Flux Cored Welding

Flux Cored Arc Welding (FCAW) is frequently referred to as flux cored welding.  Flux cored welding is a commonly used high deposition rate welding process that adds the benefits of flux to the welding simplicity of MIG welding.  As in MIG welding wire is continuously fed from a spool.  Flux cored welding is therefore referred to as a semiautomatic welding process.

Self shielding flux cored arc welding wires are available or gas shielded welding wires may be used.  Flux cored welding is generally more forgiving than MIG welding.  Less precleaning may be necessary than MIG welding.  However, the condition of the base metal can affect weld quality. Excessive contamination must be eliminated.

Flux cored welding produces a flux that must be removed.  Flux cored welding has good weld appearance (smooth, uniform welds having good contour).

Flux Cored Welding Benefits

• All position capability

• Good quality weld metal deposit

• Higher deposition rates than SMAW

• Low operator skill required

• Metallurgical benefits that can be gained from a flux 

Common Flux Cored Welding Concerns

We can help optimize your flux cored welding process variables. Evaluate your current welding parameters and techniques.  Help eliminate common welding problems and discontinuities such as those listed below:

Weld Discontinuities

• Undercutting

• Excessive melt-through

• Incomplete fusion

• Incomplete joint penetration

• Porosity

• Cracks

• Slag inclusions

Flux Cored Welding Problems

• Melted contact tip

• Irregular wire feed

• Burnback

• Porosity

Source:  Welding Engineer