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Flux Core Arc Welding (FCAW)

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Flux cored arc welding

FCAW
methods

With gas
shielding Outershield

Without gas
shielding Innershield

With metal
powder Metal core

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Outershield - principle of operation

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Innershield - principle of operation

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ARC CHARACTERISTICS
Constant Voltage Characteristic
Small change in voltage =
large change in amperage

OCV
Large arc gap
Small arc gap

The self
adjusting arc.

Volts

Amps

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Flux
Core Arc Welding (FCAW)

Flux core

Insulated extension nozzle

Current carrying guild tube

Wire joint
Flux cored hollow wire
Flux powder
Arc shield composed of
vaporized and slag forming
compounds

Flux core
wires

Solidified weld
metal and slag

Molten
weld
pool

Metal droplets covered

with thin slag coating

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Flux cored arc welding

FCAW
methods

With gas
shielding Outershield

Without gas
shielding Innershield
(114)

With active
gas shielding
(136)

With metal
powder Metal core

With inert gas

shielding (137)

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FCAW - differences from MIG/MAG

usually operates in
DCEP but some
Innershield wires
operates in DCEN
power sources need to
be more powerful due
to the higher currents
doesn't work in deep
transfer mode
require knurled feed
rolls
Innershield wires use
a different type of
welding gun

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Backhand (drag) technique

Advantages

preferred method for flat or horizontal position

slower progression of the weld
deeper penetration
weld stays hot longer, easy to remove
dissolved gasses

Disadvantages
produce a higher weld profile
difficult to follow the weld joint
can lead to burn-through on thin sheet plates

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Forehand (push) technique

Advantages
preferred method for vertical up or overhead
position
arc is directed towards the unwelded joint , preheat
effect
easy to follow the weld joint and control the
penetration

Disadvantages
produce a low weld profile, with coarser ripples
fast weld progression, shallower depth of penetration
the amount of spatter can increase

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FCAW advantages

less sensitive to lack of fusion

requires smaller included angle compared to MMA
high productivity
all positional
smooth bead surface, less danger of undercut
basic types produce excellent toughness properties
good control of the weld pool in positional welding
especially with rutile wires
seamless wires have no torsional strain, twist free
ease of varying the alloying constituents
no need for shielding gas

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FCAW disadvantages
limited to steels and Ni-base alloys
slag covering must be removed
FCAW wire is more expensive on a weight basis
than solid wires (exception: some high alloy
steels)
for gas shielded process, the gaseous shield may
be affected by winds and drafts
more smoke and fumes are generated compared
with MIG/MAG
in case of Innershield wires, it might be necessary
to break the wire for restart (due to the high
amount of insulating slag formed at the tip of the
wire)

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FCAW advantages/disadvantages
Advantages:

Disadvantages:

1) Field or shop use

1) High skill factor

2) High productivity

2) Slag inclusions

3) All positional

3) Cored wire is
Expensive

4) Slag supports and

shapes the weld Bead
5) No need for shielding
gas

4) High level of fume

(Inner-shield)
5) Limited to steels
and nickel alloys