FCAW

Flux-cored arc welding is ‘an arc welding process that uses an arc between a continuous filler metal
electrode and the weld pool. The process is used with shielding gas from a flux containd within the
tubular electrode with or without additional shielding from an externally supplied gas, and without the
application of pressure.

There are two variations, one using externally supplied shielding gas and a second which relies entirely
on shielding gas generated from the disintegration of flux within the electrode. FCAW is almost identical
to GMAW except for the electrode. In some countries, FCAW is considered as variation of GMAW.

PRINCIPLE OF OPERATION

1. The FCAW process utilizes the heat of an arc between a continuously fed consumable flux-cored
electrode and the work.
2. The heat of the arc melts the surface of the base metal and at the end of electrode.
3. The metal melted off the electrode is transferred across the arc to the workpiece, where it
becomes the deposited weld metal.
4. Shielding is obtained from the disintegration of ingredients contained within the flux-cored
electrode. Additional shielding is obtained from an envelope of gas supplied through a nozzle to
the arc area. Ingredients within the electrode produce gas for shielding and also provide
deoxidizers, ionizers, purifying agents and in some cases alloying elements. These ingredients
form a glasslike slag, which is lighter in weight than the deposited weld metal, and floats on the
surface of the weld as a protective cover. The electrode is fed into the arc automatically and
travel can be manual or by machine.

ADVANTAGE AND MAJOR USES

1. High quality weld metal deposit

2. Excellent weld appearance: smooth, uniform welds
3. Excellent contour of horizontal fillet welds
 4. Welds are variety of steel over a wide thickness range
5. High operating factor : easily mechanized
6. High deposition rate : high current density
7. Relatively high electrode metal utilization
8. Relatively high travel speed
9. Economical engineering joint designs
10. The gasless variation can be used outdoors
11. Visible arc, easy to use
12. Less precleaning required than for GMAW
13. Reduced distortion over shielded metal arc welding

It is widely used on medium thickness steel fabricating work,where the fine wire GMAW process
would not apply and where the fitup is such that submerged arc welding would be unsuitable.

METHODS OF APPLICATION AND POSITION CAPABILITIES

Mostly applied by semi automatic method. Second is fully automatic method. The FCAW process is an
all-position welding process depending on electrode size.

WELDABLE METALS AND THICKNESS RANGE

FCAW process used to weld low-and medium-carbon steels, low-alloy high-strength steels, quenched
and tempered steels, certain stainless steels, and cast iron.

The metal thickness range :

Thickness Inch .005 .015 .062 .125 3/16 1/4 3/8 1/2 3/4 1 2 4 8
Factor mm .13 .4 1.6 3.2 4.8 6.4 10 12.7 19 25 51 102 203
Single pass
no prep.
Single pass
prep.
Multi pass

WELDING CURRENT

The FCAW process normally uses direct current with the electrode positive (DCEP) . Some electrodes
operate with the electrode negative (DCEN)

The welding current vary from 50 A to 750 A

CIRCUIT DIAGRAM

JOINT DETAILS
INDUSTRIAL USE AND TYPICAL APPLICATION

FCAW process is replacing SMAW for many applications, replacing GMAW, primary the CO2 version, and
replacing SAW for thinner metal.

Industrial use :

1. The industrial equipment industry that produces machine tool bases, press frame, and so on.
2. The tank and vessel industry

Cary, Howard B. 1979. Modern Welding Technology. United State of America : BookMasters.