Flux wire is used in flux cored arc welding (FCAW) as an electrode with a flux core to join two pieces of metal together. There are two types of flux wire: gas shielded and self shielded. The type used depends on the thickness of the metals and the location of the welding.
Flux wire is used in a metal joining process known as flux cored arc welding (FCAW). It consists of a metal tube with a flux core and serves as an electrode during the arc welding process. The metal part of the wire liquefies during arc welding and is used to join two pieces of metal together, while the flux helps keep the weld free of contaminants. Flux is a generic term used to describe any of a variety of compounds that can act as chemical cleaning agents during a welding or brazing process. These cleaning properties can allow the flux wire to be used without shielding gas under certain circumstances.
There are two different types of flux cored arc welding and therefore two main types of flux wire. Each type is specifically designed to be used alone or in combination with a shielding gas. Generally, in arc welding, a shielding gas, such as argon, is used to keep the weld area free of contaminants and to help reduce oxidation as the weld wire is heated and subsequently cooled.
Gas shielded flux core wire uses the same general principle as normal gas shielded arc welding. The flux present in the wire can also help when welding in awkward locations, as the flux can cool faster than liquefied wire. This can potentially create some sort of protrusion to hold the liquid solder in place until it solidifies. Slag, or solidified flux, may also be easier to remove with this method.
The other type of flux wire is known as self shielded. This variety may be more portable and easier to use, as it does not require carrying shielding gas cylinders to the weld site. When the flux in the self-shielded flux wire melts, it can create its own protective shielding gas. While this has a similar effect to the gas used in shielded gas arc welding, it can result in less aesthetically pleasing welds.
Using a traditional gas shield method or one of the flux wire varieties is often dictated by the thickness of the metals being joined and where the welding is being done. If the solder is in an awkward spot and it may be difficult to keep the solder material in place, gas shielded flux wire is often used. Self-shielded flux wire may be convenient in other circumstances, such as if welding must be done outdoors in windy conditions. While the wind can blow away the traditional shielding gas, the self-shielding variety can continuously create a shielding pocket of inert gas as the stream is melted.
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