ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬

ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ݸ¿°¬»® ë‰ÚÔËÈ ÝÑÎÛÜ ßÎÝ ÉÛÔÜ×ÒÙ ßÐÐÔ×ÛÜ ÌÑ Ó×ÔÜ ÍÌÛÛÔÍ

ײ¬®±¼«½¬·±² Flux Cored Arc Welding (FCAW) has numerous advantages that make it the
preferred welding process for many applications. In the past, utilization of the
process was impeded by consumables that deposited welds with properties that
were inferior to other welding processes. However, in recent years consumable
manufacturers have made significant improvements in both weld metal and
diffusible hydrogen properties—to the point that FCAW is now considered
equivalent in these respects to other welding processes.

To obtain the benefits of FCAW, welders must understand the process and its
correct application. The FCAW welder must have a good understanding of the
process variables and how to control them. Therefore, the main purpose of this
training program is to enhance the welding skills of those who use the process.
Both the gas-shielded and self-shielded versions are included in this chapter.

ݸ¿°¬»® After successfully completing this chapter the supervisor should be able to:
Ѿ¶»½¬·ª»-
• List the advantages and limitations of the FCAW process

• Understand the FCAW consumable classification system

• Select wires sizes for different applications

• Understand the effect of different shielding gases

• Use the seven essential welding variables to control weld productivity and
quality

• Understand the relationship between wire feed speed, voltage, and arc
length

• Read and understand FCAW procedures

• Avoid commonly encountered FCAW defects

ɸ¿¬ ·- Ú´«¨ ݱ®»¼ FCAW is a welding process that uses an electric arc to generate the heat for
ß®½ É»´¼·²¹á welding. The electric arc is maintained between a consumable wire electrode
and the work. The electrode is a tubular wire filled with a powdered flux. The
wire electrode is fed continuously into the weld pool and becomes the weld
deposit as the wire is burned off. The welding power source provides arc

137
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

stability so that the rate of burn-off matches the rate of wire feed. The process
can be used with or without external gas shielding.

In the gas-shielded version of FCAW, a stream of gas delivered through the

welding gun protects the electrode and molten weld pool from contamination
with air (see Figure 5.1).

Ú´«¨ ½±®»¼
Ù¿- ²±¦¦´» »´»½¬®±¼»

Ý«®®»²¬ ½¿®®§·²¹
½±²¬¿½¬ ¬«¾»
Ù¿- -¸·»´¼·²¹

ͱ´·¼·º·»¼
-´¿¹
б©¼»®»¼
º´«¨
Ó±´¬»²
-´¿¹ É»´¼ °±±´

Ú·¹«®» ëòï‰Û¨¿³°´» ±º ¬¸» Ù¿-ó͸·»´¼»¼ ÚÝßÉ Ð®±½»--

A self-shielding version of FCAW is also used where contamination is con-

trolled by flux ingredients that provide some gaseous protection and specific
chemical additions (see Figure 5.2).

ß¼ª¿²¬¿¹»- ±º ÚÝßÉ

• Can be applied to many commercially important metals, such as:

– Mild Steels
– Alloy Steels
– Stainless Steels

138
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Ú´«¨ ½±®»¼
»´»½¬®±¼»

Ý«®®»²¬ ½¿®®§·²¹
½±²¬¿½¬ ¬«¾»

ß®½ -¸·»´¼ º®±³

ª¿°±®·¦»¼ º´«¨

ͱ´·¼·º·»¼
-´¿¹
б©¼»®»¼
º´«¨
Ó±´¬»²
-´¿¹ É»´¼ °±±´

Ú·¹«®» ëòî‰Û¨¿³°´» ±º ¬¸» Í»´ºó͸·»´¼·²¹ ÚÝßÉ Ð®±½»--

• FCAW has high productivity compared to the SMAW process. FCAW has
similar welding productivity to GMAW and as shown in Figures 5.3 and
5.4 has a much higher deposition rate than SMAW.

îë

îð

ïë
ÚÝßÉ ‰ ïñïê ·²ò à ðòéë ·²ò
ÝÌÌÉÜ ú ÝÑ î -¸·»´¼·²¹ ¹¿-
ïð

ë ̧°·½¿´ ÍÓßÉ º±® ®¿²¹»

±º -·¦»- ¿²¼ ½´¿--·º·½¿¬·±²-

ð
ð îðð ìðð êðð
É»´¼·²¹ ½«®®»²¬ô ß

Ú·¹«®» ëòí‰Ý±³°¿®·-±² ±º Ü»°±-·¬·±² כּ-

139
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ïñì

ïî º¬
·² ï ¸®ò

ÍÓßÉ à ïòë ´¾òñ³¿²ó¸®ò

ïñì

îì º¬
·² ï ¸®ò

ÚÝßÉ à íòï ´¾òñ³¿²ó¸®ò

Ú·¹«®» ëòì‰ÍÓßÉ ª-ò ÚÝßÉ É»´¼·²¹ Ì®¿ª»´·²¹ Í°»»¼-

• With gas shielding, FCAW is less sensitive to changes in the operating vari-
ables than other welding processes. FCAW typically has a broader range of
parameters that deposit acceptable welds than with GMAW. Lack of fusion
is a problem that can occur with GMAW when the process is not properly
applied. Because FCAW does not change the mode of metal transfer over
a large current range, it is less sensitive to this problem. The process also
provides a broader penetration profile than GMAW, which enhances the
penetration characteristics of FCAW. Refer to Figures 5.5–5.7.

• FCAW has good out-of-position welding capability and smaller wires

work well in all positions (see Figure 5.8).

• FCAW has good deposition efficiency. For example, 85% or more of each
pound of wire becomes deposited weld metal as opposed to SMAW, where
only about 60% is deposited (see Figure 5.9).

• FCAW handles mill scale much better than GMAW. The slag formed dur-
ing FCAW helps to form a smooth bead with minimal spatter, even with
heavier mill scale. This makes the process ideal for thicker materials (see
Figure 5.10).

140
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ÚÝßÉ

ʱ´¬¿¹»

ÙÓßÉ

É·®» Ú»»¼ Í°»»¼ øÉÚÍ÷

Ú·¹«®» ëòë‰Ñ°»®¿¬·²¹ •É·²¼±©-Œ ̸¿¬ Ù·ª»

ο²¹»- ±º п®¿³»¬»®- º±® ß½½»°¬¿¾´» É»´¼-

ìðð

íëð
Ú·²» ¹´±¾«´¿®

íðð

Ú·²» ¹´±¾«´¿®
îëð

îðð

Ú·²» ¹´±¾«´¿®

ïëð

ïðð

Ë-»¿¾´» ο²¹»
ëð
ïðð îðð íðð ìðð

É»´¼·²¹ Ý«®®»²¬ ø¿³°-÷ ‰ ïñïê ·²ò Ñ

Ú·¹«®» ëòê‰ÚÝßÉ Ì§°·½¿´´§ Ø¿- ¿ Ú·²» Ù´±¾«´¿® Ó»¬¿´

Ì®¿²-º»® Ѫ»® ¿ λ´¿¬·ª»´§ Ô¿®¹» Ý«®®»²¬ ο²¹»

141
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ÚÝßÉ ‰ ÝÑ î -¸·»´¼·²¹

ÙÓßÉ ‰ çëû ß®ô ëû Ñ î -¸·»´¼·²¹

Ú·¹«®» ëòé‰Ý±³°¿®·-±² Þ»¬©»»² ÚÝßÉ ¿²¼ ÙÓßÉ Í¸·»´¼·²¹

NOTE: With FCAW, the metal transfer occurs from the periphery of the
wire, which provides a broader penetration profile than GMAW.

