ESOL

THEME1.8.2
CESOL SOLDEO WITH
TUBULAR WIRE

IWE–MODULE 1
The following have collaborated in the preparation of this text:

Mr. Manuel Aracil Cadenas

This text is the integral property of the Spanish Association of Welding and Joining Technologies, hereinafter CESOL.
Any reproduction of it is strictly prohibited without the express authorization of CESOL.
 SPANISH ASSOCIATION OF WELDING AND JOINING TECHNOLOGIES–CESOL

1. INTRODUCTION .............................................................................................................................. 1

1.1. Advantages of the process.

1.2. Limitations of the process............................................................................................................. 3

2. TYPES OF TRANSFER.............................................................................................................. 4

3. TEAM............................................................................................................................................ 5

4. PROTECTIVE GASES

5. CONSUMABLES .............................................................................................................................. 10

5.1. Manufacturing of tubular wires...................................................................................... 10

5.2. Functions of the flux...................................................................................................................... 11

5.3. Identification of carbon steel wires. ...................................................................... 12

5.4. Identification of tubular wires........................................................................................ 13

6. PROCESS PARAMETERS........................................................................................................ 17

Intensity

19

6.3. Wire length.................................................................................................................. 19

6.4. Wire feed speed..................................................................................... 20

6.5. Gas flow............................................................................................................................. 20

6.6. Deposition speed............................................................................................................ 20

6.7. Nozzle angle with the welding direction............................................................ 22

7. DESIGN OF JOINTS .................................................................................................................... 23

7.1. Design of joints for tubular FCAW wires with shielding gas, for steels
carbon..................................................................................................................................... 23

7.2. Design of joints for self-shielded FCAW tubular wires, for steels at
carbon..................................................................................................................................... 24

8. QUALITY........................................................................................................................................ 27

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8.1. Storage of rolls..............................................................................................................27

8.2. Handling of open packaging.........................................................................................27

8.3. Defects .....................................................................................................................................28

9. SECURITY ...................................................................................................................................30

10. COSTS .......................................................................................................................................31

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1.INTRODUCTION

The flux cored arc welding (FCAW) process uses heat

generated for the union of an electric arc between a continuous tubular wire that is consumed and the
metal to be welded. The protection of the joint is achieved by the flux contained in the tubular wire and
that can be helped by an external gas supply.

The characteristic that distinguishes the FCAW process from other welding processes is the content
of deoxidizers within the wire that is continuously fed. The FCAW process has two
variants, depending on the method used to protect the bathroom and the joint of the
air pollution.

Self-shielded FCAW, where the welding protection is performed by the gases.

that come from the combustion and vaporization of the flux inside the wire
(figure 1).
UNE EN ISO 4063: 2011. Process 114: Arc welding with tubular wire filled with
fluxing agent and without gas protection.

Figure 1. Welding with self-shielded tubular wire (without protective gas)

FCAW GS with shielding gas, which uses a shielding gas in addition to the action of
protection of the flux inside the wire. (figure 2).
UNE EN ISO 4063: 2011. Process 136: Arc welding with tubular filler wire
flux and with active protection gas.

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Figure 2. Welding with tubular wire with protection gas

With both methods, the flux from inside the wire produces a fine slag that protects the
solidification of the weld bead. Flux-cored arc welding (FCAW) is
normally a semi-automatic process, although it can also be automatic.

In figure 3, you can appreciate the difference between the two types of tubular wires, with gas.
protection (figure 3A) and self-protected without shielding gas (figure 3B).

(A) (B)

Tubular wire with shielding gas Self-protected tubular wire (Without gas
protection

Figure 3. Difference between (A) the two types of tubular wires (FCAW) with shielding gas and (B)
self-protected (without shielding gas)

Until recently, welding with tubular wire with flux inside was considered
of the GMAW (MIG/MAG) process and it has been due to the publication of the guideline (IAB-252r1-
11) issued by the international institute of welding (IIW) when it is considered as a
independent FCAW process.

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1.1. Advantages of the process.

The applications of this process are based on the following advantages:

High quality and appearance of the welding. Similar to what can be obtained with the
shielded metal arc welding (SMAW) but at a much lower cost.
Productivity - High deposition speed.
Metallurgical effect of improvement to welding. That is produced by the flux.
Slag production. It protects, supports, and improves the bath.
Higher tolerance for pollutants and initial cleaning requirements that may originate
cracks and pores that MIG/MAG welding (GMAW)
The use of self-protected wires eliminates the need to have to
manipulate flux (SAW) and gases (MIG/MAG) and weld outdoors.

From the above, it can be deduced that the FCAW process combines advantages over other processes.
as coated electrode (SMAW), MIG/MAG (GMAW) and submerged arc (SAW).

