Flux Cored Arc Welding (FCAW) has been a viable welding process for structural steel erection, heavy equipment repair, bridge construction and other similar applications for many years.
They offer high deposition rates, excellent chemical and mechanical properties, and the weldability needed for these jobs.
Like other welding process, flux cored welding comes with some challenges, but with some know-how and a bit of practice you can prevent common problems and gain the weld quality you need.
To help we’ve put together some tips associated with common wire feeding, porosity and worm tracking problems.
The wire melts into a ball at the end of the contact tip which is most often the result of too slow of a wire feed speed and/or holding the welding gun too close to the workpiece.
Use the correct feed speed for your application and maintain a distance from the contact tip to the workpiece of no further than132mm
A tangle of wire that halts the wire from being fed.
Porosity happens when gas becomes trapped in the weld metal and can appear at any specific point on the weld or along its full length.
Worm tracking leaves marks on the surface of the weld bead which is caused by gas the flux in the core of the wire creates.
Follow the voltage parameters recommended by the filler metal manufacturer for the specific diameter of welding wire. If worm tracking does occur, reduce your voltage by increments of one half volt until you eliminate the problem.
Using these valuable tips should result in good welding technique, and your ability to prevent these problems—or identify and rectify them quickly without sacrificing time or quality.