Ú·¹«®» ëòè‰ÚÝßÉ Ø¿- Ù±±¼ Ñ«¬ó±ºóб-·¬·±² Ý¿°¿¾·´·¬§

142
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ï ´¾ò É·®»

ðòèë ´¾ò É»´¼ ³»¬¿´

Ú·¹«®» ëòç‰Û¨¿³°´» ±º Ù±±¼ Ü»°±-·¬·±² Ûºº·½·»²½§

Ó·´´ -½¿´»

ÚÝßÉ ÙÓßÉ

Ú·¹«®» ëòïð‰Ûºº»½¬ ±º Ó·´´ ͽ¿´»

Ü·-¿¼ª¿²¬¿¹»- ±º ÚÝßÉ

• Fume generation is higher than other processes. Self-shielding wires have

a particularly high fume generation rate and are used mainly in outdoor
applications (see Figure 5.11).

• Deslagging or cleaning is required between passes (see Figure 5.12).

• FCAW is generally considered to be a low hydrogen welding process (see

Figure 5.13). Most FCAW wires are classified as having up to 16 ml H 2 /
100 g of deposit (H16). Although this is not necessarily low hydrogen,
most wires contain significantly less than this level; however, not low
enough to be classified as an H8. Not all FCAW classifications are avail-
able in the H16 or lower diffusible hydrogen levels; therefore, the use of
FCAW in very thick or alloyed materials needs careful consideration. Most
manufacturers offer lower hydrogen wires for these applications. Hydrogen
content is important to prevent cracking. See Chapter 7, Steel Welding
Metallurgy, for more information.

143
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ÚÝßÉ
ø-»´º -¸·»´¼»¼÷
ÍÓßÉ

ﮬ·½«´¿¬» ÚÝßÉ øÝÑî÷

º«³»
¹»²»®¿¬·±²
®¿¬» ø¹ñ³·²÷

ÙÓß øÝÑî÷

ÙÓß ø¿®¹±²÷

ײ½®»¿-·²¹ ½«®®»²¬ ¸·¹¸»®

Ú·¹«®» ëòïï‰Ú«³» Ù»²»®¿¬·±² כּ-

Ú·¹«®» ëòïî‰Ý¸·°°·²¹ Ø¿³³»® Ë-»¼ º±® Í´¿¹ λ³±ª¿´

Ê»®§ Ô±© Ô±©

ا¼®±¹»² ا¼®±¹»² Ò±²óا¼®±¹»² ݱ²¬®±´´»¼

Ò±²ó¸§¼®±¹»²
½±²¬®±´´»¼ »´»½¬®±¼»-

꧃

ÚÝßÉ

Þ¿-·½ Û´»½¬®±¼»-

ÙÓßÉ

ë ïð ïë îð îë íð
É»´¼ ³»¬¿´ ¸§¼®±¹»² ½±²¬»²¬ô ³´ñïðð¹ ±º ¼»°±-·¬»¼ ³»¬¿´

Ú·¹«®» ëòïí‰É»´¼ Ó»¬¿´ ا¼®±¹»² Ô»ª»´- º±®

Ü·ºº»®»²¬ É»´¼·²¹ Ю±½»--»- øߺ¬»® ݱ»÷

144
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

• Air drafts can disturb the shielding gas and cause porosity when using the
gas- shielded version of FCAW (see Figure 5.14).

Ú·¹«®» ëòïì‰ß·® Ü®¿º¬-

Ю±½»-- Because it is easy to change the chemistry of the core ingredients, different
Ú«²¼¿³»²¬¿´- FCAW wires can be economically produced for different base metals or types
of applications. The supervisor should know the different types of wires and
shielding gases available and understand the important characteristics of the
process.

Ѿ¶»½¬·ª»- The objectives of this section are to:

• Understand how FCAW wires are manufactured

• Understand the AWS classification systems for FCAW consumables

• Know how wire size effects operating characteristics

• Know how to select shielding gases for different applications

• Understand the effects of resistance heating on wire burn-off

• Understand how the process melts the base metal and wire differently.

Ó¿²«º¿½¬«®» ±º The FCAW process uses a continuous tubular electrode of mild steel and a flux
ÚÝßÉ É·®»- core mixture of various powdered ingredients (see Figure 5.15).

A manufacturing system for FCAW is shown in Figure 5.16.

145
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Ü»±¨·¼·¦»®-
ß´´±§·²¹ »´»³»²¬-
ß®½ -¬¿¾·´·¦»®-
Ú´«¨ ½±®»
Í´¿¹ º±®³»®-
Ù¿- º±®³»®-
Ú´«¨·²¹ ¿¹»²¬-

Ú·¹«®» ëòïë‰ÚÝßÉ Ë-»- ¿ Ú´«¨ ݱ®» Ó·¨¬«®»

±º Ê¿®·±«- б©¼»®»¼ ײ¹®»¼·»²¬-

ͬ®·° ®»»´
Ú´«¨ ¸±°°»®

Ú´«¨ °±«®»¼ ¿¬
¬¸·- °±·²¬

Ü·»

þËþ Ú±®³·²¹ ®±´´-

þËþ Ý´±-·²¹ ®±´´-

λ»´ ©·¬¸ º±®³»¼

»´»½¬®±¼»

Ú·¹«®» ëòïê‰Ó¿²«º¿½¬«®·²¹ ͧ-¬»³ º±® ÚÝßÉ

Different methods are used for joining the tube edges. The butt, overlap, and
folded seams are shown in Figure 5.17. A macrosection of five different types
of 1/16 in. (1.6 mm) diameter wires commonly used in industry is shown in
Figure 5.18.

146
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Þ«¬¬ Ѫ»®´¿° Ú±´¼»¼

Ú·¹«®» ëòïé‰Ü·ºº»®»²¬ Ó»¬¸±¼- Ë-»¼ º±® Ö±·²¬ Ì«¾» Û¼¹»-

Ó»¬¿´ ͱ´·¼ Ϋ¬·´» Þ¿-·½ Í»´º

½±®»¼ øÙÓßÉ÷ øÌóï÷ øÌóë÷ -¸·»´¼·²¹

Ú·¹«®» ëòïè‰Ó¿½®±-»½¬·±² ±º Ü·ºº»®»²¬ ̧°»- ±º É·®»-

Ý´¿--·º·½¿¬·±² ±º Filler metals for FCAW of carbon steels are classified according to their
Ú·´´»® Ó»¬¿´- º±® operating characteristics and mechanical properties (see Figure 5.19).
ÚÝßÉ ±º Ó·´¼ ͬ»»´

É·®»- º±® Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ±º ³·´¼ -¬»»´

¿®» ½´¿--·º·»¼ ¿½½±®¼·²¹ ¬±æ

ßÉÍ ßëòîð
ß³»®·½¿² É»´¼·²¹ ͱ½·»¬§

ÝÍß Éìèóðï
Ý¿²¿¼·¿² ͬ¿²¼¿®¼- ß--±½·¿¬·±²

Ú·¹«®» ëòïç‰Ú·´´»® Ó»¬¿´- º±® ÚÝßÉ É»´¼·²¹ ±º Ó·´¼ ͬ»»´

147
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

In the U.S., AWS A5.20, Specification for Carbon Steel Electrodes for Flux
Cored Arc Welding, covers FCAW filler metals. The classification system is
shown in Figure 5.20.

