Tips For Avoiding Common Flux-Cored Problems &

Improving Your FCAW Welds

Self-shielded 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. Thats not surprising, as it
offers high deposition rates, excellent chemical and
mechanical properties, and the weldability required for
these jobs. Still, it doesnt mean that the process is without
its challenges. Fortunately, with some know-how and a bit
of practice, you can prevent some of the common
problems associated with the process and gain the weld
quality you need.
Tip One: Avoid Wire Feeding Problems
Wire feed stoppages and malfunctions are common
problems on many job sites and they can cause a
considerable amount of downtime. The two most prevalent
type of wire feeding problemsburnback and birdnesting
tend to extinguish the arc prematurely, which in turn can
lead to weld defects.
Burnback occurs when the wire melts into a ball at the end
of the contact tip and is most often the result of too slow of
a wire feed speed and/or holding the welding gun too close
to the workpiece. To prevent the problem, be sure to use the correct feed speed for your
application and maintain a distance from contact tip to the work of no further than 1 1/4inch.
Flux-cored welding offers many advantages
when welding on construction applications,
including high disposition rates, and good
chemical and mechanical properties.

To prevent birdnestinga tangle of wire that halts the wire from being fedduring FCAW
welding, always use knurled V- or U-groove drive rolls in your wire feeder. Compared to a
GMAW solid welding wire (which uses a smooth V-groove drive roll), FCAW wire is much
softer (due to its tubular design) and if you use the incorrect drive roll, it can easily
compress the wire.

Prevent burnback, as shown here, by having

the appropriate wire feed speed and MIG
gun to work piece distance.

Additionally, setting the correct drive roll tension can prevent the wire from flattening and
becoming tangled. To set the proper tension, begin by releasing the tension on the drive
rolls. Increase the tension while feeding the wire into the palm of your welding glove and
continue to increase the tension one half turn past wire slippage.

Using the correct drive rolls and tension

settings can prevent birdnesting.

Other causes of birdnesting include blockages in the liner, improperly trimmed liners or
using the wrong liner. Promptly replace your liner if you find a blockage during your routine
inspection of your welding gun and cables, and always trim the liner (using the correct
tools) according to the manufacturers recommendation. Be certain that the liner does not
have any burrs or sharp edges and always use the correct size liner for your diameter of
welding wire.
Tip Two: Stop Porosity and Worm Tracking
Porosity and wormtracking are both common weld discontinuities that can weaken the
integrity of your welds. Porosity results when gas becomes trapped in the weld metal and
can appear at any specific point on the weld or along its full length. To prevent this problem,
remove any rust, grease, paint, coatings, oil, moisture and dirt from the base metal prior to
welding. Using filler metals with added deoxidizers also helps weld through such
contaminants, but these products should never replace proper pre-cleaning. Next, maintain
an appropriate electrode extension or stick-out. As a general rule, the wire should extend no
more than 1 1/4-in. beyond the contact tip.

To prevent worm trackingmarks on the surface of the weld bead caused by gas that the
flux in the core of the wire createsavoid excessive voltage for your given wire feed setting
and amperage. It is best to follow the 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.
Tip Three: Eliminate Slag Inclusions
Slag inclusions occur when the slag generated by the molten flux in the wires core
becomes trapped inside of the weld. There are four major causes of slag inclusions, all of
which can be prevented with proper welding techniques.
First, avoid incorrect weld bead placement, especially when making multiple passes on
thick sections of metal, such as needed for the root passes of welds or wide v-groove
openings. Be certain to provide sufficient space in the weld joint for additional passes,
particularly on joints requiring multiple passes.

To prevent worm tracking, use the manufacturer's recommended

parameters for your given wire diameter and lower your voltage
setting if necessary.

Second, maintain the correct travel angle

and travel speed. In the flat, horizontal,
and overhead positions your drag angle
should be between 15 and 45 degrees. In
the vertical up position, your drag angle
should be between 5 and 15 degrees. If
you experience slag inclusions at these
angles, you should increase your drag
angle slightly. Maintain a steady travel
speed; if you travel too slowly, the weld
puddle will get ahead of the arc and create
slag inclusions.

Next, maintain proper weld heat input, as too low of welding heat input can also cause slag
inclusions. Always use the manufacturers recommended parameters for a given wire
diameter. If slag inclusions still occur, increase the voltage until the inclusions cease.
Finally, be certain to clean thoroughly between weld passes, removing any slag with a
chipping hammer, wire brush or grinding before beginning your next weld pass.
Tip Four: Prevent Undercutting and Lack of Fusion
Like other weld defects, undercutting and lack of fusion can both affect the quality of your
welds and preventing them can go far in reducing downtime and costs for rework.
Undercutting occurs when a groove melts in the base metal next to the toe of the weld, but
is not filled by the weld metal. It causes a weaker area at the toe of the weld and often
leads to cracking. Using the proper welding current and voltage are key to preventing
undercutting (remember to follow your welding parameters), as is adjusting to the right gun
angle. Maintain a travel speed that allows the weld metal to fill the melted-out areas of the
base metal completely, or if you are using a weaving technique, pause at each side of the
weld bead.
To prevent lack of fusion, the failure of the weld metal to fuse completely with the base
metal (or the preceding weld bead in multi-pass applications), maintain the correct work
angle and heat input. Obtain the correct angle by placing the stringer bead in its proper

location at the joint, adjusting the work angle or widening the groove to access the bottom
during welding as needed. Keep the arc on the trailing edge of the welding puddle and
maintain a gun angle drag of 15 to 45 degrees. If using a weaving technique, momentarily
hold the arc on the groove sidewalls when welding. Increase your voltage range and/or
adjust the wire feed speed as necessary to obtain complete fusion. Also, if you feel that the
wire is getting ahead of the work puddle, simple adjustments, such as increasing travel
speed or using a higher welding current, can prevent problems.
Finally, be certain to clean the surface of the base metal prior to welding to remove
contaminants to prevent lack of fusion.
Tip Five: Avoid Excessive Penetration or Lack of Penetration
Maintaining the appropriate heat input during welding is key to avoiding problems like
excessive penetration. Excessive penetration occurs when the weld metal melts through the
base metal and hangs underneath the weld. It most often results from too much heat. If the
problem occurs, select a lower voltage range, reduce wire feed speed and increase travel
speed.
Conversely, selecting a higher wire feed speed, a higher voltage range and/or reducing
travel speed can prevent problems like lack of penetrationthe shallow fusion between the
weld metal and the base metal. In addition, prepare the joint so as to permit access to the
bottom of the groove, while also maintaining proper welding wire extension and arc
characteristics.
Final Tips
Self-shielded FCAW is a reliable process for many construction applications, but obtaining
high quality welds with it isnt a matter of luck. Its the result of good welding technique, the
proper choice of parameters and your ability to prevent problemsor identify and rectify
them quickly. Remember, arming yourself with some basic information will allow you to
prevent most common problems associated with self-shielded FCAW welding without
sacrificing time or quality.