70:
the arc. This type of FCAW is attractive because it is portable and generally has good penetration into the base metal. Also, windy conditions need not be considered. Some disadvantages are that this process can produce excessive, noxious smoke (making it difficult to see the weld pool). As with all welding processes, the proper electrode must be chosen to obtain the required mechanical properties. Operator skill is a major factor as improper electrode manipulation or machine setup can cause
78:
69:
One type of FCAW requires no shielding gas. This is made possible by the flux core in the tubular consumable electrode. However, this core contains more than just flux. It also contains various ingredients that when exposed to the high temperatures of welding generate a shielding gas for protecting
99:
or GMAW processes. In practice it also allows a higher production rate, since the operator does not need to stop periodically to fetch a new electrode, as is the case in SMAW. However, like GMAW, it cannot be used in a windy environment as the loss of the shielding gas from air flow will produce
85:
Another type of FCAW uses a shielding gas that must be supplied by an external source. This is known informally as "dual shield" welding. This type of FCAW was developed primarily for welding structural steels. In fact, since it uses both a flux-cored electrode and an external shielding gas, one
90:) and FCAW. The most often used shielding gases are either straight carbon dioxide or argon carbon dioxide blends. The most common blend used is 75% Argon 25% Carbon Dioxide. This particular style of FCAW is preferable for welding thicker and out-of-position metals. The
94:
created by the flux is also easy to remove. The main advantages of this process is that in a closed shop environment, it generally produces welds of better and more consistent mechanical properties, with fewer weld defects than either the
239:
57:
is sometimes used, but often the flux itself is relied upon to generate the necessary protection from the atmosphere, producing both gaseous protection and liquid
374:
213:
Porosity – the gases (specifically those from the flux-core) don’t escape the welded area before the metal hardens, leaving holes in the welded metal.
243:
267:
222:
Changing filler metals requires changing an entire spool. This can be slow and difficult as compared to changing filler metal for SMAW or GTAW.
130:
Reverse polarity (Electrode
Positive) is used for FCAW Gas-Shielded wire, Straight polarity (Electrode Negative) is used for self shielded FCAW
336:
297:
199:
Of course, all of the usual issues that occur in welding can occur in FCAW such as incomplete fusion between base metals, slag inclusion (
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Metallurgical benefits from the flux such as the weld metal being protected initially from external factors until the slag is chipped away
367:
283:"Flux Cored Welding." Welding Procedures & Techniques. 23 June 2006. American Metallurgical Consultants. 13 Sep 2006 <
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Melted contact tip – when the contact tip actually contacts the base metal, fusing the two and melting the hole on the end.
203:), and cracks in the welds. But there are a few concerns that come up with FCAW that are worth taking special note of:
360:
329:
290:
Groover, Mikell P. Fundamentals of Modern
Manufacturing. Second. New York City: John Wiley & Sons, INC, 2002.
512:
322:
457:
293:"Solid Wire Versus Flux-Cored Wire - When to Use Them and Why." Miller Electric Mfg. Co. 13 Sep 2006 <
434:
96:
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No shielding gas needed with some wires making it suitable for outdoor welding and/or windy conditions
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264:
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651:
399:
200:
507:
294:
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FCAW may be an "all-position" process with the right filler metals (the consumable electrode)
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558:
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308:
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A high-deposition rate process (speed at which the filler metal is applied) in the 1G/1F/2F
50:
8:
467:
584:
522:
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472:
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39:
482:
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The amount of smoke generated can far exceed that of SMAW, GMAW, or GTAW.
31:
646:
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631:
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35:
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43:
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Less equipment required, easier to move around (no gas bottle)
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process. FCAW requires a continuously-fed consumable tubular
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http://www.millerwelds.com/education/articles/article62.html
280:
American
Welding Society, Welding Handbook, Vol 2 (9th ed.)
156:
91:
87:
265:
Are
Welding Fumes an Occupational Health Risk Factor?
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More costly filler material/wire as compared to GMAW.
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Irregular wire feed – typically a mechanical problem.
240:""CHOOSING A SHIELDING GAS FOR FLUX-CORED WELDING""
152:Some "high-speed" (e.g., automotive) applications
86:might say that it is a combination of gas metal (
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16:Semi-automatic or automatic arc welding process
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368:
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159:, there is less skill required for operators.
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285:http://www.weldingengineer.com/1flux.htm
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127:Shielding gas composition (if required)
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263:American Society of Safety Engineers,
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318:
103:
133:Contact tip to work distance (CTWD)
81:A drawing of FCAW at the weld point
30:) is a semi-automatic or automatic
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162:Less precleaning of metal required
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689:
344:
194:
190:Some wearfacing/surfacing alloys
435:Shielded metal (Stick/MMA/SMAW)
425:Gas tungsten (Heliarc/TIG/GTAW)
420:Gas metal (Microwire/MIG/GMAW)
257:
232:
46:or, less commonly, a constant-
1:
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176:Used on the following alloys:
400:Atomic hydrogen (Athydo/AHW)
7:
382:
138:Advantages and applications
10:
694:
53:. An externally supplied
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577:
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458:Electric resistance (ERW)
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181:Mild and low alloy steels
168:Porosity chances very low
155:As compared to SMAW and
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201:non-metallic inclusions
187:Some high nickel alloys
309:Flux Cored Arc Welding
100:porosity in the weld.
82:
20:Flux-cored arc welding
652:Tools and terminology
80:
61:protecting the weld.
51:welding power supply
488:Friction stir (FSW)
463:Electron-beam (EBW)
124:Electrode wire type
115:Electrode extension
585:Heat-affected zone
513:Oxyacetylene (OAW)
300:2006-10-15 at the
270:2013-07-21 at the
83:
665:
664:
608:
607:
468:Electroslag (ESW)
415:Flux-cored (FCAW)
104:Process variables
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498:Laser beam (LBW)
405:Electrogas (EGW)
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311:before the 1950s
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242:. Archived from
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184:Stainless steels
121:Electrode angles
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595:Residual stress
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450:Other processes
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440:Submerged (SAW)
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302:Wayback Machine
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272:Wayback Machine
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109:Wire feed speed
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67:
42:and a constant-
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12:
11:
5:
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590:Photokeratitis
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508:Magnetic pulse
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578:Related terms
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569:Shielding gas
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493:Friction stud
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246:on 2019-03-02
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195:Disadvantages
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55:shielding gas
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38:containing a
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33:
29:
25:
21:
559:Power supply
549:Filler metal
503:Laser-hybrid
430:Plasma (PAW)
414:
346:Metalworking
259:
248:. Retrieved
244:the original
234:
198:
175:
174:
118:Travel speed
84:
68:
27:
23:
19:
18:
678:Arc welding
622:Fabrication
600:Weldability
392:Arc welding
307:History Of
112:Arc voltage
32:arc welding
642:Metallurgy
523:Ultrasonic
518:Spot (RSW)
473:Exothermic
250:2019-03-02
227:References
637:Machining
632:Jewellery
544:Electrode
537:Equipment
36:electrode
672:Category
647:Smithing
483:Friction
298:Archived
268:Archived
72:porosity
657:Welding
627:Forming
617:Casting
384:Welding
48:current
44:voltage
554:Helmet
564:Robot
528:Upset
478:Forge
410:Flash
304:>.
287:>.
65:Types
157:GTAW
97:SMAW
92:slag
88:GMAW
59:slag
40:flux
24:FCAW
28:FCA
26:or
674::
74:.
376:e
369:t
362:v
338:e
331:t
324:v
253:.
22:(
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