1.2. Limitations of the process

The limitations that may restrict its application are:

The process produces slag that needs to be removed. This can be a drawback,
compared to welding with MIG/MAG wires (GMAW) without slag, due to the cost per
need time to eliminate it between passes, especially in the root pass and in
robot welding where the slag would cause problems with the clamping tools
of the pieces to be welded.

Due to containing flux and slag formers inside, its efficiency is lower than that of the
solid wires.
It does not allow welding of all metals like other processes. It is mainly limited to
ferrous metals and nickel alloys.
The equipment is more expensive and complex than that of the shielded metal arc welding (SMAW) process.

It needs to bring the feeder and group close to the welding site.
For the version of the type of wire that needs gas protection, its use is limited.
for welding outdoors due to the wind being able to displace the projection gas.
It generates a greater volume of fumes when compared to the GMAW and SAW processes.

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2. TYPES OF TRANSFER

In solid wire welding, when the intensity is increased, when passing the
transfer from short arc to long arc, it goes through an intermediate arc transfer
globular, which is not usable for welding due to the many projections it causes (especially
when the gas used is CO2In metal cored wire welding, by increasing the
intensity and increase the current density, the outer steel tube is melted first and
The metallic powder inside flows in the form of fine droplets within the melting bath. The
intensity to achieve long arc transfer is higher with solid wire than
with metal cored.

With tubular wires with flux inside (Flux cored Arc Wires), it is not possible to achieve a
authentic long-arc transfer, but depending on the composition of the flux, it may be possible
achieve an 'almost' long-arc transfer. The rutile-type tubular wires are capable
to operate in this type of transfer almost like a long arc with low intensities. The wires
tubulars with basic type gas and self-protected ones do not operate with this type of "almost"
long arch transfer. (table 1).

Table 1. Types of transfer for different types of solid wires, metal cored, and wires
tubular.

Process Arch Arch Long arch Arch

short spherical pressed

MIG (Metal Inert Gas)

FCAW GS (Flux-Cored Arc Welding Gas Shielded)

It is not totally
tubular wire with gas
long arch
protection

FCAW SS (Submerged Arc Welding)

wire tubular car

protected - without gas from

protection

Metal Cored (Welding with

tubular wire without flux in
the interior–without slag

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3.EQUIPMENT

The equipment used has the same characteristics as those used in welding.
MIG/MAG (GMAW) are constant voltage and constant current power sources.
(flat characteristics). Most of the equipment is below 500 A (figure 4).

(A) (B)

(C)

Figure 4. (A). Installation diagram and (B and C) installation photos with independent feeder and
compact installation

The wire feeder and the rollers are two of the critical points. If already in the process
MIG/MAG (GMAW) with solid wire, these components are important in the process
FCAW is more so because it is a tubular wire. The feeder is not essential that
it has 4 rollers, but higher quality equipment carries them (figure 5D).

To prevent the rollers from crushing the tubular wire, the lower roller is usually in a 'U' shape and with
stripes to improve the drag and the adjustment pressure must be monitored to avoid deformation
the wire and cause drag problems in the spiral conduit or at the contact tip
(figure 5A).

An accessory used in applications with tubular wires that present difficulties.

In the hauling, it is the straightener (figure 5C) that presents the following advantages:

Reduce the tension that the wire has while in the coil.
It reduces the friction that occurs in the spiral duct, making the work easier.
push of the rollers.
Facilitates the tracking of the wire end through the joint.

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(A) (B) (C)

(D) (E)

Wires masses Wires massive wires tubular.

carbon steels e soft Aluminum. Bottom roller with
stainless Roller Roller inferior y stripes.
inferior with guide in 'V' superior with guide in
y upper roller U
plan.

Figura 5. (A)Esquematización del ajuste del hilo con rodillos, (B) Rodillos, (C) Enderezador, (D)
Feeder with 4 rollers and coil protector and (E) types of rollers suitable for each application

The torches for semi-automatic welding are designed to make it easier for the welder.
manipulation, but at the same time they must be resilient enough for the application.
They can be air-cooled or water-cooled. Water-cooled torches are more
compact and light, maintaining lower temperatures, which leads to a greater
duration of the spare parts (nozzles, diffusers, and contact tips). For an application
Determined, the intensity is the fundamental variable for the decision to use a torch.
air-cooled to water-cooled and usually range between 500 and 600 A. Other factors that
they can be influenced by the utilization factor to which the torch and the shielding gas are subjected
employee (in the case that the application is with protective gas).

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(A) (B)

(C)

Figura 6. (A) Esquema de soplete para alambre flux cored autoprotegido, (B) Boquilla con tubo guía
isolated for welding torch with self-shielded wire and (C) diagram of cooled torch
air for flux cored wire with shielding gas

Self-protected wires require a minimum wire length to generate the gases.

necessary to provide protection to the welding. For this type of wires, the
soldering iron generally has an insulated guide tube with sufficient length to ensure
minimum length of wire needed (figure 6C).