Û È È Ì ó È Ó Ø Æ
Ñ°¬·±²¿´ Øî
¼»-·¹²¿¬±®

Û´»½¬®±¼»
éëŠèðû ß®

Ó·²·³«³ ¬»²-·´» Í´¿¹ -§-¬»³

-¬®»²¹¬¸ ½«®®»²¬ô °±´¿®·¬§ô
ê ã êð µ-· -¸·»´¼·²¹ ¹¿-
é ã éð µ-·

Ì«¾«´¿® ©·®»

É»´¼·²¹ °±-·¬·±²-æ
ð ã ¸±®·¦±²¬¿´ ¿²¼ º´¿¬
ï ã ¿´´ °±-·¬·±²-

Û¨¿³°´»æ ÛéðÌóë
Û ã Û´»½¬®±¼»
é ã éð µ-· ³·²·³«³ ¬»²-·´» -¬®»²¹¬¸
ð ã ر®·¦±²¬¿´ ¿²¼ º´¿¬ °±-·¬·±²-
Ì ã Ú´«¨ ½±®»¼ »´»½¬®±¼»
ë ã Þ¿-·½ º´«¨ ¬± ¾» «-»¼ ©·¬¸
-¸·»´¼·²¹ ¹¿-

Ú·¹«®» ëòîð‰ßÉÍ ßëòîð Ý´¿--·º·½¿¬·±² ͧ-¬»³

Û´»½¬®±¼» Í·¦» A large range of electrode sizes is available for the semiautomatic mode of
FCAW, ranging from 0.035 in. (0.9 mm) to 3/32 in. (2.4 mm). The electrode
diameter selected must be suitable for the intended application.

Typically, electrode diameters for the gas-shielded process are classified as all-
position wires for diameters 1/16 in. (1.6 mm) and less (see Figure 5.21).

It is important to understand the effect of wire diameter on base metal fusion,

because the resistance heating of the wire extension is a major contributor to
the melting of the wire (see Figure 5.22). Smaller diameter wires (for the same
deposition rate) need less welding current, therefore, they produce less pene-
tration into the base metal. In addition, the welding amperage for a given wire
diameter will not increase proportionally with the wire feed speed (WFS). Both
of these effects are discussed later in this chapter.

148
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

̧°·½¿´´§ ¿´´ °±-·¬·±²-

òðíð òðìë ïñïê ëñêì íñíî

̧°·½¿´´§ º´¿¬ ¿²¼ ¸±®·¦±²¬¿´

Ú·¹«®» ëòîï‰Û´»½¬®±¼» Ü·¿³»¬»®- º±® Ü·ºº»®»²¬ б-·¬·±²-

Ô¿®¹» ¼·¿³»¬»® ©·®» ͳ¿´´ ¼·¿³»¬»® ©·®»

Ø·¹¸ ½«®®»²¬ Ô±© ½«®®»²¬

Í¿³» ¼»°±-·¬ ¿®»¿

Ú«-»¼ ¿®»¿

Ú·¹«®» ëòîî‰Ûºº»½¬ ±º É·®» Ü·¿³»¬»® ±² Þ¿-» Ó»¬¿´ Ú«-·±²

The practical result is that the wire diameter used should increase with the
material thickness as shown in Figure 5.23.

149
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

̸·½µ²»--

Þ¿-» ³»¬¿´ ¬¸·½µ²»--

Ú·¹«®» ëòîí‰É·®» Ü·¿³»¬»® Ë-»¼

͸±«´¼ ײ½®»¿-» ©·¬¸ Ó¿¬»®·¿´ ̸·½µ²»--

Ûºº»½¬ ±º ͸·»´¼·²¹ A variety of shielding gases are available for the FCAW process, therefore, it
Ù¿-»- is important to make the correct gas selection for a particular application.
The most important function of the shielding gas is to protect the transferred
molten droplets and weld pool from contamination with air (see Figure 5.24).

ß·®
͸·»´¼·²¹
¹¿-

Ú·¹«®» ëòîì‰Ûºº»½¬ ±º ͸·»´¼·²¹ Ù¿-

Some gas is produced by the core ingredients of self-shielding wires, however,

that alone is not totally effective in providing shielding (see Figure 5.25).
Therefore, self-shielding wires use other means to handle the nitrogen and
oxygen that enter the weld pool. These wires produce excellent results without
draft protection.

150
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ß·®
͸·»´¼·²¹ ¹¿-

Ú·¹«®» ëòîë‰Ì¸» Ù¿- Ю±¼«½»¼ ¾§ Í»´ºó͸·»´¼·²¹ É·®»- ·-

Ò±¬ ̱¬¿´´§ Ûºº»½¬·ª» ·² ͸·»´¼·²¹ ¬¸» É»´¼ б±´

One method commonly used with self-shielded wires is to add aluminum to the
weld pool (see Figure 5.26). Aluminum reacts preferentially with contaminants
to eliminate porosity. The amount of aluminum transferred across the arc
depends on the voltage. Too high a voltage burns off most of the aluminum
before it reaches the weld pool.

ß·®

ß´ õ Òî â Ü»²·¬®·¼·²¹
ß´ õ Ñî â Ü»±¨·¼·¦·²¹

Ú·¹«®» ëòîê‰ß´«³·²«³ ß¼¼·¬·±²- ¿®» Ûºº»½¬·ª» ·²

λ¼«½·²¹ б®±-·¬§ ©·¬¸ Í»´ºó͸·»´¼»¼ É·®»-

For gas-shielded FCAW, the carbon dioxide (CO2) content of the shielding gas
has a major effect on penetration and fusion characteristics. As shown in
Figure 5.27, 100% CO2 provides a better penetration profile than an Ar-CO2
mixture, which ensures better side-wall fusion.

151
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ÚÝßÉ ‰ ÝÑ î -¸·»´¼·²¹ ÚÝßÉ ‰ éëû ß®ô îëû ÝÑ î -¸·»´¼·²¹

Ú«-»¼ ¾¿-» ³»¬¿´ ¿®»¿ ø³³î÷

çéû ß® Š íû Ñî ïìòí
Ú«-»¼ ¿®»¿ ±º
éëû ß® Š îëû ÝÑî îîò𠾿-» ³»¬¿´

ïððû ÝÑ î îèòî

Ú·¹«®» ëòîé‰ïððû ÝÑî Ю±ª·¼»- ¿ Þ»¬¬»® л²»¬®¿¬·±²

Ю±º·´» ¬¸¿² ¿² ß®óÝÑî Ó·¨¬«®»

The CO2 content also has an effect on the amount of fume. Shielding gases
higher in argon content produce less fume (see Figure 5.28).

