Flux Core Arc Welding (FCAW) is a welding process that uses a flux-filled consumable hollow electrode. It can use external shielding gas or rely on the flux content of the electrode. FCAW has advantages over shielded metal arc welding, including high welding speeds and less pre-cleaning. FCAW machines work with constant voltage or current power supplies and offer flexibility in electrode extension lengths, feeding rate, angle, and physical speed. FCAW can be used in locations not practical with SMAW processes and allows efficient welding in windy outdoor conditions without using a shielding gas.
Flux Core Arc Welding (FCAW) is an automated or semi-automated arc welding process that uses a flux filled consumable hollow electrode. FCAW machines typically operate on a constant voltage power supply, although some examples use constant current power supplies. There are two basic types of FCAWs: one that uses an external shielding gas supply and one that relies on the flux content of the electrode to ensure surface protection. Flux core arc welding is suitable for a wide range of metals and has several advantages over shielded metal arc welding processes. These include high welding speeds, less pre-cleaning of workpieces and a wide range of convenient welding positions.
Conventional manual or shielded metal arc welding (SMAW) processes use single electrodes covered in flux to generate the arc. Flux core arc welding uses a continuous, consumable electrode that is hollow in cross section and filled with flux. The electrode is wound onto a drum or coil on the FCAW machine. As the electrode wears at the weld point, the machine advances the electrode coil, thus ensuring continuous electrode contact.
FCAW machines work with constant voltage or constant current power supplies. On constant voltage machines, the voltage is set and the arc current or amperage can be manipulated to suit the needs of the job; constant current machines have a set amperage. The two main types of flux core arc welders are those that use external shielding gas supplies and those that rely on the electrode flux core alone to protect the weld surface from oxidation.
The animated welding process is quite flexible and offers several variables that can be manipulated to suit the demands of the job. These include the extension lengths of the electrode and the rate at which the electrode feeds. The angle of the electrode and the physical speed of movement can also be adjusted. When external shielding gas supplies are used, there is also a selection of shielding gas compositions to choose from.
The FCAW process offers many advantages over manual arc welding. Flux core welders can be used in a range of locations that are not practical with SMAW processes. Welding speeds are also higher with less need for pre-cleaning of weld materials. The electrode design of flux core arc welders also allows efficient welding in windy outdoor conditions without having to use a shielding gas. A point to remember in this regard is that the gases emitted from the process in the absence of a shielding gas can be extremely toxic and require forced ventilation.
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