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4. PROTECTIVE GASES

Carbon dioxide (CO2It is the most used gas in the FCAW process when heated by
The electric arc at high temperature dissociates into carbon monoxide (CO) and oxygen (O)2).
Oxygen combines with the deoxidizers carried by the wire.

Reaction 1

Iron Fe reacts with CO2producing iron oxide and CO2.

Reaction 2

At high temperatures, CO also dissociates into carbon and oxygen.

Reaction 3

This carbon will affect, increasing the carbon content of the bath, if it has %C < 0.05 or
decreasing the carbon content if the bath has %C >0.10. The loss of carbon is
attributes to the formation of carbon monoxide (CO) and when this reaction occurs, the
carbon monoxide can become trapped in the form of pores.

Argon mixtures with 20 or 25% CO2they are also very used, they provide a
reduction of fumes, better transfer characteristics, and welding with higher strength
the elastic limit than those made with CO2also improving the stability of the arch and its
sellability.

It is always advisable to consult the thread manufacturer's information, as just as

they use a large number of tubular wires that have been designed to be weldable
both with CO2 and with a mixture of argon and 20 or 25% CO2, there are also some that have been
designed to be welded exclusively with CO2 and if welded with a mixture of argon with 20 or 25
% of CO2may contain manganese, silicon, and other materials in the fusion bath
deoxidants are very high and affect the mechanical properties. This is especially
important in multi-pass welding.

Argon-oxygen mixtures are not generally used with tubular wires with
flux because it would affect the slag.

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 Table 2. Gas selection guide for the process with tubular wire (FCAW)

Metal Denomination Characteristics

Ar-20% CO2 It is the most suitable mixture for welding with flux-cored wires.
cored, although you need to have information from the thread manufacturer. In
M21 Generally, good weldability and slag detachment are achieved.
Little loss of elements, good shape of the cord, low level of smoke and
Carbon Steel and Low Ar-25% CO2 splashes. It favors welding in all positions.
Alloy

To be used with the wires specially designed by the manufacturer for

CO2 C1 use with CO2Wider penetration, higher levels of smoke and
splashes and greater loss of elements than with Ar-CO mixtures2.

Ar-20% CO2 They are the most suitable mixtures for welding with flux-cored wires.
cored, although it is necessary to have the information from the thread manufacturer. In
M21 In general, a good weldability and slag removal is achieved.
Little loss of elements, good shape of the cord, low level of smoke and
Ar-25% CO2 splashes. It favors welding in all positions.
Stainless steels

For use with the wires specially designed by the manufacturer for
CO2 C1 use with CO2. Wider penetration, higher levels of smoke and
splashes and greater loss of elements than with Ar-CO mixtures2.
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CONSUMABLES

The selection of the appropriate consumable for an application should aim to produce
a metal solder with two basic characteristics:

Having mechanical and physical properties equal to or superior to those of the base metal or
to provide the base metal with some improvement, such as corrosion resistance or strength
to wear. A welded metal even with the same composition as the base metal will have
some metallurgical characteristics that will depend on factors such as thermal input and the
cord configuration.
Obtain a quality soldered metal. This will be achieved with a suitable wire, which
in the case of a tubular wire (FCAW) it may:
Favor with the slag, welding in the position that is most suitable or
thank you for the application.
Allow better than solid wires, with the flux and the slag that forms,
able to weld on surfaces with possible dirt or oxidation.
Make welding possible in the outdoors, generate gases that eliminate the influence of
air in the bathroom and in the area affected by the heat.
Achieve a reduction in costs

5.1. Manufacturing of tubular wires

The production of flux-cored wires allows for great versatility due to the great
variety of components that can be included within the tubular wire. The electrode
it usually consists of a low carbon content carbon steel tube, carrying
inside the alloying elements and the flux. The composition of the flux may vary according to
with the classification of the wire and the technology of the company that manufactured it.

Most of the tubular wires are part of a flat band (figure 7A) that passes through
the rollers first transform it into a 'U' section that is then filled with the
alloying elements and with the flux with the appropriate dosage (figure 7B), it is passed through
successive types of rollers that close, compress the tube and finally stretch and reduce it to
final diameter. Depending on the type of rollers that perform the closure of the tube and the final stretching,
Different sections of tubular wires (C) can be available.

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(A) (B)

(C)

Figure 7. (A) Initial band, U-shaped section, (B) filling of alloying elements and flux, and (C) different
sections of tubular wires

Each manufacturer of tubular wires develops its own technology to through a

appropriate selection of the components inside the wire and in combination with the
composition of the metal tube to achieve:

Produce the range of tubular wires necessary to cover the applications that
they can achieve high deposition speeds in horizontal position or
special for "roof" welding or universal with intermediate characteristics of
deposition speed and welding to "ceiling".
Produce tubular wires that can be used with gas, with CO.2or with mixtures of
argon, or gas-free, self-protected.
Vary the composition of the soldered metal, with reduced costs, from carbon steels.
up to stainless steels.