íð

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îð

îðð ïë

ïð

ë
ïðð íðð

ïððû
ÝÑ î

íð

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îð

îðð ïë

ïð

ë
ïðð íðð

ß® õ
îëû ÝÑ î

É»´¼·²¹ п®¿³»¬»®-
ÛéðÌóç ïñïê ·²ò ¼·¿ò
îéë ¿³°-
îè ª±´¬-

Ú·¹«®» ëòîè‰Í¸·»´¼·²¹ Ù¿-»- Ø·¹¸»® ·² ß®¹±² Ю±¼«½» Ô»-- Ú«³»

152
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

A summary of shielding gas effects is shown in Figure 5.29.

íð

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îðð ïë

ïð

ë
ïðð íðð

ïððû ÝÑî

Ó±-¬ ©·¼»´§ «-»¼

ïððû Ô»¿-¬ »¨°»²-·ª»

ÝÑ î
Þ»-¬ º«-·±² ¿²¼ °»²»¬®¿¬·±²

íð

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îðð ïë

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ë
ïðð íðð

ß®¹±² ‰ ÝÑî ³·¨»-

ͳ±±¬¸»® ¿®½

ß® õ Ô»-- -°¿¬¬»®
ïëŠìðûÝÑ î
Û¨½»´´»²¬ ¿°°»¿®¿²½»

Ô±©»® º«³»

Ú·¹«®» ëòîç‰Í«³³¿®§ ±º ͸·»´¼·²¹ Ù¿- Ûºº»½¬-

Û´»½¬®±¼» ¿²¼ An electric light bulb circuit is much like a welding circuit, because electricity
Þ¿-» Ó»¬¿´ Ó»´¬·²¹ from a battery or power source is used to generate heat and light (see Figure
5.30).

Ú·¹«®» ëòíð‰ß² Û´»½¬®·½ Ô·¹¸¬ Þ«´¾ Ý·®½«·¬

·- Ê»®§ Ó«½¸ Ô·µ» ¿ É»´¼·²¹ Ý·®½«·¬

153
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

An electric arc is also an energy conversion device that converts electrical

energy into heat to melt the base metal and to burn off the wire (see Figure 5.31).

ÛÔÛÝÌÎ×Ý×ÌÇ

ØÛßÌ

ÛÔÛÝÌÎ×Ý×ÌÇ

Ú·¹«®» ëòíï‰ß² Û´»½¬®·½ ß®½ ·- ¿´-± ¿² Û²»®¹§ ݱ²ª»®-·±² Ü»ª·½»

An important characteristic of the FCAW process is that arc heating is not the
only type of heating that occurs. A high current flows through the electrode
extension, which becomes very hot due to resistance heating effects (see
Figures 5.32 and 5.33).

λ-·-¬¿²½» ¸»¿¬·²¹ ß®½ ¸»¿¬·²¹ øß²±¼»÷

½±²¬®·¾«¬»- ¬± ©·®» ½±²¬®·¾«¬»- ¬± ©·®»
³»´¬·²¹ ³»´¬·²¹

ß®½ ¸»¿¬·²¹ ³»´¬-

¾¿-» ³»¬¿´

Ú·¹«®» ëòíî‰Î»-·-¬¿²½» Ø»¿¬·²¹ ݱ²¬®·¾«¬»- ¬± É·®» Ó»´¬·²¹

154
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Ú·¹«®» ëòíí‰Ý«®®»²¬ Ú´±©·²¹ ̸®±«¹¸ ¿ É·®» Ù»²»®¿¬»- ݱ²-·¼»®¿¾´» Ø»¿¬

Total heating and melting of the electrode results from both resistance heating
and arc heating (see Figure 5.34).

ó Ý«®®»²¬ ø¿³°-÷ ó Ý«®®»²¬ ø¿³°-÷

Ý«®®»²¬
ø¿³°-÷
õ ó É·®» ¼·¿³»¬»®
ó Û´»½¬®±¼»
ã ó É·®» ¼·¿³»¬»®
ó Û´»½¬®±¼»
»¨¬»²-·±² øÝÌÌÉÜ÷ »¨¬»²-·±² øÝÌÌÉÜ÷

Ú·¹«®» ëòíì‰ß®½ Ø»¿¬·²¹ õ λ-·-¬¿²½» Ø»¿¬·²¹ ã ̱¬¿´ Þ«®²óѺº כּ

Resistance heating increases by:

• Increasing amperage

• Increasing electrode extension (stickout) past the contact tube

• Using smaller diameter electrodes

Longer CTTWDs reduce the welding amperage, because resistance heating

effects are increased. When the wire feed speed (WFS) is set to a particular
value, the resulting amperage depends on the CTTWD as shown in Figure
5.35. CTTWD is the contact tube to work distance.

With gas-shielded FCAW, the deposition rate (wire melting) does not depend
significantly on the electrode type or manufacturer for the commonly used
E7XT-1 and E7XT-9 classifications. However, for self-shielding FCAW,
the electrode type has a major impact on the deposition rate. Even electrodes
of the same classification can have different deposition rate characteristics.
Therefore, careful selection of these types of electrodes is necessary to ensure
optimum welding productivity (see Figure 5.36).

155
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ìðð

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ï ·²ò ÝÌÌÉÜ
íðð

îëð

îðð

íñì ·²ò ÝÌÌÉÜ

ïëð

ïðð

ëð
ïðð îðð íðð ìðð
É»´¼·²¹ Ý«®®»²¬ ø¿³°-÷ ‰ ïñïê ·²ò Ñô ÛéïÌóç

Ú·¹«®» ëòíë‰ÉÚÍ ª-ò ß³°»®¿¹»

ïëòð

ïîòë ëñêì ·²ò ¼·¿ò ÛéðÌóé

-»´ºó-¸·»´¼·²¹
©·®»-
ïðòð

éòë ÛéïÌóè

ëòð
ÛéïÌóè
îòë

ð
ð îðð íðð ìðð
É»´¼·²¹ ½«®®»²¬ô ß

Ú·¹«®» ëòíê‰Ý±³°¿®·-±² ±º Ü»°±-·¬·±² כּ-

øëñêì ·²ò Ü·¿³»¬»® Í»´ºó͸·»´¼·²¹ É·®»-÷

156
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

NOTE: Base metal melting depends only on amperage or arc heating;

wire melting depends both on arc heating and also on resistance heating

ÚÝßÉ Û--»²¬·¿´ The FCAW process is controlled by seven essential welding variables that are
É»´¼·²¹ Ê¿®·¿¾´»- set by the welder (see Figure 5.37).

É·®» Ú»»¼ Í°»»¼ øÉÚÍ÷ Ì®¿ª»´ ß²¹´» ±º Ù«²

ʱ´¬¿¹» Ì®¿²-ª»®-» ß²¹´» ±º Ù«²

Ì®¿ª»´ Í°»»¼ Û´»½¬®±¼» б-·¬·±²

ݱ²¬¿½¬ Ì«¾» ¬±
ɱ®µ Ü·-¬¿²½»

Ú·¹«®» ëòíé‰Ì¸» Û--»²¬·¿´ É»´¼·²¹ Ê¿®·¿¾´»- º±® ÚÝßÉ

The FCAW essential welding variables control welding speed, bead appear-
ance, penetration, and spatter. These essential variables are the key settings
that make a weld what it is. A welder’s knowledge and control of these vari-
ables are important to consistently achieve high productivity rates and quality
welds.

