Flux-Cored Arc Welding (FCAW): Definition, Applications & Equipment Guide

Today I will be discussing the definition, applications, diagram, equipment, advantages and disadvantages of flux-cored arc welding (FCAW). Previously, some articles were published on arc welding. checkout!

• Understanding Metal inert gas welding (MIG)
• Understanding shielded arc welding (SMAW) 
• Working principles of SMAW

What is Flux cored arc welding (FCAW)?

Flux cored arc welding is another type of arc welding process that uses consumable electrode that contain flux around it. it is known as semi-automatic or automatic arc welding process. The coalescence of metal is produce by heating with an arc between continuously fed electrode and the base metals. The shielding is obtained by the flux in the electrode. Additional shield may and may not be added from an externally supplied inert gas. That is, shielding gas is supplied from an external source such as gas cylinder or a shield flux coated around the electrode which is deposited when melted.

The flux melts together with the electrode during the welding process and shield the joint, granting the entire weld area with shielding gas. It protects the welds pool from atmosphere.

Applications

The followings are the applications of FCAW:

• This arc welding process is find important in shipbuilding industry as it save huge labour cost.
• It is also used in many construction industries in welding aspect.
• It is widely applicable in mechanical industries.
• FCAW can be used on plain carbon, alloy, stainless and duplex steels.
• It is used for hard facing and surfacing.

Diagram of flux cored arc welding:

Working of FCAW

The working of flux cored arc welding FCAW is less complex and can be easily understood. Unlike other arc welding process that uses AC or DC power supply, FCAW supplies power only from DC electric arc to the welding gun. The arc is produce when the gun is struck between the continuously fed consumable filler wire and the workpiece. It create the weld pool and bond when the pool solidifies.

Watch the video below to learn more on the working of flux cored arc welding FCAW:

Advantages and disadvantges of flux cored arc welding (FCAW)

Advantages

Below are the advantages of FCAW:

• It has different ways of supplying shielding gas
• It may be applied to all welding position
• Shielding gas is not needed for some its wires are suitable in windy conditions
• It has high deposition rate
• Chances of porosity are very low
• Less cleaning of base metal

Disadvantages

Despite the great benefits of FCAW, some disadvantages still occur. Below are the limitations of flux cored arc welding in their various applications.

• It produces slag, which must be removed after welding
• It produces more smoke which is hazardous to the welder
• Cost of applied wire
• It Is complex and more expensive
• It produces more spatter

That is all for this article, where the definition, applications, diagram, equipment, advantages and disadvantages of flux core welding (FCAW) are being discussed. I hope you get a lot from the reading, if so, kindly share with other students. Thanks for reading, see you next time!