5.2. Functions of the flux

By adjusting for proper composition, it facilitates mechanical properties.

metallurgical and corrosion resistance.
Forming quality welds by helping to protect the welded metal from the influence of
oxygen and nitrogen from the air.
To produce a refinement in the molten metal, carrying the impurities to the slag.

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Produce the slag, necessary to protect the metal that is solidifying from the air and
control the type of bead in the different welding positions for which the
the wire is designed.
Stabilize the arc, allowing for a metal transfer without projections that facilitates
a uniform deposition with the appropriate cord size.

5.3. Identification of carbon steel wires.

In the welding of low carbon steels and low alloy steels, it is necessary that there is
an appropriate relationship of oxidizing and denitrifying elements (in the case of the wires
self-protected tubulars) in order to produce joints with the appropriate ductility and toughness.
Deoxidizers such as silicon and manganese combine with oxygen to form oxides.
established. This helps control the loss of alloying elements through their oxidation, and
the formation of CO that could cause porosity. The denitrifying elements, such as
aluminum combines with nitrogen and fixes it as stable oxides. This prevents porosity
due to nitrogen and the formation of nitrides that could be harmful. Table 3 includes
the most commonly used elements in a tubular wire with flux, the way in which it is present and the
function they perform within the flux.

The components that carry these wires inside are what establish the difference.
fundamental with the GMAW process, they are responsible for providing the necessary elements
for:

Provide the mechanical or metallurgical properties for each application.

Provide the necessary alloying elements, as the outer wire is usually made of
steel almost free of carbon.
Refining and desoxidation of the welding.
Produce the appropriate slag for cord protection and to assist in welding.
the different positions for which the wire is suitable.
Stabilize the arc and protection of the welding.
Contribute the metal powder filler that improves the gravimetric performance of the wire.
In self-protected wires (without shielding gas), they generate their own as they melt.
protective atmosphere.

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Table 3. Function of the elements that make up the flux of a tubular wire (FCAW)

Elements Form in which it is present Function that performs

Aluminum Metal powder. Deoxidizer and denitrifying agent

Minerals such as calcium fluoride (CaF2) y
Soccer Protection and slag trainer
calcium carbonate (CaCO)3).
Element contained in
Carbon ferroalloys as Increases hardness and resistance
ferromanganese.
Improve the property of maintaining the
Chrome Ferroalloys or metal powder resistance with temperature, hardness,
mechanical resistance and resistance.
Alloy matrix in iron base deposits,
Iron Ferroalloys and iron powder nickel-based alloys and other deposits
non-ferrous.
Deoxidizer; prevents cracking in
Ferroalloys such as hot, combining with sulfur to
Ferromanganese or as powder to form manganese sulfide (MnS);
metallic increases hardness and strength; trainer
of scoria.
Addition to increase hardness and
resistance, and in stainless steels
Molybdenum Ferroalloys
austenitic, increase corrosion by
sting.
Alloying agent to increase hardness,
Nickel Metal powder resilience, tenacity, and resistance to
corrosion.
Minerals such as feldspar or silicate
Potassium It stabilizes the arc and is a slag former.
potassium
Ferroalloys such as ferrosilicate or
Silicon silicomanganese; minerals such as Deoxidizer and slag former.
silicates and feldspars.
Sodium Minerals such as feldspar and silicates Arc stabilizer and slag former
Deoxidizer and denitrifier; forming of
Ferroalloys such as ferrotitanium; in
Titanium slag; stabilizes carbon in some steels
mineral, rutile
stainless.
Deoxidizing and denitrifying; forming of
Zirconium Oxide or metallic powder
slags.
Vanadium Oxide or metallic powder Increase the resistance

5.4. Identification of tubular wires

In table 4, the most commonly used standards and some examples of designations can be observed.
of tubular wires (FCAW).

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Table 4. Most used standards in the designation of tubular wires (FCAW).

Process FCAW

UNE-DIN EN ISO
136
4063:2011

METAL CARBON STEELS

ASME II PART C
UNE-DIN EN ISO 17632 A SFA 5.20/
SFA 5.20M

T 46 2 PM 1 H5 E71 T1 MJH4

T 42 4 BC(M) 2 H5 E70 T5 MJH4

METAL LOW ALLOY STEELS

ASME II PART C

UNE-DIN EN ISO 18276 SFA 5.29/

SFA 5.29M

T55 4 1NiMo B M(C) 2 H5 E90 T5 GC(M) H5

METAL CHROME-MOLYBDENUM STEELS

ASME II PART C

UNE-DIN EN ISO 17634 SFA 5.29/

SFA 5.29M

T CrMo2 BC(M)2 H5 E 80 T5 B3C H4

METAL STAINLESS STEEL

ASME II PART C

UNE-DIN EN ISO 17633 A SFA 5.22/

SFA 5.22M

T19 9 L R M(C) 3 E308LT0-4

Table 5 shows a summary of the specification of ASME II Part SFA 5.20 E in case of doubt.
The complete specification should be consulted and Table 6 shows an example of a designation.
of a tubular wire.