157
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

To consistently obtain quality welds, the welder must:

• Understand how the essential welding variables affect weld quality and
productivity

• Know how to set the essential welding variables for different welding
applications

• Understand how the essential welding variables affect bead shape, penetra-
tion and spatter

• Know how to avoid common FCAW defects

É·®» Ú»»¼ Í°»»¼ øÉÚÍ÷

1. Effect of Wire Feed Speed on Base Metal Fusion and Penetration

As discussed earlier in this chapter, there is a direct relationship between WFS

and welding current. Increasing the WFS increases the welding current, as
shown in Figure 5.38.

Welding current provides heat to melt the electrode and base metal. Increasing
welding current increases both arc heating and resistance heating (see Figure
5.39).

Increasing WFS increases penetration (arc heating) and fill (electrode melting)
as shown in Figure 5.40. A minimum WFS is required to obtain adequate
penetration depending on the thickness of the material. Essentially, a given
material thickness requires a minimum amperage to achieve adequate pene-
tration in a T-joint (see Figure 5.41).

2. Effect of Wire Feed Speed on Travel Speed

Travel speed is predominately determined by the WFS setting. Keeping

in mind that welding productivity is significantly affected by travel
speed, then selecting and maintaining the WFS is very important with FCAW.
Figure 5.42 shows the effect of increasing the WFS for a 5/16 in. (8 mm) fillet
weld.

158
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ìðð

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íñì ·²ò ÝÌÌÉÜ

íðð

îëð

îðð

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ïðð

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ïðð îðð íðð ìðð
É»´¼·²¹ Ý«®®»²¬ ø¿³°-÷ ‰ ïñïê ·²ò Ñô ÛéïÌó ç

Ú·¹«®» ëòíè‰×²½®»¿-·²¹ ¬¸» ÉÚÍ ×²½®»¿-»- ¬¸» É»´¼·²¹ Ý«®®»²¬

É»´¼·²¹ ½«®®»²¬ Û´»½¬®±¼» »¨¬»²-·±²

®»-·-¬¿²½» ¸»¿¬·²¹
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É»´¼·²¹ ½«®®»²¬
¿ºº»½¬- ¿®½ ¸»¿¬·²¹
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É»´¼·²¹ ½«®®»²¬
¿ºº»½¬- ¿®½ ¸»¿¬·²¹
¬± ³»´¬ ¬¸» ©·®»

Ú·¹«®» ëòíç‰×²½®»¿-·²¹ ¬¸» É»´¼·²¹ Ý«®®»²¬ ײ½®»¿-»-

Þ±¬¸ ß®½ Ø»¿¬·²¹ ¿²¼ λ-·-¬¿²½» Ø»¿¬·²¹

159
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Ù®»¿¬»® º·´´

Ù®»¿¬»® °»²»¬®¿¬·±²
ײ½®»¿-·²¹ ÉÚÍ ¿²¼ º«-·±²

Ú·¹«®» ëòìð‰×²½®»¿-·²¹ ¬¸» ÉÚÍ ×²½®»¿-»- л²»¬®¿¬·±² ¿²¼ Ú·´´

-·¦»

-·¦»

Ó·²·³«³ ®»¯«·®»¼ ÉÚÍ

ïñïê ·²ò ¼·¿ò

íñì ·²ò ÝÌÌÉÜ
ÝÑî -¸·»´¼·²¹ ¹¿-

̸·½µ²»--

Ú·¹«®» ëòìï‰Ó¿¬»®·¿´ ̸·½µ²»-- λ¯«·®»- Ó·²·³«³ ß³°»®¿¹»

¬± ß½¸·»ª» ß¼»¯«¿¬» л²»¬®¿¬·±² ·² ¿ ÌóÖ±·²¬

NOTE: Penetration and fusion for self-shielded FCAW electrodes can be

less than for gas-shielded FCAW. This is because of the use of electrode
negative polarity for some wires (typically out-of-position) and other
characteristics of the self-shielding version (such as longer CTTWDs for
some electrodes).

160
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ÉÚÍ ã îðð °³

É»´¼ -·¦» ã ëñïê ·²ò º·´´»¬

É·®» -·¦» ã ïñïê ·²ò ¼·¿ò
éòë ·°³

ÉÚÍ ã íðð °³

ïî ·²òñ³·²

Ú·¹«®» ëòìî‰Ì®¿ª»´ Í°»»¼ ·- Ü»¬»®³·²»¼ ¾§ ¬¸» ÉÚÍ Í»¬¬·²¹

The effect of WFS on travel speed for different fillet sizes is shown in Figure
5.43 for a 1/16 in. E71T-9 electrode.

NOTE: WFS has a major impact on both quality (fusion and penetration)
and productivity.

Note that the polarity for self-shielding FCAW electrodes depends on the
electrode classification being used. Some electrodes (e.g., E70T-4) operate on
electrode positive (DCEP) and others (e.g., E70T-8) operate on electrode nega-
tive (DCEN). Ensure that you have the correct polarity for the electrode being
used.

Most gas-shielded electrodes operate on electrode positive (DCEP).

161
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ìðð

ëñïê ·²ò
íëð íñè ·²ò

íðð
ïñì ·²ò

îëð

îðð

-·¦»
ïëð

-·¦»
ïðð

ëòð ïðòð ïëòð îðòð îëòð

Ì®¿ª»´ Í°»»¼ ø·°³÷

Ú·¹«®» ëòìí‰ÉÚÍ ª-ò Ì®¿ª»´ Í°»»¼ øÚÝßÉ ÛéïÌóç ïñïê ·²ò Ü·¿ò÷
º±® Ü·ºº»®»²¬ Ú·´´»¬ É»´¼ Í·¦»

ʱ´¬¿¹»

1. Effect of Voltage on Bead Shape

Voltage controls arc length (see Figure 5.44). Increasing the voltage increases
the arc length and arc width. Bead width also increases as arc length increases
(see Figure 5.45).

The voltage at the power source, or the machine voltage, is the voltage that the
welder reads and sets. The voltage at the arc, or arc voltage, is less dependent
on the voltage drop between the power source and arc. The difference depends
on cable size and length as well as welding amperage, but these voltages go up
and down proportionately; therefore, for this discussion the effect of voltage is
the same.

162
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ß®½ ´»²¹¬¸

ß®½ ©·¼¬¸

Ú·¹«®» ëòìì‰×²½®»¿-·²¹ ʱ´¬¿¹» ײ½®»¿-»- ß®½ Ô»²¹¬¸ ¿²¼ ß®½ É·¼¬¸

ײ½®»¿-·²¹ ª±´¬¿¹»
ײ½®»¿-·²¹ ¿®½ ´»²¹¬¸

Ú·¹«®» ëòìë‰Þ»¿¼ É·¼¬¸ ײ½®»¿-»- ¿- ß®½ Ô»²¹¬¸ ײ½®»¿-»-

Once the correct arc length is set for a given weld, it should be kept constant—
even when WFS is increased or decreased. As shown in Figure 5.46, it is
necessary to change voltage along with WFS to maintain a constant arc length.

2. Effect of Voltage on Undercut and Penetration

Voltage has a major effect on heat input to the plate surface. Voltage also
affects the amount of radiated heat, therefore, longer arcs seem much hotter to
the welder. As a result of this surface heating effect, the voltage also has a
significant impact on bead shape and undercut (see Figure 5.47). In multipass
welds, undercut or poor bead shape can trap slag, leading to slag inclusions in
the complete weld.

