Flux-Cored Arc Welding

Welding involves joining different materials together. In the welding process a good amount of 'melting' of the metals takes place while fixing two metals together, andn this is what differentiates it from soldering and brazing. Usually metals or thermoplastics are used in the welding process. Flux-cored arc welding (FCAW) is one of the popular welding processes. It is an automatic or semi-automatic arc procedure. Introduced in the 1950s, this process involves the use of a new kind of wire electrode on an MIG welding machine. This is the reason why flux-cored is regarded as similar to MIG welding process. The equipments used in both the processes are same, so are wire fields and power supply. The wire used in this purpose is the tubular wire and not that the usual solid wire.

Basically there are two types of flux-cored wire:

• Self-shielded

• Dual Shield

While self-shielded wires do not use any external gas shield, rather they employ the flux to shield the molten weld puddle; dual shield wire uses both the external shielding gas as well as the flux to protect the molten weld puddle. Usually carbon dioxide and argon are used as shielding gases in dual shield flux cored wire.

If we compare flux-cored arc with MIG welding process, then it is has greater productivity. While a MIG welder can produces on an average 5 to 8 pounds of weld in an hour, FCAW produces above 25 pounds of weld per hour. Along with higher productivity, flux-core welding can weld 1/2” plates at a time that too on both the sides with full penetration. This is the precise reason why this welding process is used in the ship building industry which requires high quality welds which are not time consuming and can work even in windy conditions. It is also used in construction industry due to its speed and portability.

Advantages of Flux-cored arc welding

• This welding process involves minimal weld clean up

• It requires lower heat inputs.

• The electrode efficiency is extremely high.

• No external shielding gas is required.

• Reduced welding fumes.

Disadvantages of Flux-cored arc welding

• It is recommended for heavy material only. Thus cannot be used for thin materials.

• Lot of smoke is generated in the whole process.

• Produces a lot of slag.

• The cost of the equipment is extremely high.

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