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Table 5. Summary of the specification of ASME II Part SFA 5.20 for tubular steel wires
carbon

The most important characteristics of an EXXT-1 wire are to have a slag type
rutiles that completely cover the cord and have a high deposition rate. It can
to be used with CO2or with a mixture of 20-25% CO 2and the rest argon. According to the manufacturer, the
argon - CO mixture2welding in position must improve. The increase of argon gas in the
mix produces an increase of manganese and silicon in the welded metal that will result in a
increase in the elastic limit that can affect impact values. They are designed to
welding with a single pass or multiple with CCEP (direct current electrode at the pole
positive). The wires classified as EX0T-1 are used for welding with a single
past or multiple in butt joints horizontally and angle joints in cornice position. The
wires classified as EX1T-1 are used for welding in all positions. The
EXXT-1 wire has a transfer like a long arc, with hardly any projections and with a
slightly convex cord

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Table 6. Example of designation for carbon steel tubular wire according to ASME II
SFA Part 5.20

The most important features of an EXXT-5 wire are its ability to have a
basic slag that produces welds with certain impact values and a resistance.
superior to the cracking in cold and hot superior to that of EXXT-1 type wires with slag
Rutile type. It can be used with CO.2or with a mixture of 20-25% CO2and the rest argon that would reduce the
projections. The wires classified as EX0T-5 are used for welding with a
single past or multiple in butt joints horizontally and angle joints in cornice position.
The transfer is globular and the cord is slightly convex. According to the manufacturer,
argon - CO mixture2It must improve the welding in position. The increase of argon gas in the
mix produces an increase of manganese and silicon in the welded metal that will result in a
increase in the elastic limit that can affect impact values. The wires EX1T-5
connected to CCPN can be used in all positions, but the solderability is lower than the
from the EX1T-1 rutile type wires.

Table 7 shows a summary of the UNE-DIN EN ISO 17632 A standard and an example of it.
designation of a tubular wire. In case of doubt, the specification should be consulted
complete.

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Table 7. Example of designation of carbon steel tubular wire according to UNE-EN ISO
17632 A

6.PROCESS PARAMETERS

6.1. Intensity

For a tubular wire of diameter, composition, and length of wire, the intensity is
proportional to the wire feed speed. In figure 8 and figure 9, it can
observe this relationship between the wire feed speed and the intensity for
carbon steel wires with shielding gas and without shielding gas respectively.

Using a constant potential rectifier and maintaining the voltage (arc length), if
the rest of the variables are kept constant, for a given wire diameter, a
an increase in intensity would produce:

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An increase in the deposition speed.

An increase in penetration.
An excess of intensity would produce a convex cord with a poor appearance.
A low intensity can lead to poor goal transfer and excessive
splashes.

Figure 8. Variation of wire feed speed with welding intensity for

a tubular wire E70T1 and with CO shielding gas2

Figure 9. Variation of wire feed speed with welding intensity for

a self-protected tubular wire

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6.2. Voltage

The voltage and the length of the arc are closely related. The voltage that can be read
in the equipment is the sum of the voltage drop across the welding circuit, which
includes the drop through the welding cable, the wire length, the arc, the metal to be welded
and the mass. The voltage affects the appearance of the cord and its properties. Too much voltage
(too long arc) can lead to wide cords, with irregular shape and excessive
projections. With self-protected wires, a too long arc may take in the
a excessive amount of nitrogen, which can cause porosity in steels when
carbon. With stainless steels, excessive nitrogen intake can reduce the content
of ferrite of the solder metal and give rise to cracking. A voltage that is too low (arc
too short) can lead to a convex, narrow cord, with low penetration and with
excessive projections.

6.3. Wire length

The length of wire is the distance between the end of the contact tip and the end of the
wire and the adjustment must be different, depending on the process used (figure 10). It is a
important variable because it affects the arc energy, the deposition speed (Kg/h), to the
penetration, to the stability of the arch and to the quality. In general, the recommendations of the
manufacturers of tubular wires are from 20 to 35 mm for gas-shielded wires and
from 30 to 60 mm for self-protected ones (without gas). In these last ones, some may be necessary.
minimum wire lengths required to achieve good protection. The torches
for these self-protected wires, they can carry an insulated guide tube to maintain
these elevated lengths of wire (figure 6B).

Figure 10. Wire length

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6.4. Wire feed speed

The wire feed speed influences the penetration and the contour of the
cord. Keeping the rest of the variables constant, penetration at low speeds is more
higher than high welding speeds. If low welding speeds and high are used
intensity, overheating of the sheet can occur or it can be perforated. Speeds of
Excessive welding can lead to irregular beads.