Because a longer arc is also wider, it is more likely to cause undercut in a fillet
weld (see Figure 5.48).

163
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ìð

íë ÉÚÍ

íð ß- §±« ¬«®² «° ¬¸»

ݱ²-¬¿²¬ ¿®½ ´»²¹¬¸ ÉÚÍô ¬¸» ª±´¬¿¹» ³«-¬
ø»ò¹òô ïñè ·²ò÷ ¿´-± ¾» ·²½®»¿-»¼ ¬±
µ»»° ¬¸» ¿®½ ´»²¹¬¸
îë ½±²-¬¿²¬

îð ʱ´¬¿¹»

ïðð îðð íðð ìðð ëðð êðð

É·®» Ú»»¼ Í°»»¼ ø·²òñ³·²÷

Ú·¹«®» ëòìê‰Þ±¬¸ ʱ´¬¿¹» ¿²¼ ÉÚÍ Ò»»¼ ¬± ݸ¿²¹»

¬± Ó¿·²¬¿·² ¿ ݱ²-¬¿²¬ ß®½ Ô»²¹¬¸

б--·¾´» -´¿¹ б--·¾´» -´¿¹

»²¬®¿°³»²¬ »²¬®¿°³»²¬

ʱ´¬¿¹» ʱ´¬¿¹»
¬±± ¸·¹¸ ¬±± ´±©

Ú·¹«®» ëòìé‰Ê±´¬¿¹» Ø¿- ¿ Í·¹²·º·½¿²¬ ׳°¿½¬

±² Þ»¿¼ ͸¿°» ¿²¼ ˲¼»®½«¬

ß®½ ´»²¹¬¸ ¬±± -¸±®¬ ݱ®®»½¬ ¿®½ ´»²¹¬¸ ß®½ ´»²¹¬¸ ¬±± ´±²¹

Ú·¹«®» ëòìè‰Ûºº»½¬ ±º ß®½ Ô»²¹¬¸

164
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

3. Effect of Voltage on Spatter

Spatter is minimal with gas-shielded FCAW wires of the E7XT-1 or E7XT-9

classifications. However, very low or high voltages can increase spatter levels.
The E7XT-5 classification produces considerable spatter with CO2 shielding
gas. Some improvement with this classification can be made with the use of
argon mixtures and pulsed arc power sources.

4. Effect of Voltage for Self-Shielding Wires

Because the voltage setting determines the amount of aluminum transferred,

too high a voltage setting results in excessive porosity with self-shielding wires
(see Figure 5.49).

б®±-·¬§

ʱ´¬¿¹» ¬±± ¸·¹¸

ʱ´¬¿¹» ½±®®»½¬

ʱ´¬¿¹» ¬±± ´±©

Ú·¹«®» ëòìç‰Ûºº»½¬ ±º ʱ´¬¿¹» º±® Í»´ºó͸·»´¼·²¹ É·®»-

NOTE: Voltage has a major impact on surface heating, which affects

bead shape and undercut. In the case of self-shielding wires, voltage also
affects porosity levels.

Ì®¿ª»´ Í°»»¼

1. Travel Speed and Productivity

Travel speed has a major effect on welding productivity. The faster the speed,
the less time it takes to make a weld. Most welders never measure their travel
speeds, because they generally have a good feel for how slow or fast the travel

165
ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

speed is. It is difficult to manually travel above 30 ipm in the horizontal position.
Examples of travel speed ranges are shown in Figure 5.50 for fillet welding.

̱± -´±© ×¼»¿´ Ó»½¸¿²·¦»¼ ©»´¼·²¹

´¿®¹»® -³¿´´»®
º·´´»¬- º·´´»¬-

ð ïð îð íð ìð ëð êð

Ú·¹«®» ëòëð‰Ì®¿ª»´ Í°»»¼ ο²¹»-

2. Effect of Travel Speed on Penetration

A general pattern emerges as travel speed is decreased:

• Heat input per inch is increased

• More filler metal is applied per inch and consequently, the weld is larger

• Penetration increases in a bead-on-plate test as shown in Figure 5.51,

because the metal spreads out.

Ó±®» º·´´
Þ»¿¼ó±²ó°´¿¬» ®»-«´¬- ±²´§

Ü»½®»¿-·²¹ ¬®¿ª»´ -°»»¼

Ú·¹«®» ëòëï‰Ûºº»½¬- ±º Ü»½®»¿-·²¹ Ì®¿ª»´ Í°»»¼

·² ¿ Þ»¿¼ó±²óд¿¬» É»´¼

Bead-on-plate welds are generally not made, and when the puddle is allowed to
build up in a groove or fillet weld, penetration decreases if the welding speed is
too slow (see Figure 5.52).

166
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ß -´±© ¬®¿ª»´ -°»»¼ ³¿µ»- ·¬ ¼·ºº·½«´¬ º±®

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½¿«-»- «²¼»®½«¬ò

Ú¿-¬»® ¬®¿ª»´ -°»»¼ °®±¼«½»- ´»-- º·´´

¿²¼ ´»-- ¼»°¬¸ ±º ©»´¼ °±±´ ¿´´±©·²¹
¾»¬¬»® ¿®½ °»²»¬®¿¬·±²ò

Ú·¹«®» ëòëî‰Ð»²»¬®¿¬·±² Ý¿² Ü»½®»¿-»

ɸ»² É»´¼·²¹ Í°»»¼ ·- ̱± Í´±©

NOTE: Always keep the arc at the front of the pool.

ݱ²¬¿½¬ Ì«¾» ¬± ɱ®µ Ü·-¬¿²½» øÝÌÌÉÜ÷

Throughout most of the welding circuit, heavy copper cables carry the welding
current, which can be as high as 500 amps in FCAW. However, once past the
contact tube, the current is forced to flow through a small steel wire, which is a
poor conductor of electricity (see Figure 5.53). This extension of the wire elec-
trode is very hot and, in effect, becomes preheated before it reaches the arc.

The length of the wire past the contact tip is called the electrical stickout (see
Figure 5.54). The CTTWD is the electrical stickout plus the arc length.

167
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ݱ²¬¿½¬ ¬·°

Ú·¹«®» ëòëí‰Û´»½¬®·½¿´ Û¨¬»²-·±²

Û´»½¬®·½¿´
-¬·½µ±«¬ ݱ²¬¿½¬ ¬·°
¬± ©±®µ ¼·-¬¿²½»

Ú·¹«®» ëòëì‰Û´»½¬®·½¿´ ͬ·½µ±«¬

When a wire feed speed setting is made, the heat needed to melt the wire off is
a combination of both arc heating and resistance heating (see Figure 5.55).

When the CTTWD is changed, the ratio of arc heating to resistance heating is
also changed. With small diameter wires and long CTTWDs, high resistance
heating of the electrode extension can cause burnoff of the wire—even when
the amperage is relatively low.

168
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Í¿³» ©·®»
-°»»¼ º»»¼
ß®½
¸»¿¬·²¹

λ-·-¬¿²½»
¸»¿¬·²¹

͸±®¬ Ô±²¹
ÝÌÌÉÜ ÝÌÌÉÜ

Ú·¹«®» ëòëë‰É·®» Ó»´¬·²¹ ã Ó»´¬·²¹ º®±³

λ-·-¬¿²½» Ø»¿¬·²¹ õ Ó»´¬·²¹ º®±³ ß®½ Ø»¿¬·²¹

1. Effect of CTTWD on Welding Current

Changing the CTTWD changes the welding amperage as shown in Figure

5.56.

