Repri nt ed f rom

Pract i cal Wel di ng Today

January/ February 2000
USI NG FLUX-CORED AND
METAL-CORED WI RE
W.F. Garth Stapon
Praxair, Inc.
Marketing Manager
Metal Fabrication
January/February 2000 Vol. 4 No.1
By W. F. Garth Stapon
F
lux cored arc welding (FCAW) use
continues to grow in industry, in-
cluding shop fabrication and con-
struction, because it offers benefits com-
pared to other open-arc processes. This
process has grown primarily because of
the conversion from shielded metal arc, or
stick, electrode welding (SMAW) to FCAW.
FCAW is a good choice for flat and hor-
izontal welding of mild and stainless
steels that are thicker than
1
8 inch, and it
also is available in out-of-position formu-
lations that allow vertical-up and over-
head welding.
The introduction of smaller-diameter,
all-position flux-cored wires and metal-
cored wires has contributed to the
increased use of this process. In addition,
weld quality on mildly contaminated base
materials may improve by switching from
stick electrodes to FCAW.
Compared to stick electrodes, FCAW
offers greater deposition efficiency and in-
creased deposition rates on steel and
stainless steel. Improved deposition ef-
ficiency means that more filler metal is
deposited for each pound of weld metal
purchased.
Typically, welding with stick elec-
trodes offers a deposition rate of 2 to 8
pounds per hour, depending on the weld-
ing position, electrode diameter, and oper-
ating current. Flux-cored wires can deposit
filler metal from 6 to 20 pounds per hour.
Deposition efficiency for FCAW also is
increased when compared to SMAW.
Typically, deposition efficiency of SMAW
ranges from 50 to 65 percent, but may be
lower because of excessive stub loss.
Because FCAW uses a continuously fed
wire electrode, the operators duty cycle is
Tips for power source
selection and gas use
improved. Welding with stick electrodes
ranges from 10 to 30 percent operator
duty cycle. Flux-cored wire can achieve
20 to 40 percent duty cycle, with metal-
cored wire achieving as high as 45 per-
cent. (More time can be spent welding
because less time is spent changing elec-
trodes.)
Welding deposition efficiency is influ-
enced by electrode grade and diameter,
welding position, alloying elements, shield-
ing gas, and operating conditions. Flux-
cored wire efficiency ranges from 82 to 95
percent when using metal- cored wires.
FCAW offers other operating advan-
tages. The process offers improved weld-
ing penetration when compared to gas
metal arc welding (GMAW), or MIG weld-
ing. Factors impacting penetration in-
clude filler metal diameter, type of
shielding gas, welding technique, oper-
ating current, electrical stick-out, and
base metal thickness. The process can
produce high-quality results with a lower
level of operator skill. Push and pull tech-
niques can be applied while controlling
welding undercut.
Resistance to mild base-metal contam-
ination also is an advantage, particularly
when compared to GMAW. Preweld clean-
ing always is recommended, but some
specific types of electrodes have been
developed that have improved resistance
to mild base-metal contamination.
The greatest operational benefit of
FCAW is productivity improvement. Al-
though welding can be achieved most
economically in the flat and horizontal
positions, if large structures prevent such
positioning, wires that have a fast-freeze
flux that increases control and productiv-
ity when compared to SMAW or pulsed
GMAW are available.
Shielding Gas for
Gas-shielded Wires
Some filler metal formulations are
available that do not require a shielding
gas, but the most widely applied wires
use an auxiliary shielding gas. Shielding
gas selection should be matched accord-
ing to the filler metal manufacturers rec-
ommendations.
The two most commonly applied
shielding gases are carbon dioxide (CO
2
)
and C-25 [75 percent argon (Ar)/25 per-
cent CO
2
]. Some metal-cored wires can be
used with 90 percent Ar/10 percent CO
2
and 95 percent Ar/5 percent O
2
.
When welding with large-diameter
wires (more than
3
32 inch), CO
2
is the
most commonly used shielding gas. These
gases are used on thick material (more
than
1
2 inch) in the flat or horizontal
welding positions. A by-product of this
combination is additional welding fume
when compared with GMAW, but total
fume produced varies, depending on the
wire grade and manufacturer.
Shielding gas also impacts the amount
of welding spatter and fume production.
Some shielding gases, such as 75 percent
Ar/25 percent CO
2
, have good electrical
conductivity and low reactivity. This limits
the oxidizing power of the shielding gas
because argon remains inert at arc oper-
ating temperatures.
Because argon-based mixtures conduct
electrical current better than CO
2
, arc
starts are improved, and spatter levels are
reduced. Changing the shielding gas from
CO
2
to an argon-based blend can result in
up to a 5 percent improvement in deposi-
tion efficiency. Bead profile also is
enhanced because the mixed gas im-
proves weld puddle fluidity.
When welding out of position, the
controlled oxidizing power of the mixed
gas also yields lower free-oxygen content,
which enables the weld puddle to freeze
faster. This may enhance productivity
because it permits the use of higher oper-
ating conditions, including higher wire
feed speeds and voltages, when compared
to the use of straight CO
2
shielding gas.
Some heat conductivity is sacrificed
when compared to pure CO
2
. However,
the penetration profile can be maintained
as penetration is impacted positively by
the higher operating conditions.
Shielding Gas Tips
When using pure CO
2
, it may be neces-
sary to throttle back or reduce the op-
erating condition to control weld spatter.
Less spatter may be the result, but this
may have an adverse impact on produc-
tivity because the welder must use
reduced wire feed speeds and voltages to
prevent it.
Both argon-based mixtures and CO
2
are heavier than air. When flat-position
welding, these gases are an asset as
greater specific gravity means that suffi-
cient shielding can be achieved with a
flow rate as low as 30 cubic feet per hour
(CFH).
When welding out of position, the
shielding gas flow must be increased to
prevent porosity. Shielding gas flow must
be matched closely to electrical stick-out.
When the nozzle-to-work distance is
increased, the flow rate also must be
increased.
The maximum recommended flow rate
should be 55 CFH. If greater flows are
used, costs increase.
Welders typically do not monitor gas
flow as closely as they should; thus, us-
ing a limiting orifice device helps to con-
trol the gas flow rate without compromis-
ing weld quality. These devices also limit
gas surge. When tack welding or skip
welding, costs can be reduced because less
shielding gas is needed.
Although CO
2
shielding gas commonly
is applied to support FCAW, its use may
contribute to excessive welding fume.
The welding arc can reach very high tem-
peratures, causing the shielding gas to
disassociate into carbon monoxide and
free oxygen.
Because the alloying elements in the
wire are designed to work with specific
shielding gases, care should be taken
when selecting a wire and shielding gas
combination. Follow the wire manufactur-
er recommendations; failure to do so may
result in weld cracking.
Selecting the Power Supply
In many cases, productivity can be
increased without investing in a pulsed
GMAW system. Because operating condi-
tions range from 150 to 450 amps, the
power supply should be designed for the
application at hand.
Constant-voltage (CV) equipment
Article reprinted with permission from the Jan/Feb 2000 issue of Practical Welding Today