6.5. Gas flow

The gas flow affects the quality of the welding; if it is scarce, there will be poor protection.
bath and the result will be a weld with pores and oxidized. If the flow is very high, they can
turbulence will originate that mixes air with the protective gas and then the quality will be affected
equally affected. The flow that is necessary to use with a tubular wire with a
the determined diameter must be 10-20% higher than that used with the same diameter with a
solid wire. This is due to the fact that higher speeds are generally achieved.
deposition and using longer wire lengths, having the gas nozzle higher
separated from the welding. The correct gas flow will depend on the type of:

Welding material. A wire for stainless steel welding should be used lightly.
higher flow rate.

Wire diameter. The larger the diameter of the wire, fusion baths will be formed.
higher, that would require greater gas flows.

Intensity. The greater the welding intensity, the greater the gas flow must be.

Nozzle diameter. The larger the nozzle diameter, the greater the gas flow.

Wire length. The gas flow must be greater.

Welding outdoors. If welding outdoors with FCAW wire with gas, in addition to
enable the welding area so that air does not carry away the shielding gas, it should be used
a conical nozzle and a higher flow rate.

6.6. Deposition speed

The deposition rate is the weight of material deposited per unit of time. It depends on
welding variables such as wire diameter, wire composition, length of
wire and welding intensity.

In figure 11 and figure 12, the relationship between the deposition velocity and the
intensity for tubular wires of various diameters with and without protection gas
respectively.

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The deposition efficiency is the ratio between the weight of the deposited metal and the weight of the metal.
consumed. The deposition efficiency of FCAW tubular wires is in the range of 80
90% for gas-protected wires and in the range of 78 to 87% for the wires.
self-protected.

Figure 11. Variation of wire feed speed with intensity for a wire
carbon steel E70T-1 and with CO2as a shielding gas

Figure 12. Variation of wire feed speed with intensity for a wire of
self-protected steel

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6.7. Torch angle with the welding direction

It is the angle that the tubular wire forms with the welding direction. It determines the direction.
in which the force of the arc is applied to the fusion bath. This angle is especially
important in overhead and vertical welding to counter the force of the arc against gravity. In the
welding with tubular wire FCAW and with coated electrode SMAW, the strength of the arc not only
it is used as an aid to obtain the required type of lace, it also helps to avoid
that the slag gets ahead of the welding bath and can become trapped in the welded metal.

For horizontal welding, it can be seen in figure 13A that the angle must be 10°-20° with
the vertical.

For angle welding, in eaves position, the angles must be 45° with respect to vertical.
and from 70 to 80° with respect to the direction of advance of the welding (figure 13C).

(A) (B)

(D)

Figure 13. (A) Torch position in horizontal welding, (B) torch position in the
downward and upward vertical welds and (C) torch position in corner welding
cornice

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For downward and upward vertical welding, the angles concerning the
perpendiculars can be on the order of 10° (figure 13B).

7.DESIGN OF JOINTS

In general, the preparations used for welding with coated electrode are
applied for welding with tubular wire FCAW with both types of wires, with gas of
protection and self-protected. When a specific design of the joint needs to be made for the
tubular wire welding, there may be some differences between the two processes of
FCAW welding, with gas and without protection gas and with the coated electrode procedure
SMAW.

7.1. Design of joints for tubular wires FCAW with gas

protection for carbon steels

In general, compared to the shielded metal arc welding (SMAW) process, using
tubular wires FCAW with protective gas, the joints must be designed to be used with the
advantage of being able to achieve penetration by using high current densities. It
they can use preparations with narrower angles, larger margins, and separations
narrower roots.

For the designs of butt joints, the following points must be taken into account:

The design of the joint must allow the wire length to remain constant during the
successive passes of the union.

The design of the joint must allow the root to be accessible and the torch and the wire to be able to
easily manipulated during welding.

Table 8 contains the most commonly used designs and welding procedures for wires.
tubulars with FCAW gas of carbon steels.

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Table 8. Type of joint and parameters for FCAW gas (EXXT-1) tubular wire for steels
carbon and low alloy.

7.2. Design of joints for self-shielded FCAW tubular wires,

for carbon steels

The types of joints for the gas-shielded FCAW processes and coated electrode SMAW
they are generally also suitable for the self-shielded FCAW process. There may be
differences in specific preparations that allow for taking advantage of special characteristics
of self-protecting wires, with high deposition speed and lower penetration.

The maximum length of wire for self-protected wires must be taken into account for
to have an adequate penetration in the root. In table 9 are the most commonly used designs and the
welding parameters for self-shielded FCAW tubular wires of carbon steels.