As the wire CTTWD is increased, less current is needed to melt the wire,
because there is more preheat in the electrode extension. Less current means
less heat into the work, and therefore, less penetration. The opposite occurs
when the CTTWD is reduced in length. The CTTWD is important and should
be held constant at the correct value.

Some typical settings are shown in Table 5.1. The CTTWD is typically greater
with larger diameter wires. Some self-shielding FCAW wires are designed for
very long CTTWDs.

169
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

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º»»¼ -°»»¼
Ò±®³¿´
-¬·½µ±«¬

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Ê ã ³¿½¸·²» ª±´¬¿¹» ø½±²-¬¿²¬÷ ¢ ¬±¬¿´ ª±´¬¿¹» ¿½®±-- ©·®» ¿²¼ ¿®½

× ã ©»´¼·²¹ ½«®®»²¬

Ú·¹«®» ëòëê‰Ý¸¿²¹·²¹ ¬¸» ÝÌÌÉÜ Ý¸¿²¹»- É»´¼·²¹ Ý«®®»²¬

Ì¿¾´» ëòï‰Ý±²¬¿½¬ Ì«¾» ¬± ɱ®µ Ü·-¬¿²½»

É·®»
·²ò ø³³÷ ͸·»´¼·²¹ ÝÌÌÉÜ

ðòìë øïòî÷ Ù¿-ó-¸·»´¼»¼ íñèŠëñè

ïñïê øïòê÷ Ù¿-ó-¸·»´¼»¼ ïñîŠéñè
íñíî øîòì÷ Ù¿-ó-¸·»´¼»¼ íñìŠïóïñè
ðòðêè øïòé÷ Í»´ºó-¸·»´¼»¼ ÛéïÌóè ïñîŠíñì
íñíî øîòì÷ Í»´ºó-¸·»´¼»¼ ÛéðÌóì îóïñîŠí

Ì®¿ª»´ ß²¹´» ±º É»´¼·²¹ Ù«²

The wire forms an angle in a plane parallel to the direction of travel, which is
the travel angle. In terms of a “push” or “drag,” the travel angle has a sig-
nificant effect on the weld bead. The effect of travel angle on bead shape and
penetration is shown in Figure 5.57.

With the FCAW process, a drag angle typically is used to avoid pushing slag
ahead of the arc. Slag can be trapped between passes and is a particular
problem at slower travel speeds (see Figure 5.58).

A drag angle helps push the slag back from the front of the pool and also
provides increased penetration (see Figure 5.59).

170
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Ы-¸
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ݱ²¬¿½¬ ¬«¾»

Ó±´¬»² -´¿¹

Ó±´¬»² -´¿¹
ͱ´·¼·º»¼ -´¿¹

п®»²¬
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É»´¼ б±´

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ݱ²¬¿½¬ ¬«¾»

Ó±´¬»² -´¿¹
ͱ´·¼·º»¼ -´¿¹

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É»´¼ °±±´
п®»²¬ п®»²¬
³»¬¿´ Ó»¬¿´

Ú·¹«®» ëòëç‰ß Ü®¿¹ ß²¹´» Ø»´°- Ы-¸ ¬¸» Í´¿¹ Þ¿½µ

º®±³ ¬¸» Ú®±²¬ ±º ¬¸» б±´

171
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

A drag angle from 10p to 20p is typically used with the FCAW process (see
Figure 5.60).

ïð Šîð

Ú·¹«®» ëòêð‰ß Ü®¿¹ ß²¹´» ±º ïðpŠîðp ·- ̧°·½¿´ ±º ¬¸» ÚÝßÉ Ð®±½»--

Ì®¿²-ª»®-» ß²¹´» ±º É»´¼·²¹ Ù«²

The electrode forms an angle with the workpiece in a plane perpendicular to

the to the direction of travel, which is the transverse angle (see Figure 5.61).
This angle can affect bead shape, penetration, and undercut. Excessive trans-
verse angle also can cause incomplete fusion.

ݱ®®»½¬
¿²¹´»
ß²¹´» ß²¹´»
ìðpŠìëp ¬±± ¸·¹¸ ¬±± ´±©

Ú·¹«®» ëòêï‰Ì®¿²-ª»®-» ß²¹´» ±º É»´¼·²¹ Ù«²

Û´»½¬®±¼» б-·¬·±²

The position of the electrode in the joint is an important factor in making a

quality weld (see Figure 5.62). Even if all the other operating variables are
correctly set, incorrect electrode position in the joint results in poor quality
welds.

172
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ß½½»°¬¿¾´» ˲¿½½»°¬¿¾´» ˲¿½½»°¬¿¾´»

ø»´»½¬®±¼» °±-·¬·±² ø»´»½¬®±¼» °±-·¬·±²
¬±± º¿® º®±³ ®±±¬ô ¬±± º¿® º®±³ ®±±¬ô
ª»®¬·½¿´´§÷ ¸±®·¦±²¬¿´´§÷

Ú·¹«®» ëòêî‰Û´»½¬®±¼» б-·¬·±²-

With semiautomatic applications, the welder usually positions the electrode so

that the weld pool is in the right location and the exact position of the electrode
is not a concern (see Figure 5.63).

Ú·¹«®» ëòêí‰É»´¼»® Ù«·¼·²¹ ¾§ Í·¹¸¬

With mechanized or automated welding, the welder must position the electrode
in the correct location before starting. For a horizontal fillet weld a slight offset
is often used to obtain an equal leg fillet weld (see Figure 5.64).

For circumferential joints under rotation, the position of the electrode relative
to top dead center has a major effect on bead shape. The bead shape can be
convex, flat, or concave as shown in Figure 5.65.

173
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Ѻº-»¬

Ú·´´»¬ -·¦» Ѻº-»¬

ë ³³ ±® ´»-- ð
ê ³³ ±® ¹®»¿¬»® ïŠïòë ©·®» Ñ

Ú·¹«®» ëòêì‰ß Í´·¹¸¬ Ѻº-»¬ ·- Ѻ¬»² Ë-»¼ ¬±

Ѿ¬¿·² ¿² Û¯«¿´ Ô»¹ Ú·´´»¬ É»´¼

ݱ²ª»¨

Ú´¿¬

ݱ²½¿ª»

Ú·¹«®» ëòêë‰Ì§°»- ±º Þ»¿¼ ͸¿°»- ɸ»² É»´¼·²¹

¿ Ý·®½«³º»®»²¬·¿´ Ö±·²¬ ˲¼»® ન¬·±²

174
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Í«³³¿®§ ±º ¬¸» Remember the seven essential welding variables. They are the key to making
Í»ª»² Û--»²¬·¿´ quality welds with the FCAW Process (refer to Figure 5.66).
É»´¼·²¹ Ê¿®·¿¾´»-

λ³»³¾»® ¬¸» -»ª»²

»--»²¬·¿´ ©»´¼·²¹ ª¿®·¿¾´»-ò
̸»§ ¿®» ¬¸» µ»§ ¬± °®±¼«½¬·ª·¬§ ¿²¼ ¯«¿´·¬§ ·² ÚÝßÉò

Ú·¹«®» ëòêê‰Î»³»³¾»® ¬¸» Í»ª»² Û--»²¬·¿´ É»´¼·²¹ Ê¿®·¿¾´»-

ÚÝßÉ Û¯«·°³»²¬ Typical FCAW Equipment is shown in Figure 5.67.

