{"id":123,"date":"2018-01-10T16:24:13","date_gmt":"2018-01-10T16:24:13","guid":{"rendered":"http:\/\/weldnotes.com\/?p=123"},"modified":"2018-02-15T15:11:14","modified_gmt":"2018-02-15T15:11:14","slug":"what-is-flux-cored-arc-welding-fcaw","status":"publish","type":"post","link":"http:\/\/weldnotes.com\/?p=123","title":{"rendered":"What is Flux Cored Arc Welding (FCAW)?"},"content":{"rendered":"<div class=\"video-container\"><iframe loading=\"lazy\" title=\"What is Flux Cored  Arc Welding? (FCAW)\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/TPSQJXqSwTg?feature=oembed&#038;wmode=opaque\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/div>\n<p>&nbsp;<\/p>\n<p>Flux core is an arc welding process that uses a tubular wire electrode with a flux-filled inner core. \u00a0The American Welding Society calls this process \u201cFlux Cored Arc Welding\u201d or FCAW.<\/p>\n<p>&nbsp;<\/p>\n<p>All flux core welding is done on equipment that is similar to (and sometime <i>identical <\/i>to) the equipment used in MIG or Gas Metal Arc Welding. \u00a0If you are not familiar with MIG welding, you might want to watch our \u201c<a href=\"https:\/\/www.youtube.com\/watch?v=twUAa5LWUvk\"><i>What is MIG Welding<\/i><\/a>\u201d video before continuing. \u00a0But you should understand that flux core welding has some important differences from MIG welding.<\/p>\n<p>&nbsp;<\/p>\n<p>In flux core welding, the wire electrode is fed through a wire feed unit. \u00a0Usually, this wire feeder requires knurled rollers that can grip the tubular wire without flattening or damaging it. \u00a0This is different from the smooth rollers used with solid MIG welding wire.<\/p>\n<p><a href=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/DSCN2440.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-medium wp-image-124\" src=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/DSCN2440-300x225.jpg\" alt=\"\" width=\"300\" height=\"225\" srcset=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/DSCN2440-300x225.jpg 300w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/DSCN2440-768x576.jpg 768w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/DSCN2440-1024x768.jpg 1024w\" sizes=\"auto, (max-width: 300px) 100vw, 300px\" \/><\/a><\/p>\n<p>As in MIG welding, an electric arc forms between this wire electrode and the workpiece and heats both metals above their melting point. \u00a0These metals mix together or \u201ccoalesce\u201d and solidify to join the workpieces into a single piece. \u00a0The metal in the parts to be joined is called the \u201cbase metal\u201d and the metal that comes from the melting wire electrode is called \u201cfiller metal.\u201d \u00a0\u00a0Because the wire electrode melts as it is being used, the Flux Core wire is called a \u201cconsumable electrode.\u201d \u00a0\u00a0\u00a0Flux core welding always adds filler metal to the joint.<\/p>\n<p><a href=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/fcaw3.png\"><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-medium wp-image-127\" src=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/fcaw3-300x134.png\" alt=\"\" width=\"300\" height=\"134\" srcset=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/fcaw3-300x134.png 300w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/fcaw3-768x344.png 768w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/fcaw3-1024x458.png 1024w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/fcaw3.png 1638w\" sizes=\"auto, (max-width: 300px) 100vw, 300px\" \/><\/a><\/p>\n<p>The job of the flux that is inside the electrode depends on which type of flux cored process it was designed for. \u00a0You see, there are two main types of flux core arc welding: \u00a0Self shielded (known as FCAW-S) and Gas shielded (which is FCAW-G). \u00a0You need to be sure you are using wire in the way it was designed to be used, because the chemistry behind these two processes is different.<\/p>\n<p>&nbsp;<\/p>\n<p>Flux Cored electrodes that are designed to be self-shielded contain a flux that completely protects the molten weld pool. \u00a0\u00a0The flux in these electrodes creates a protective cloud that prevents \u00a0gases like nitrogen and oxygen from reacting with the hot metal. \u00a0One advantage of the self-shielded Flux core process is that the added cost and inconvenience of gas shielding equipment is eliminated. \u00a0Also, self-shielded electrodes are less sensitive to drafts and breezes that easily contaminate gas-shielded processes like MIG welding. \u00a0This can be a real advantage in some applications.