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Department
Faculty of Petroleum and Mining Engineering, Suez University
Welding Metallurgy,
MTE 452 A1
ميتالورجيا اللحام
FLUX CORE ARC WELDING
8/12/2015
1
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
2
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Content
1- Introduction
2- Power supply
3-Electrode Feeding
4-FCAW Electrode classification
5- Guns
6-Smoke Extraction Nozzles
7-the advantage of the system
8-operation
9-process paramter
10-travel speed
11-gun angle
12-advatage and disadvantage
13- Discontinuity
3
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Introduction
• Flux cored arc welding (FCAW) is fusion
welding process.
• weld heating is produced from an arc
between the work and a continuously fed
filler metal electrode.
• Atmospheric shielding is provided by the
flux sealed within the tubular electrode.
4
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Power supply
• The FCA welding power supply is
called constant-voltage (CP, CV(
5
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
6
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
MOLTEN
WELD POOL
BASE METAL
Electrode feeding
• Many feed systems are designed with dual
feeders so that solid wire and flux core run
in sequence.
• FCAW feeders are designed to use large-
diameter wire and most often have two
sets of feed rollers.
• The two sets of rollers help reduce the
drive pressure on the electrode.
9
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
E70 T - 1
Electrode
Type Gas, Usability
Minimum UTS and Performance
70,000 psi
Flux Cored /Tubular
Position Electrode
Guns
• Gun : FCA welding guns are available as water-
cooled or air-cooled.
• Industry needs water-cooled gun because of the
higher heat caused by longer welds made at
higher currents.
• The air-cooled gun is more portable because it
has fewer hoses, and it may be made lighter so
it is easier to produce than the water-cooled gun
11
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
12
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
13
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
14
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Operation
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Process parameters
• Wire feed speed and current
• Arc voltage
• Travel speed
• Gun angles
• Electrode wire type
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Travel speed
• travel speed is the linear rate at which the
arc is moved along the weld joint.
Cont.
• This causes the weld bead to have groove
melted into the base metalnext to weld so
left unfilled by the weld.
• This condition is undercut.
• Slower travel speeds will at first increase
penetration and increase the filler weld
metal deposited.
• As the filler metal increases, the weld
bead will build up in the weld pool.
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Gun angle
• The gun angle , work angle , and travel angle
are used to refer to the relation of the gun to
the work surface.
• gun angle can be used to control the weld pool
• The electric arc produces an electrical force
known as the arc force. The arc force can be
used to counteract the gravitational pull that
tends to make the liquid weld pool sag or run
ahead of the arc.
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Cont.
• By manipulating the electrode travel angle
for the flat and horizontal position of
welding to a 20to 45° angle from the
vertical the weld pool can be controlled.
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
22
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
High Quality
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University Arc Welding
Flux-Cored
Advantages
• High deposition rates
• Deep penetration
• High-quality
•
pre-cleaning
•
Slag covering helps with larger
out-of-position welds
• Self-shielded FCAW is draft
tolerant.
• Stick electrode unnecessary.
• Closed shop environment.
•
Better mechanical properties
• It allows a higher production rate
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University Arc Welding
Flux-Cored
Limitations
• Slag must be
removed
• Spatter
• FCAW wire is expensive
• Equipment is
expensive and
complex
25
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
Discontinuity
• Slag inclusions
• Porosity
• Incomplete fusion
• Incomplete joint penetration
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
27
Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University
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Welding Metallurgy 4th Year Students 2015/2016