.
FABRICATORS & MANUFACTURERS ASSOCIATION, INTL. 833 FEATHERSTONE RD. ROCKFORD, IL 61107-6302
815-399-8700 Fax: 815-484-7700 Web Site: www.fmametalfab.org E-mail: info@fmametalfab.org
typically is required to perform FCAW.
Special feeders that allow cored wire to
be used on a direct current (DC)/con-
stant-current (CC) power supply are
available. However, these systems typi-
cally are limited to small-diameter wires
(up to 0.045 inch) and operating cur-
rents of 300 amps or less.
Care should be taken in selecting a
power supply with adequate output be-
cause many SMAW power supplies are
rated at 40 percent duty cycle at 250
amps. By operating at 300 amps, the duty
cycle is reduced to approximately 25 per-
cent within the range of the process. By
not allowing sufficient cooling time for
the power supply, overheating and possi-
ble failure may result.
The voltage-sensing feeder is designed
so that the wire feed motor can maintain
arc length with a change in arc character-
istics. These are low-cost systems but do
not lend themselves to use in high-pro-
ductivity applications. G
W. F. Garth Stapon is Marketing Manager
Metal Fabrication for Praxair, Inc., 39 Old
Ridgebury Road, Danbury, Connecticut 06810,
phone 800-PRAXAIR or 716-879-4077, fax 800-
772-9985 or 716-879-2040, e-mail garth_
stapon@praxair.com, Web site www.praxair.
com. Praxair, Inc., produces, sells, and distrib-
utes atmospheric, process, and specialty gases
and surface coatings.
Copyright 2000 Praxair Technology, Inc.
All rights reserved
Praxair, Inc.
39 Old Ridgebury Road
Danbury, CT 06810-5113
USA
www.praxair.com
info@praxair.com
Telephone:
1-800-PRAXAIR
(1-800-772-9247)
(716) 879-4077
Fax:
1-800-772-9985
(716) 879-2040
Praxair and the Flowing Airstream design
are trademarks or registered trademarks of
Praxair Technology, Inc. in the United States
and/or other countries.
The information contained herein is offered
for use by technically qualified personnel at
their discretion and risk without warranty of
any kind.
Printed in the United States of America
2-2000
P-8452 3M