Are you thinking about a career in industrial welding or welding engineering technology? Whether you want to enter the welding industry as a capable technician or are simply looking to update your skill set, a welding engineering technology program will help you meet these professional goals.
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Welding requires a specific set of skills, knowledge, experience, and talent. Though there are many welding processes, Flux-Cored Arc Welding (FCAW) is a particularly popular method used throughout the field. Listed below, you'll find everything you need to know about the flux-cored arc welding process.
Flux-cored arc welding or FCAW, as it is popularly referred to, is one of the most productive manuals or semi-automatic welding processes.
First introduced in the 's as an alternative to manual metal arc welding or stick welding, flux-cored arc welding has since become the preferred welding mechanism for various applications across industry segments.
FCAW processes involve using a continuous wire-fed electrode, a constant-voltage welding power supply, and the same equipment used in metal active gas welding (MAG welding). Flux-cored arc welding occurs with or without shielding gas and is way more productive and economical than MAG welding.
FCAW utilizes the heat created by an electric arc to fuse the base metal in the weld joint region. It uses a hollow or tubular electrode filled with a flux compound (also called a flux-cored wire) that protects the weld pool by forming a gas.
Thanks to the penetrative properties of the flux-cored wires and high deposition rates, the FCAW process finds its use extensively in outdoor welding or welding on contaminated materials. Flux-cored arc welding does not need external shielding gas to safeguard the weld from atmospheric elements.
The use of FCAW for thick materials results in 'slag.' You can whittle it out later to give it a clean and polished appearance.
Flux-Cored Arc Welding (FCAW) Uses and MethodsThe flux-cored arc welding process takes place in two ways. It is primarily divided into two types based on the shielding method:
Method 1: FCAW by using an external shielding gasThe 'dual shield welding' method involves using carbon dioxide with flux to provide additional shielding. The most common shielding gases include carbon dioxide and blends of argon (75%) and carbon dioxide (25%).
The shielding carbon dioxide gas, provided externally using a high-pressure gas cylinder, safeguards the weld pool from oxidation. The metal is also protected by the slag formed as a result of flux melting.
This process is generally applied when thicker metals or materials require welding together. The continuously-fed cylindrical electrode enables high deposition rates and amplified production (compared to solid wire or stick electrode).
Perhaps the only drawback of this process is that strong winds may disturb the carbon dioxide gas shielding and affect welding quality in harsh outdoor conditions.
Method 2: FCAW by relying on the flux core to protect the weld areaThis method relies on the gaseous protection and slag formed by the flux-cored electrode to cover and safeguard the molten material or metal in the weld. The filler wire core consists of agents that create shielding gases when the welding arc heat burns them.
This type of welding is extensively used in heavy outdoor projects, irrespective of weather conditions. The biggest advantage here is that you don't need external shielding gas as windy conditions don't disrupt the welding procedure, making it ideal for external (outdoor) applications.
Equipment Needed for FCA WeldsThe basic equipment you will need for flux-cored arc welding includes:
Electrodes are what differentiate flux-cored arc welding from MIG welding. While the latter uses solid wires as the filler material or filler metal, the former involves using electrode wires with a hollow flux-filled center. The electrode wires fill with flux, shielding the weld joint from corroding or contaminating due to natural elements.
Which Metals Can Be Welded with FCAW?FCAW is among the most popular welding processes because of its flexibility and versatility. Metals like cast iron, stainless steel, carbon steel, high-nickel alloys, and low-alloy steels can be easily welded using the flexible FCAW process.
What Are the Advantages and Disadvantages of FCAW? AdvantagesThe flux-cored arc welding process finds its use in industries like construction, heavy equipment repair, structural steel erection, shipbuilding, etc. The primary reason for this is that, unlike most other welding processes, FCAW works on all kinds of materials even if contaminated (except for dealing with contaminants like oils, water, and paint).
It can dissolve mill scale and rust, too.
Here's a look at some of the most significant pros of flux-cored arc welding and the factors that make it essential today's world:
While the FCAW process offers high deposition, protection against the wind and other atmospheric elements, and a host of other benefits, there are a few limitations or restrictions that you should know.
Factors like the electrode angles, wire feed speed, arc voltage, electrode extension, and travel speeds can prove the difference between a perfect weld finish and a defective one. Here are some of the most common problems you are likely to face when working on a flux core weld and how to deal with them or prevent them:
Metal Inert Gas (MIG) welding, GMAW, or Gas Metal Arc Welding involves using a continuous solid wire electrode along with shielding gas.
Gas metal arc welding is a common welding process used for vehicle manufacturing, industrial production, construction, and aerospace. Since this type of welding uses gas externally, the wind can hamper the process. GMAW finds its use as a semi- or fully-automatic welding technique.
While FCAW is quite similar to GMAW, the biggest difference is that it doesn't require you to have an external shielding gas. It revolves around a continuous wire feed process. There are two separate processes associated with flux-cored arc welding, one of which involves using shielding gas.