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Table 9. Type of joint and parameters for self-shielded tubular wire made of carbon and low alloy steels
alloy

a. (P) Polarity: + electrode to positive; - electrode to negative

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Table 10. Type of joint and parameters for self-shielded FCAW tubular wire for steels.
carbon and low alloy. (Continuation)

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8. QUALITY

8.1. Storage of spools

The manufacturer's instructions must be followed and may vary depending on whether it is a wire.
tubular with basic shielding gas or rutile or self-shielded, Generally, they must
follow the following recommendations:

They must be stored under the right conditions to keep the levels low.
moisture and prevent oxidation from occurring on the surface of the wire, which
it may hinder its dragging or produce welds with hydrogen content not
permissible for the wire specification.
They must be kept in their original packaging and their breakage can seriously reduce the
time for its use.
Storage time should be as short as possible.
They should not be stored for more than a year.

8.2. Handling of open packaging.

The coil should be consumed as soon as possible, preferably within the day. It should always be
stay in a dry place while in use. Wires should not be left in the
welding machines or outdoors for long periods of time, especially during
the night since the condensation of air moisture could occur on the surface of
wire. For example:

For a relative humidity of 50%, if the difference between the air temperature
and if the coil is above 10 °C, the humidity would condense on the coil.
For a relative humidity of the air of 70%, if the difference between the air temperature
and if the coil is more than 5 °C, humidity would condense on the coil.

Therefore, to avoid condensation it is necessary to control both the air temperature

as the relative humidity. In the case that the coil has been consumed during the day of
work must be placed in the original packaging and stored at temperature conditions
controlled humidity.

It is not always the moisture in the tubular wire that causes the presence of hydrogen.
Welding, other sources such as oils, paints, markings, or others should also be avoided.
Substances that can release hydrogen with the electric arc.

The wires that are rusty or have been exposed to possible moisture uptake.
for a long period of time, they must be discarded.

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8.3. Defects

Discontinuities in FCAW are like in most fusion welding processes,

the main cause of the origin of defects and these are due to an inadequate:

Preparation, arrangement, or cleaning of the pieces to be joined.

Execution of the welding

Weldability of the base metal
Selection of consumables (gases, filler metal.....)

The UNE-EN ISO 6520 standard classifies the defects produced by fusion welding into the
following groups:

Cracks or fissures
Blowouts and pores
Solid inclusions, (slag, oxides, tungsten inclusions, copper.)
Lack of fusion
Imperfectiоns of shape and dimension (bite, overlap, overthickness)
excessive, excessive penetration, incorrect oversize angle, lack of alignment
angular deformation, lack of welding metal, drilling, shrinkage, excess of
asymmetry in angle welding, irregular width and irregular surface, joint
defective
Other imperfections. (Arcing bleed, splashes or projections, local tearing,
grinding mark or engraving mark, excessive grinding

Table 11 summarizes the main imperfections that arise in welds with the
FCAW process.

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Table 11. Main defects in FCAW welding, cause and corrective action

Defect Cause Corrective action

Increase gas consumption

Low gas flow
Clean splashes from the nozzle.
High gas flow Reduce flow to eliminate turbulence
Wind Protect the welding area
Check the gas supply, cylinder,
Contaminated gas tank.
Check the gas circuit.
Contaminated metal base Clean the welding area.
Porosity Remove oils and contaminating substances.
Wire contamination
Check for possible moisture.
Lack of flow inside the
Change the wire
wire.
Excessive voltage Adjust the voltage
Excessive wire length Adjust wire length and intensity.
Insufficient wire length
Adjust wire length and intensity.
self-protected wires
Excessive welding speed Adjust speed
Direct the wire correctly to the root of the
Bad manipulation
union.
Increase the intensity.
Reduce the welding speed.
Missing of
Reduce the length of wire.
fusion o Incorrect parameters
Reduce the diameter of the wire.
penetration
Increase the welding speed
(self-protected wires).
Increase the opening at the root.
Poor design of the union
Reduce the heel.
Reduce bracing.
Excessive embedding in the Preheat.
union. Use a wire with greater ductility.
Cracking Relieve tensions.
Inappropriate wire
Lack of deoxidizers or flux in the Check the wire and type of flux
wire

Excessive wear of the tip of

Reduce the pressure on the rollers.
contact.
Bad
nutrition Reduce the voltage.
Contact point and wire
of wire Adjust the current delay.
fused.
Replace the worn spiral duct

Dirt in the spiral duct. Change or clean the spiral duct with air

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9. SECURITY

The safety measures for the FCAW process are analogous to those of GMAW, regarding the
handling of electrical equipment, handling of gases, with FCAW wires that need them and to
use of heat-resistant clothing and special protective equipment. Helmets must be worn
appropriate crystals for the level of intensity.

The generation of smoke for FCAW welding is similar to that produced by the amount of metal.
deposited in the shielded metal arc welding (SMAW) process, but since the deposition rate with
tubular FCAW wire is several times that of GMAW, the generation of smoke in grams per
minutes, it is much higher than that of SMAW. It is important to verify that the concentration of
smoke remains below the permitted exposure limit values.

