NAME MOHD ASLAM 11/IME/065

High-quality weld deposit with excellent appearance

Can be used to join many types of metals over a wide thickness range

Relatively high electrode efficiency and process duty cycle

Excellent weld penetration simplifies joint design

The arc is visible and easy to use

Because of its greater tolerance for base plate contamination, Flux Cored Welding requires less pre-cleaning than MIG

Deposition rate is up to four times greater than Stick Welding

The use of self-shielded electrodes eliminates the need for flux handling or gas apparatus, and is more tolerant of windy conditions present in outdoor construction than gas-shielded processes

Flux cored electrodes may be used for welding carbon steels

low alloy high strength steels

high strength quenched and tempered steels

welding stainless steels and abrasion resistant steels

self-shielded - core provides ingredients for shielding

gas-shielded - uses external shielding gases

In the case of dual shielding being used with a flux cored electrode the choices of shielding gasses are limited. The choices are as follows:

CO2 – Carbon dioxide

Ar – Argon

CO2 / Ar – A mixture of the two

Ar / Ox – A mixture of the two

Flux cored electrodes are tubular

Hollow tube with flux in the center

Flux cored electrodes come in standard sizes

As

.035

.045

.052

1/16

Wire feed speed (and current)

Arc voltage

Electrode extension

Travel speed and angle

Electrode angles

Electrode wire type

Shielding gas composition (if required)

Reverse polarity (Electrode Positive) is used for FCAW Gas-Shielded wire, Straight polarity

(Electrode Negative) is used for self shielded FCAW

Mild and low alloy steels

Stainless steels

Some high nickel alloys

Some wearfacing/surfacing alloys

Porosity chances very low

FCAW may be an "all-position" process with the right filler metals (the consumable electrode)No shielding gas needed with some wires making it suitable for outdoor welding and/or windy conditionsA high-deposition rate process (speed at which the filler metal is applied) in the 1G/1F/2FSome "high-speed" (e.g., automotive) applicationsAs compared to SMAW and GTAW, there is less skill required for operators.Less precleaning of metal requiredMetallurgical benefits from the flux such as the weld metal being protected initially from external factors until the slag is chipped awayFCAW requires with or wthout shielding gas

Melted Contact Tip – happens when the contact tip actually contacts the base metal, thereby fusing the two and melting the hole on the endIrregular wire feed – typically a mechanical problemPorosity – the gases (specifically those from the flux-core) don’t escape the welded area before the metal hardens, leaving holes in the welded metalMore costly filler material/wire as compared to GMAWThe equipment is less mobile and more costly as compared to SMAW or GTAW.The amount of smoke generated can far exceed that of SMAW, GMAW, or GTAW.Changing filler metals requires changing an entire spool. This can be slow and difficult as compared to changing filler metal for SMAW or GTAW.Creates more fumes than stick weldingThin plate does not weld by FCAWA slight change in a knob position can make a big difference in the arc

High production rateflux core welding can weld 1/2" plates in a single pass with full penetration on both sidesFlux core welding produces high quality welds, fast and even when in windy conditions.Used in the ship building industry. Ships are made of heavy

plate

E71T-1 (FCAW-G): Highest deposition rates out-of-position.E71T-8 (FCAW-S): Highest deposition rates out-of-position without a shielding gas.E70T-4 (FCAW-S): Highest deposition rates in the flat position.E70T-1 (FCAW-G): Highest deposition rates in the flat position with Charpy properties.E71T-14 (FCAW-S): Fastest travel speed on galvanized and coated steels.E70T-5 (FCAW-G): Fastest way to weld hard-to-weld steels.

Control the heat to weld thin plate

Control the fumes generate in FCAW

Control noise and spatred at time of welding of material

American Society of Safety Engineers, Are Welding Fumes an Occupational Health Risk Facto

Flux Cored Welding." Welding Procedures & Techniques. 23 June 2006. American Metallurgical Consultants. 13 Sep 2006 <http://www.weldingengineer.com/1flux.htm>.

Groover, Mikell P. Fundamentals of Modern Manufacturing. Second. New York City: John Wiley & Sons, INC, 2002.

"Solid Wire Versus Flux-Cored Wire - When to Use Them and Why." Miller Electric Mfg. Co. 13 Sep 2006 http://www.millerwelds.com/education/articles/article62.html

Wikipedia