The other one relies on self-shielding agents (produced when fluxing agents decompose within the welding wire).
FCAW vs. SMAWShielded Metal Arc Welding SMAW, also referred to as 'stick welding,' is a welding technique used on all ferrous materials. The electrode coating helps de-oxidize the weld area. This generates a shielding gas that protects the weld area from atmospheric contamination.
SMAW finds its use both indoors and outdoors for welding low-alloy and high-alloy steels, nickel alloys, carbon steel, and cast iron (like FCAW). Just like flux-cored arc welding, SMAW, too, creates a layer that you can chip off later.
Flux-cored arc welding is a semi-automatic or manual welding technique that is rarely used indoors. It is generally used outdoors or on contaminated materials. In this case, an electric arc fuses the base material with a continuous filler metal electrode. The shield gas offered by the flux helps protect the weld pool from atmospheric elements.
10 Tips to Improve the Quality of Your FCAWWhile the flux-cored arc welding technique has been viable and convenient for several years now, that doesn't mean the process doesn't have its own set of pitfalls. As highlighted above, you might face certain challenges with the weld arc area, electrode wires, welding equipment, arc stability, arc length, shielding, voltage, and more.
Here are some pro tips to ensure that your weld joint is of the highest quality and free of complications '
For more information, please visit Flux-Cored Hardfacing Machine.
Learn FCAW with NEIT's Welding Program
The New England Institute of Technology, one of the
best welding schools
in Rhode Island, offers anAssociate in Science in Welding Engineering Technology
, which focuses on developing hands-on welding capabilities. Delivering the perfect blend of theoretical and practical training, this program helps you understand the concepts and best practices applied in the welding industry.If you're interested in analyzing, designing, fabricating, and testing welded metal structures or products, this program is for you!
In addition to popular welding processes such as flux-cored arc welding (FCAW), GMAW, SMAW, GTAW, oxy-acetylene and air-carbon arc cutting, and pipefitting, you also learn about the application of important peripheral subjects like:
Upon graduation, you will be eligible to kick-start your career in the welding industry as an entry-level welding technician with a solid foundation in design, welding, and fabrication. NEIT's associate degree program helps students do the following upon successful graduation:
There is no shortage of opportunities for qualified and highly-skilled welding technology graduates. As you gain more experience in the industry and hone your skills, you will be able to pursue any of the following roles in welding technology or related fields:
This comprehensive program is a great choice for adult learners' needs, those looking to make a career switch, or even industry professionals looking for a skill upgrade in welding technology.
Learn how NEIT can help you achieve the required skills and abilities to make it big in the welding industry.
Request more information about our program here. You can also give us a call to speak to our team today!
FAQs What are the 4 types of welding?While there are various types and methods used in welding (broadly speaking), here are the four most common ones:
Read this article to learn more about each of these processes and their application.
What is FCAW welding used for?Flux-cored arc welding (FCAW) is primarily used for welding thick materials and metals. These include cast iron, carbon steel, stainless steel, high-nickel alloys, and low-alloy steels for activities such as shipbuilding, bridge construction, structural steel erection, and heavy equipment repair across a wide range of heavy industries, including construction.
The continuously-fed tubular electrode helps increase deposition rates and improve productivity. Flux-cored arc welding is generally used for welding contaminated or dirty materials, thanks to its self-protecting properties.
Learn some techniques when using the self-shielded flux-cored process for welding mild steel ' an ideal process for welding outdoors.
Self-shielded flux-cored welding can be an excellent process to use for welders of all skill levels who frequently need to weld outside or on dirty material.
Self-shielded flux-cored welding is a wire welding process in which a continuous hollow wire electrode is fed through the welding gun into the weld joint. It differs from MIG welding in that it doesn't require an external shielding gas, such as carbon dioxide or argon, to protect the weld pool from contamination. Instead, a flux compound contained within the wire reacts with the welding arc to form a gas that protects the weld pool. Another process, gas-shielded flux-cored welding, does require a shielding gas. It's often used in heavy-duty industrial fabrication and manufacturing and is not typically recommended for beginner and hobbyist applications.
Because the flux creates the shielding gas in self-shielded flux-cored welding, this process does not encounter the weld problems that can occur when a strong wind blows the shielding gas away when MIG welding outside. The flux contained in the electrode also allows the process to be more forgiving of base metal that is somewhat rusty, dirty or otherwise contaminated.
Flux-cored welding produces a slag that sits on top of the finished weld and must be chipped off. It also tends to produce welds that aren't as visually attractive as MIG welds. For these reasons, it makes sense to switch to the MIG process for indoor welding.