The places to look for information about the indices that should not be exceeded are:

INSHT (Institute of Safety and Hygiene at Work). The list of adopted limit values
will be expanded and reviewed, at least annually, based on the needs posed by the
changes in production processes and the introduction of new substances, of the new
technical and scientific knowledge, as well as the evolution of the legal framework in which
apply.

OSHA (Occupational Safety and Health Administration)

ACGIH (American Conference of Governmental Industrial Hygienists).

The change that can occur in the formation of smoke when at a workplace is
change from one welding procedure to another, for example from GMAW welding with wire
FCAW solid with tubular wire with shielding gas, it can be important, in figure 14A
A comparison between different processes can be observed, and in figure 14B, the formation
of smoke depending on the intensity and with different processes.

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(A) (B)

Figure 14. (A) Comparison of smoke generation speed with different processes and (B)
smoke formation as a function of welding intensity with different processes

10.COSTS

A large number of applications where FCAW wires are used come from the
replacement of GMAW welding. From a cost perspective, generally speaking, it can be
to say that per unit of length, the cost of the GMAW process is more economical than FCAW
although there may be factors such as thickness, welding position, and critical aspects of the
union that can change the decision towards FCAW wires. From the point of view of
costs, it should be considered that the GMAW process would produce fewer spatter, especially
with a long bow, but it is limited to the horizontal position and the drawn bow or the short bow,
it would have a lower deposition rate. In the FCAW process, it would be necessary to take into account the
advantage of a higher deposition speed and the possibility of being used in all the
positions, but due to producing slag, it is necessary to account for the cost of the time spent removing it and having
Keep in mind that these wires have lower efficiency. The slag causes these wires
they are not usable for robotic welding. According to the above, in Figure 15
You can observe a cost calculation between the GMAW and FCAW processes for a welding in
angle with a 6 mm throat, wire diameters of 1.2 mm, arc time of 0.45 and
0.40 and efficiencies of 0.97 and 0.87 respectively.

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GEOMETRY OF THE UNION

EXIT i PROTECTION GAS COST (€ / m)

PROCESS SELECTION PROCESS1 PROCESS2
WELDING PROCESS MAG MAG
PROTECTION GAS Ar-8%CO2 Ar-20%CO2
0.25
FORM OF SUPPLY
0.20
a.- GAS PRICE (€ / m3) 5.5 4.5
b.- GAS FLOW (l/min.) 1 14 16 0.15

Welding speed (cm/min) 2 3 4 5

31 37.8 0.10
PARAMETERS
PARAMETROSTIG
MIG/MAG 0.05

TOTAL PROTECTION GAS COST (€ / M) 0.25 0.19 0.00

ABOUT TOTAL 5.04 3,90 Ar-8%CO2 Ar-20%CO2

MAG MAG
a (€/m3) x b (l/min.) 0
WELDING PROCESS
----------------------------------------
c (cm/min) x 10
WELDER COST (€ / m)

LABOR

4.20
a.- LABOR + OVERHEAD COSTS (€ / h) i 35 35
4.10
b.- ARCH TIME (%) ARCH TIME i 0.45 0.4 4.00
WELDING SPEED (cm/min.) 31 37.8 3.90
3.80
TOTAL LABOR COST (€ / M) 4.18 3.86 3.70 4
ABOUT TOTAL 84.83 79.00 3.60
Ar-8%CO2 Ar-20%CO2
a (€/h) x 100
MAG MAG
-------------------------------------------- WELDING PROCESS
b (%) x c (cm/min.) x 60

CONSUMABLE COST (€ / m)
CONSUMABLES

a.- PRICE OF CONSUMABLES (€/Kg) 1.4 2.1

b.- CONSUMABLE EFFICIENCY (%) 7 i 0.97 0.87 0.90
c.- METAL SOLDIER (Kg/m) 8 9 10 11 i 0.35 0.35 0.80
0.70
0.60
TOTAL COST OF CONSUMABLES (€/m) 0.50 0.84 0.50 1
ABOUT TOTAL 10,13 17.10 0.40
c (Kg/m) x a (€/Kg) 0.30
0.20
---------------------------------------- 0.10
b (%) 0.00
Ar-8% CO2 Ar-20%CO2
MAG MAG

TOTAL COST (€ / m) 4.93 4.88 Welding process

TOTAL COST (€ / m)
PROCESS1 PROCESI2

Ar-20%CO2 Ar-8%CO2 5.00

PROTECTION GAS (€/m) 0.25 0.19 4.50
4.00
LABOR (€/m) 4.18 3.86
3.50
CONSUMABLES (€/m) 0.50 0.84 3.00
TOTAL COST (€ / m) 4.93 4.88 2.50
2.00
1.50
1.00
0.50
0.00
Ar-8%CO2 Ar-20%CO2

MAG MAG
WELDING PROCESS

EXIT

Figure 15. Cost comparison between GMAW and FCAW processes

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