Fluxed Core Arc Welding (FCAW)

Introduction

Flux-cored welding, is a type of metal welding that uses a flux-cored wire made of a metal similar to the material being welded. The flux cored wire is protected by a shielding gas atmosphere, usually argon or carbon dioxide, to isolate the weld from oxygen and other airborne components that can affect the quality of the weld.

During welding, the filler wire is passed through a nozzle and fed into an arc where it is melted and applied to the weld. The welder uses the heat from the arc and the filler metal to join the parts being welded.

Flux-cored welding is particularly good for thin sheets and tubes because it produces a smooth, clean weld with little distortion or deformation. It is widely used in the manufacture of cars, machinery, equipment and structures in the construction industry. It is also a good choice for repair and maintenance work as it is quick and easy to carry out.

Areas of application

Flux-cored welding is suitable for a wide range of applications, including

• Automotive and engineering: It is widely used in the manufacture of cars, commercial vehicles, machinery and equipment.
• Construction: It is used to join steel structures, bridges, buildings and other structures.
• Repair and maintenance: It is good for repairing damaged parts and maintaining equipment.
• Container construction: Used to assemble containers for storing chemicals, gases and other materials.
• Agriculture: Used to assemble agricultural equipment such as tractors, combines and harvesters.
• Aerospace: It is used to join aircraft structures and rocket components.

Flux-cored welding is suitable for a wide range of industrial and commercial applications where high quality welds and quick and easy execution are required.

Advantages and disadvantages

The advantages of flux-cored welding are

• High quality: It produces clean and smooth welds with little distortion or deformation.
• Speed: It is a fast welding method and is therefore well suited to production-oriented applications.
• Simplicity: It is easy to learn and perform and requires little equipment.
• Versatility: It can be applied to a wide range of materials including steel, aluminium and stainless steel.

The disadvantages of flux cored welding are

• Cost: The flux cored wire and shielding gas can be expensive, especially if large quantities are required.
• Material build-up: There can be a build-up of material at the edge of the weld, which can affect accuracy.
• Cleaning: Thorough cleaning of the weld is required to maximise weld quality.
• Shielding gas requirement: It requires a shielding gas atmosphere which is not possible or difficult to achieve in some environments.