<\/p>\n<p><a href=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/basefiller2.png\"><img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-126 size-medium\" src=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/basefiller2-300x179.png\" alt=\"\" width=\"300\" height=\"179\" srcset=\"http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/basefiller2-300x179.png 300w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/basefiller2-768x458.png 768w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/basefiller2-1024x611.png 1024w, http:\/\/weldnotes.com\/wp-content\/uploads\/2018\/01\/basefiller2.png 1712w\" sizes=\"auto, (max-width: 300px) 100vw, 300px\" \/><\/a><\/p>\n<p>Electrodes designed to be <i>gas<\/i>-shielded rely on a secondary shielding gas to do the job of protecting the molten weld. \u00a0The high pressure gas cylinders used for this process are of the same design as those used in MIG and TIG welding. \u00a0The cylinders contain gas under extremely high pressure, and a device called a regulator brings the gas to a useable pressure. \u00a0One of the most common gases used to shield Flux core is pure CO2. Other gases, such as a CO2\/Argon blends are also used, but one advantage of FCAW-G is that low cost CO2 can be used to shield the weld.<\/p>\n<p>&nbsp;<\/p>\n<p>Another benefit of gas shielded flux core is the high deposition rate that can be achieved with the combination of flux and gas. \u00a0Flux core -G has the ability to lay down metal at a really fast rate.<\/p>\n<p>&nbsp;<\/p>\n<p>In both self shielded and gas-shielded processes, the flux forms a thin layer of slag that protects the weld as it cools. \u00a0This slag also helps the solidifying weld to take a consistent, low profile shape.<\/p>\n<p>&nbsp;<\/p>\n<p>In flux core welding, all of the machine controls are set on the machine itself. \u00a0The most important of these are polarity, wire speed and voltage. The trigger on the gun is just and on\/off switch. \u00a0For most flux core welding, the current is Direct Current or DC. \u00a0DC is like the current flowing from a car battery. \u00a0One wire is always the negative and one is always the positive.<\/p>\n<p>&nbsp;<\/p>\n<p>In \u00a0self-shielded flux core welding, the electrode is usually negative, and the workpiece is positive. \u00a0The term DCEN is used for this, \u00a0indicating that the current is \u00a0DC, and the \u00a0electrode is negative. \u00a0\u00a0You might also hear this called \u201cstraight polarity.\u201d<\/p>\n<p>&nbsp;<\/p>\n<p>In gas-shielded flux core welding, the electrode is usually positive, and the workpiece is negative. \u00a0The term for this is DCEP, \u00a0indicating that the current is \u00a0DC, and the \u00a0electrode is positive. \u00a0\u00a0This is also called \u201creverse polarity,\u201d but DCEP is a more descriptive term.<\/p>\n<p>&nbsp;<\/p>\n<p>Keep in mind that these are the most common settings, always check your manufacturer\u2019s recommendations.<\/p>\n<p>&nbsp;<\/p>\n<p>In an electric circuit the current flows in a loop. In Flux core welding, \u00a0the current has to flow in a complete circle from the machine, to the gun, into the work, and back to the machine. \u00a0A work lead is clamped to the work to complete the circuit from the workpiece back to the machine.<\/p>\n<p>&nbsp;<\/p>\n<p>So in summary, Flux core is an electric arc welding process. \u00a0It uses a consumable, tubular wire electrode that contains flux material inside of it. \u00a0Filler metal is added to the weld automatically as the wire electrode melts.<\/p>\n<p>&nbsp;<\/p>\n<p>In self-shielded flux core, the weld is protected by the flux itself, and in gas shielded flux core the shielding comes from a high pressure cylinder.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>&nbsp; Flux core is an arc welding process that uses a tubular wire electrode with a flux-filled inner core. \u00a0The American Welding Society calls this process \u201cFlux Cored Arc Welding\u201d or FCAW. &nbsp; All&#46;&#46;&#46;<\/p>\n","protected":false},"author":1,"featured_media":125,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[20],"tags":[],"class_list":["post-123","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-welding"],"_links":{"self":[{"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/posts\/123","targetHints":{"allow":["GET"]}}],"collection":[{"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"http:\/\/weldnotes.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=123"}],"version-history":[{"count":1,"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/posts\/123\/revisions"}],"predecessor-version":[{"id":128,"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/posts\/123\/revisions\/128"}],"wp:featuredmedia":[{"embeddable":true,"href":"http:\/\/weldnotes.com\/index.php?rest_route=\/wp\/v2\/media\/125"}],"wp:attachment":[{"href":"http:\/\/weldnotes.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=123"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"http:\/\/weldnotes.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=123"},{"taxonomy":"post_tag","embeddable":true,"href":"http:\/\/weldnotes.com\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=123"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}