Before tackling any welding project, make sure you have the proper safety apparel. Basic welding safety apparel includes leather shoes or boots, cuff-less full-length pants, a flame-resistant and long-sleeve jacket, leather gloves, a welding helmet, safety glasses and a bandana or skull cap to protect the top of your head from sparks and spatter. Also remove any potential fire hazards from the welding area.
Miller offers a wide range of safety accessories for everyone from the occasional hobbyist to the full-time professional welder. Your owner's manual contains additional information about safety apparel and precautions.
As mentioned earlier, flux-cored welding is more tolerant of surface contamination than MIG welding. However, you should always clean the surface of the base metals as thoroughly as possible to ensure that a rusty or scaly surface does not contaminate the final weld. A metal brush or grinder work well for cleaning the base metals. Also, be sure to clean the portion of the base metal where you plan to attach the ground clamp. Poor contact with the ground clamp will create resistance in the welding circuit and could result in poor weld quality.
For material over 1/4 inch, it's usually a good idea to bevel the edges of the base materials to ensure complete fusion of the two parts. This is especially true for butt joints.
Although flux-cored welding is more forgiving of dirty
metal than MIG welding, it's still a good idea to clean
off as much surface contamination as possible prior to welding.
Be sure to conduct a thorough inspection of your equipment prior to welding.
For general purpose mild steel welding applications, a flux-cored wire with the designation E71T-11 can be used in any position, is available in a wide range of sizes and provides excellent welding characteristics for both thin and thicker material. Hobart® Filler Metals offers such a wire under the name Fabshield® 21B (E71T-11).
As for wire diameter, .030-inch diameter is a good all-around choice for welding a wide range of metal thicknesses. For welding thicker material at higher total heat levels, use .035-inch wire (or .045-inch wire if it's within your welder's output range).
How much voltage and amperage a weld requires depends on metal thickness, joint configuration, welding position and wire diameter. Reference charts are available on your power source to help set the correct voltage and wire feed speed based on the wire diameter and material thickness. Our flux-cored welding calculator is also a great tool to utilize. Consider these tools to be rough guides from which you can fine-tune your final parameters based on a few test welds.
Your power source contains reference charts for setting
the correct electrical and wire feed parameters.
Stickout is the length of unmelted electrode extending from the tip of the contact tube, and it does not include arc length. Generally, flux-cored welding requires a stickout of around 3/4 inch, which is about twice the recommended stickout for MIG welding.
A stickout of approximately 3/4 inch is recommended for flux-cored welding.
With flux-cored welding, you should always use a drag (pull) technique. This involves pointing the tip of the welding gun back at the weld pool and dragging it away from the completed weld. An easy rule of thumb for remembering which technique to use is: 'If there's slag, you drag.'
Travel angle is the angle relative to the gun in a perpendicular position within the plane of the weld joint. Normal welding conditions in all positions call for a travel angle of 5 to 15 degrees. Travel angles beyond 20 to 25 degrees can lead to more spatter, less penetration and general arc instability.
Work angle is the gun position relative to the plane of the welding joint, and it varies with each welding position and joint configuration (see below).
Because of the effects of gravity, the gun work angle must be dropped slightly by 0 to 15 degrees so that the welding gun is pointing upward toward the top piece of metal. Without changing the work angle, the filler metal may sag or rollover on the bottom side of the weld joint. The travel angle generally remains the same as for a weld joint in the flat position.
When making multi-pass welds on thick metal or to bridge a slight gap where fit-up is poor, a slight weave may be used to fill a weld joint. A slight hesitation at the top toe of the weld helps prevent undercut and ensure proper tie-in of the weld to the base metal. Voltage and amperage settings for flux-cored welding in the horizontal position are usually the same or slightly less than settings for welding in the flat position.
Angle the welding gun slightly upward for horizontal welds to accommodate for gravity.
Vertical welding, both up and down, can be difficult. This makes pre-weld setup very important for producing high-quality welds. Since you are fighting gravity, consider reducing the voltage and amperage 10 to 15 percent from the settings for the same weld in the flat position.
Remember to weld upward for increased penetration and downward for thinner metals.
An overhead weld is the most difficult weld to make, and it should be avoided if possible. If you cannot avoid welding in the overhead position, try using the smallest wire possible, lowering your welding parameters by 15 to 20 percent, keeping your weaving to a minimum and maintaining a fast travel speed. Even following these tips, it still may be difficult to achieve a sound overhead weld.
Overhead welds are tricky. Use a thin wire, fast travel speed and
turn your electrical parameters down by 15 to 20 percent.
Creating a successful flux-cored weld (or any arc weld for that matter) requires more than just memorizing the correct parameters and gun travel guidelines. Only through practice and learning to read the weld pool will you be able to consistently achieve sound flux-cored welds. With practice, you'll begin to learn to troubleshoot and self-correct any shortcomings in your welds.
So, don't get frustrated if your welds don't look perfect on your first try. Just keep practicing and before you know it, you'll be scouring your garage for new things to repair or fabricate!
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