175
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

Ú´±©³»¬»®

Ù¿- ®»¹«´¿¬±® íð

îë

îð

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ïð

ë
ïðð íðð

ʱ´¬¿¹» ½±²¬®±´

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-»´»½¬·±²

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Ú·¹«®» ëòêé‰Ì§°·½¿´ ÚÝßÉ Û¯«·°³»²¬

176
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

É»´¼·²¹ Ý®¿¬»® Ú·´´·²¹

Ì»½¸²·¯«»-
A properly filled crater is important to ensure full throat thickness for the
complete length of the weld. Two different crater filling techniques are shown
in Figures 5.68 and 5.69.

Ì®¿ª»´ Ò±®³¿´ ©·®» °±-·¬·±²

Ó±ª» ©·®» ¬± ¾¿½µ ±º °«¼¼´»

©¸»² ®»¿¼§ ¬± ½®¿¬»® º·´´

ر´¼ °±-·¬·±² ¬± º·´´ ½®¿¬»®

¿²¼ ¬¸»² ®»´»¿-» ¬®·¹¹»®

Ú·¹«®» ëòêè‰Ý®¿¬»® Ú·´´·²¹ Ó»¬¸±¼ ï

177
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

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®»¿¼§ ¬± ½®¿¬»® º·´´

Ì®·¹¹»® ¹«² ±²ñ±ºº ¬©·½»

¬± º·´´ ½®¿¬»®

Ú·¹«®» ëòêç‰Ý®¿¬»® Ú·´´·²¹ Ó»¬¸±¼ î

178
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ͬ±°óͬ¿®¬-

To ensure good fusion and root penetration at a stop-start location, a proper

technique is required as shown in Figure 5.70.

ß®½ -¬¿®¬ É»´¼ -¬±°ñ-¬¿®¬ ͬ±° ©»´¼ ©·¬¸±«¬ ½®¿¬»® º·´´

ͬ¿®¬ ¿®½ ïñî ·²ò ¬± íñì ·²ò ¿¸»¿¼

±º ©»´¼ -¬¿®¬ °±-·¬·±² ¿²¼ ¯«·½µ´§
³±ª» ¾¿½µ ¬± ©»´¼ -¬¿®¬ °±-·¬·±²

ïñî ·²ò ¬± íñì ·²ò

Ó±ª» ¾¿½µ º¿® »²±«¹¸ ¬± ½±ª»®

Ì®¿ª»´ ½®¿¬»® ¿²¼ ©»´¼ º±®©¿®¼ ¿¬
²±®³¿´ -°»»¼

Ú·¹«®» ëòéð‰Í¬±°ñͬ¿®¬ Ì»½¸²·¯«»

179
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

λº»®»²½» The AWS Welding Handbook, Volume 2, Welding Processes, Chapter 5.

Û¨»®½·-»- To obtain maximum benefit from this chapter it is recommended that you fol-
low this guide and complete the exercises. It is important that you thoroughly
study each section carefully before moving to the next section. The exercises
are designed to give you an indication of whether you understand the material
presented. If you get a question wrong go back and read that section again.

1. The electrode wire for FCAW is:

A. Solid
B. Tubular and filled with flux
C. Tubular and filled with metal powder
D. Flux coated

2. The range of WFS and voltage for FCAW to produce acceptable welds is:
A. Less than GMAW
B. Same as GMAW
C. Greater than GMAW

3. Which of the following welding processes has the best deposition rate?
A. SMAW
B. FCAW
C. GTAW

4. The deposition efficiency of FCAW is approximately:

A. 50%
B. 25%
C. 85%
D. 100%

5. For the classification E71T-1, the 71 stands for:

A. 71,000 lb. tensile strength
B. 70,000 lb. tensile strength and all positions
C. 70,000 lb. tensile strength and flat and horizontal positions
D. 70,000 lb. Tensile strength and low hydrogen

6. Which of the following is an advantage of an Argon/CO2 shielding gas

mixture?
A. Less expensive than CO2
B. Better penetration
C. Lower fume level
D. Can use a longer contact tip to work distance

180
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

7. True or False?
Self-shielding wires produce insufficient gases to protect the weld pool
from contamination. True False

8. True or False?
Melting of the base metal (penetration) depends mainly on the amperage.
True False

9. True or False?
For self-shielding FCAW, the wire type for the same diameter does not
effect the deposition rate. True False

10. Amperage in FCAW depends mainly on:

A. Voltage
B. Wire feed speed
C. Travel speed
D. Wire feed speed and contact tip to work distance

11. List the seven essential welding variables for the FCAW process:

(1) ________________________________________________________

(2) ________________________________________________________

(3) ________________________________________________________

(4) ________________________________________________________

(5) ________________________________________________________

(6) ________________________________________________________

(7) ________________________________________________________

12. When increasing WFS or amperage with FCAW, which of the following
will occur?
A. Higher voltage
B. More porosity
C. Greater penetration
D. Less penetration
E. Greater deposition rate
F. More spatter
G. C and E

181
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

13. Too high voltage in a multipass weld leads to which of the following?

A. Slag inclusions
B. Undercut
C. Smaller weld sizes
D. A and B

14. True or False?

A push travel angle tends to produce more of a concave bead.

True False

15. When making a horizontal fillet weld with the FCAW process, the trans-
verse gun angle should be:

A. 15° to 20°
B. 40° to 45°
C. 60° to 65°
D. 90° to 95

16. Increasing arc voltage will increase which of the following?

A. Bead width
B. Penetration
C. Contact tip to work distance
D. Weld reinforcement

17. With gas-shielded FCAW, the electrode is connected DCEP. What does
this mean?

A. The welding gun is connected positive and the work lead is negative
B. The welding gun is connected negative and the work lead is positive
C. Alternating current is used
D. None of the above

18. With self-shielded FCAW, too high a voltage leads to which of the
following?

A. Narrow bead width

B. Convex bead
C. Porosity
D. None of the above

182
 ßÉÍ ÝÉÍ Ó¿²«¿´ º±® Ï«¿´·¬§ ¿²¼ Ю±¼«½¬·ª·¬§ ׳°®±ª»³»²¬
ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

19. True or False?

Increasing the contact tip to work distance will increase the current.
True False

20. For 1/16 in. diameter FCAW (E71T-9), at a CTTWD of 3/4 in., what wire
feed speed is necessary to obtain approximately 300 amps?

___________________________________________________________

183
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ݸ¿°¬»® ë‰Ú´«¨ ݱ®»¼ ß®½ É»´¼·²¹ ß°°´·»¼ ¬± Ó·´¼ ͬ»»´-

ß²-©»®- 1. B
2. C
3. B
4 C
5. B
6. C
7. True
8. True
9. False
10. D
11. (1) WFS
(2) Voltage
(3) Travel Speed
(4) Contact tip to work distance
(5) Travel angle
(6) Transverse angle
(7) Wire position
12. G
13. D
14. True
15. B
16. A
17. A
18. C
19. False
20. 275

184