very high deposition rates. FCAW offers advantages over solid wire and SMAW, including faster welding and enhanced performance from core materials.
wire is easy-to-use and effective for many applications, it does have some limitations Why flux cored ?
GMAW is slow for out-of-position
welding
GMAW in short circuit transfer had
tendency for lack of fusion defects
GMAW requires clean steel
Why flux cored ?
A flux cored wire is optimized to obtain
performance not possible with a solid wire
For many welding applications like vertical
up welding and flat welding a flux cored wire can do it better and faster. Why flux cored ?
Ability to add a variety of materials to
the core of the welding wire allows many performance enhancements to be made wire Why flux cored ?
Slag formers are added to shield the weld
pool and shape and support the weld
Iron powder is used to increase deposition
rate
Scavengers and fluxing agents are used to
refine the weld metal FCAW -G
Gas shielded flux cored wires were
introduced around 1957
Core ingredients are formulated to
obtain performance impossible to achieve with solid GMAW wire FCAW -G
As all of shielding is provided by the
shielding gas , the core materials can be carefully selected to maximize certain area of welding performance, such as obtaining spray type transfer with 100% CO2 shielding gas and welding speeds twice as fast in vertical position FCAW -S
Self shielded flux cored wires were
introduced around 1961
Core ingredients are formulated to
provide all the shielding. The core materials generate its own shielding gases, slag formers and compounds to refine the weld pool. FCAW Types of cored wire
Gas Shielded Rutile flux cored
Gas Shielded basic flux cored
Gas shielded metal powder cored
Self Shielded flux cored
FCAW-G Rutile flux cored
Contain high proportion of rutile in flux
Can be used in all position in spray
arc condition
Offer ease of use , low spatter levels
and self releasing slag FCAW-G Rutile flux cored
Widely used in shipbuilding
All position capability gives high
production rates on components that are too large to be turned to flat position FCAW-G Rutile flux cored Typical welding parameters for 1.2 mm dia positional wire
vertical up position at 160 -200 amps, 24-26 V
Horizontal & flat position
at 230 - 280 amps, 25 -28 V FCAW-G Basic flux cored
Contain high proportion of calcium
carbonate and calcium fluoride in flux
Fluid slag cover limits use to flat and
horizontal positions
Arc is coarser than rutile wires, with
higher levels of spatter and more tightly adhering slag FCAW-G Basic flux cored
Weld metal has high toughness and
good crack resistance
Generally used to weld heavy sections
where there is increased risk of cracking slag FCAW-G Basic flux cored Typical welding parameters for 1.2 mm dia
Horizontal & flat position
at 240 - 300 amps, 26 -29 V FCAW-G Metal cored
Filled with very fine iron powder
Generally used for high deposition rate
welding in flat and horizontal positions
Arc is smooth with low levels of
spatter and minimal slag volume FCAW-G Metal cored
Widely used in shipyard panel lines for
fillet welding of stiffeners to primed panels
Increasingly used for mechanised
welding FCAW-G Metal cored Typical welding parameters for 1.2 mm dia
Horizontal & flat position
at 240 320 amps, 29 -31 V FCAW-G Metal cored Typical welding parameters for 1.6 mm dia
flat position at 300 380 amps, 30 -33 V FCAW-S Self shielded flux cored
Do not require gas shield
Generally used on open site conditions
in place of SMAW electrodes
Not as productive as gas shielded type
flux cored wires FCAW-S Self shielded Flux cored
Significant advantage over SMAW
electrodes where gas shielded wires cannot be used
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