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FCAW Welding Techniques and Angles

This document discusses flux cored arc welding (FCAW). It covers several key points: 1) When making horizontal fillet welds, the electrode should point close to the bottom plate corner with a work angle of 45-50 degrees to counteract weld pool flow perpendicular to the travel direction. 2) For gas-shielded electrodes, the shielding gas flow rate must be correctly set - inadequate or excessive flow can cause porosity, oxidation or turbulence issues. 3) Deposition rate and efficiency in FCAW depends on variables like electrode diameter, composition, extension and current. Rates and efficiencies typically range from 80-90% for gas-shielded electrodes and 78-

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236 views1 page

FCAW Welding Techniques and Angles

This document discusses flux cored arc welding (FCAW). It covers several key points: 1) When making horizontal fillet welds, the electrode should point close to the bottom plate corner with a work angle of 45-50 degrees to counteract weld pool flow perpendicular to the travel direction. 2) For gas-shielded electrodes, the shielding gas flow rate must be correctly set - inadequate or excessive flow can cause porosity, oxidation or turbulence issues. 3) Deposition rate and efficiency in FCAW depends on variables like electrode diameter, composition, extension and current. Rates and efficiencies typically range from 80-90% for gas-shielded electrodes and 78-

Uploaded by

kapsarc
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd

FLUX CORED ARC WELDING CHAPTER5 241

When fillet welds are made in the horizontal posi-


TRAVEL tion, the weld pool tends to flow both in the direction
(DRAG) of travel and at right angles to it. To counteract the
ANGLE latter, the electrode should point at the bottom plate
close to the corner of the joint, and in addition to the
drag angle, a work angle of 45" to 50" from the vertical
member should be used. Figure 5.20B shows the elec-
trode offset and the work angle used for horizontal
fillet welds.

SHIELDING GAS FLOW


DIRECTION
____.)
For gas-shielded electrodes, the gas flow rate is a
variable that can affect weld quality. Inadequate flow
will result in poor shielding of the weld pool, causing
weld porosity and oxidation. Excessive gas flow can
result in turbulence and mixing with air. The effect on
the weld quality will be the same as inadequate flow.
Either extreme will increase weld metal impurities. Cor-
rect gas flow depends on the type and the diameter of
the gun nozzle, the distance of the nozzle from the
work, and air movements in the immediate region of
the welding operation.

DEPOSITION RATE AND EFFICIENCY


The deposition rate in any welding process is the
weight of material deposited per unit of time. Depo-
4-I I
sition rate is dependent on welding variables such as
electrode diameter, electrode composition, electrode
extension, and welding current. Deposition rates versus
(B) welding current for various diameters of gas-shielded
and self-shielded mild steel electrodes and for self-
shielded stainless steel electrodes are presented in
Figure 5.20-Welding Electrode Positions
Figures 5.21, 5.22, and 5.23, respectively.
Deposition efficiency is the ratio of the weight of the
metal deposited to the weight of the electrode con-
sumed. Deposition efficiencies of FCAW electrodes
range from 80% to 90% for those used with gas shield-
ing, and from 78% to 87% for self-shielded electrodes.
The proper drag angle depends on the FCAW
method used, the base metal thickness, and the position
of welding. For the self-shielded process, drag angles
should be about the same as those used with shielded
metal arc welding electrodes. Drag angles can vary from JOINT DESIGNS AND
approximately 20" to 45" for the flat and horizontal WELDING PROCEDURES
positions. Larger angles are used for thin sections to
decrease penetration.
With gas-shielded FCAW, the drag angle should be The joint designs and welding procedures appropriate
small, preferably 0" to 15", but no more than 35". If the for flux cored arc welding depend on whether
drag angle is too large, the effectiveness of the shielding the gas-shielded or self-shielded method is used. How-
gas will be lost. ever, all the basic weld joint shapes can be welded
In uphill (vertical-up) welding the arc force helps by both FCAW methods. There may be some differ-
hold the molten metal in place and shape the resulting ences between the two methods of FCAW in specific
weld bead. A push angle of 5" to 35" is recommended. groove dimensions for a specific joint. For example, the

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