FLUX CORED
ARC
WELDING
(FCAW)
Objective:
SWBAT to identify and describe the FCAW
process.
Trade Terms
Arc- In Welding the electric arc is produced when
the welding current is forced to jump a gap and
pass through the air. The air has a high resistance
to electrical flow causing the high temperatures,
in excess of 10,000 degrees F, need to melt the
base materials.
Flux-The role of a flux in joining processes is
typically dual: dissolving of the oxides on the
metal surface, which facilitates wetting by molten
metal, and acting as an oxygen barrier by coating
the hot surface, preventing its oxidation.
Trade Terms
Shielding- In welding shielding is the act of
protecting the molten weld metal from
atmospheric contamination. Shielding can be
achieved by a shielding gas or by a flux.
Electrode- In arc welding an electrode is used
to conduct current through a work piece to fuse
two pieces together. In FCAW the electrode is
consumed as part of the completed weld.
The Flux Cored Arc Welding
Process
As defined by the American Welding Society
(AWS), flux cored arc welding (FCAW) is an
electric arc welding process that fuses metallic
parts by heating them with an arc between a
continuously fed, consumable, flux cored
electrode and the work. Primary shielding for
the molten weld metal is obtained from the
fluxing ingredients within the tubular electrode
that are deposited as slag on top of the weld.
The flux cored electrode may be supplemented
by an external shielding gas.
SELF-SHIELDED FCAW
FCAW Process Types
There are two process types used for the deposition of
metal.
Self Shielded – All of the fluxing ingredients required for
the proper transfer of the filler material and shielding of
the molten pool are included in the core material.
Gas Shielded – A shielding gas is used in addition to the
shielding from the flux core. Carbon dioxide (CO2) can be
used alone or with Argon (Ar) in a specified mixture to
shield the molten weld metal from outside atmosphere.
Modes of operation
FCAW can be done in one of two ways.
Semi-automatic- where the weld is made using
FCAW equipment and a manual welding gun.
Automatic- The weld is made using specialized
equipment and controls that are monitored by
the machine operator.
FCAW Equipment
Power Supply
The power supply provides the welding current
needed to melt the base metal and the
electrode.
FCAW uses two types of welding current.
Direct Current Electrode Negative (DCEN) for self
shielded FCAW
Direct Current Electrode Positive (DCEP) for gas
shielded FCAW
FCAW Equipment
Wire Feeder
The wire feeder is the device that feeds the
required amount of filler material at a fixed
rate of speed throughout the welding
operation.
FCAW EQUIPMENT
GUNS
The gun is held by the welder during the
welding operation. It is at the tip of the gun
where the electrical current is transferred to the
filler material. The gun trigger controls the start
and stop operation of the machine.
GAS-SHIELDED FCAW
EQUIPMENT
SELF-SHIELDED FCAW
EQUIPMENT
FCAW Advantages
High productivity
Deep penetration
High quality welds
All position welding
Tolerates contamination better than GMAW
More suitable for field work than GMAW
Combines the advantages of SMAW (good
shielding) and GMAW (high productivity)
FCAW Disadvantages
Slag to contend with during welding
Slag removal
Smoky process (esp. self shielded)
Electrode cost
Equipment complexity
FCAW Discontinuities
Slag inclusions
Porosity
Incomplete fusion
Incomplete joint penetration
FCAW Applications
General fabrication of steel and stainless steel
Structural steel fabrication
Pressure vessels for gasses and liquids
Heavy equipment fabrication and repair
Surfacing components to protect against wear.
Hardfacing
Maintenance and repair
Review Questions
EXXT-X
FCAW Electrode Classification System
Electrode
EXXT-X
FCAW Electrode Classification System
Minimum Specified Tensile Strength
EXXT-X
FCAW Electrode Classification System
Welding Position(s)
EXXT-X
FCAW Electrode Classification System
Tubular
EXXT-X
FCAW Electrode Classification System
Chemical Composition
Operating Characteristics
Typical FCAW Classification
E71T-1
Stainless Steel Electrodes
Typical Applications
E308T-X - Welding 304 Base Metal
E308LT-X - Welding 304 or 304L Base Metal
E316T-X - Welding 316 Base Metal
E316LT-X - Welding 316 or 316L Base metal
E309T-X - Welding Stainless to Carbon
For Stainless FCAW Electrodes,
the “X” Indicates the Type of Gas Shielding
How Do They Make FCAW Wires
