5 Welding Processes

Part 3 of 3

5.5 FLUX CORED ARC WELDING (FCAW)

FCAW is an arc welding process that uses an arc between continuous tubular
filler metal electrode and the weld pool. The process is used with shielding
gas evolved from a flux contained within the tubular electrode, with or without
additional shielding from an externally supplied gas, and without the
application of pressure. Normally a semiautomatic process, the use of FCAW
depends on the type of electrodes available, the mechanical property
requirements of the welded joints, and the joint designs and fit-up.
The recommended power source is the dc constant-voltage type, similar to
sources used for GMAW. Figures 7 and 8 show a schematic of FCAW
equipment and welding process with additional gas shielding. Figure 9 shows
a schematic of the self-shielded FCAW process where no additional gas is
used.

CV

Flux cored arc welding (FCAW)

FCAW

CV

FCAW

CV

FCAW-Self shield

CV

FCAW-Self shield

CV

FCAW

FCAW

FCAW

FCAW

3G FCAW WPQT

FCAW

CV

FCAW

http://www.brewerweldingandfabrication.com/OrbitalWelding.htm

5.5.1 Advantages of FCAW

Some commonly accepted advantages of the FCAW process include:
a. The metallurgical benefits that can be derived from a flux.
b. Slag that supports and shapes the weld bead.
c. High deposition and productivity rates than other processes such as
SMAW.
d. Shielding is produced at the surface of the weld that makes it more
tolerant of stronger air currents than GMAW.
5.5.2 Limitations of FCAW
Limitations associated with FCAW process are:
a. Equipment is more complex, more costly, and less portable than that for
SMAW.
b. Self-shielding FCAW generates large volumes of welding fumes, and
requires suitable exhaust equipment.
c. Slag requires removal between passes.
d. Backing material is required for root pass welding.

CV

5.6 SUBMERGED ARC WELDING (SAW)

Submerged arc welding is an arc welding process that uses an arc or arcs
between a flux covered bare metal electrode(s) and the weld pool. The arc
and molten metal are shielded by a blanket of granular flux, supplied through
the welding nozzle from a hopper. The process is used without pressure and
filler metal from the electrode and sometimes from a supplemental source
(welding rod, flux, or metal granules). SAW can be applied in three different
modes: semiautomatic, automatic, and machine. It can utilize either a CV or
CC power supply. SAW is used extensively in shop pressure vessel
fabrication and pipe manufacturing. Figure 10 shows a schematic of the SAW
process.
Manual
Semiautomatic
Automatic
Machine

CV

5.6.1 Advantages of SAW

Some commonly accepted advantages of the SAW process include:
a. Provides very high metal deposition rates.
b. Produces repeatable high quality welds for large weldments and repetitive
short (defective) welds.
5.6.2 Limitations of SAW
Limitations associated with SAW are:
a. A power supply capable of providing high amperage at 100% duty cycle is
recommended.
b. Weld is not visible during the welding process.
c. Equipment required is more costly and extensive, and less portable.
d. Process is limited to shop applications and flat position.

CV

SAW

CV

Submerged arc welding (SAW)

Submerged arc welding (SAW)

Submerged arc welding (SAW)

Submerged arc welding (SAW)

Submerged arc welding (SAW)

Submerged arc welding (SAW)

Submerged arc welding (SAW)

Submerged arc welding (SAW)

SAW Twin electrodes in tandem with guider

SAW- Triple Electrodes Set-up (tilted)

SAW- Portable single Electrode Unit

SAW Experts at Work

Spiral welding SAW- API 5LS

Spiral Welded SAW Pipes

SAW- Pressure Vessel Conical Head Welding

SAW- Vessel Internal Welding

2G SAW Tank Semi-Automatic Welding

SAW- Spiral Welded Pipes

SAW
SAW- Internal Welding Leg Cane

SAW- Serious Experts at Work

SAW- Welding on a Rotorary Wheel Set-up

SAW- Vessel Ellipsoidal Disk Head

SAW- Pressure Vessel

SAW- Pipe Can Welding

SAW- Structural Mud Mats

SAW- Structural Welding

5.7 STUD ARC WELDING (SW)

SW is an arc welding process that uses an arc between a metal stud or
similar part and the work piece. Once the surfaces of the parts are properly
heated, that is the end of the stud is molten and the work has an equal area
of molten pool, they are brought into contact by pressure. Shielding gas or
flux may or may not be used. The process may be fully automatic or
semiautomatic. A stud gun holds the tip of the stud against the work. Direct
current is typically used for SW with the stud gun connected to the negative
terminal (DCEN). The power source is a CC type. SW is a specialized
process predominantly limited to welding insulation and refractory support
pins to tanks, pressure vessels and heater casing.

5.7.1 Advantages of SW
Some commonly accepted advantages of the SW process include:
a. High productivity rates compared to manually welding studs to base metal.
b. Considered an all-position process.
5.7.2 Limitations of SW
Limitations of SW are:
a. Process is primarily suitable for only carbon steel and low alloy steels.
b. Process is specialized to a few applications.

Stud arc
welding (SW)

Stud arc welding (SW)

Stud arc welding (SW)

Stud arc welding (SW)

Stud arc welding (SW)

Welding Transfer Modes:

SMAW
TIG
SW
SAW
GMAW
FCAW

- CC
- CC
- CC
- CC or CV
- CV
- CV

Further Reading: (Non Examination)

1.
2.
3.
4.

GMAW Welding 1
GMAW Welding 2
CV & CC Welding Modes
Other Interesting Readings

1. Reading 1
Considering the benefits of pulse spray transfer GMAW
PRACTICAL WELDING TODAY SEPTEMBER/OCTOBER 2001
October 25, 2002
By: Paul Niskala
http://www.thefabricator.com/article/arcwelding/considering-the-benefits-of-pulse-spray-transfer-gmaw

1.0

General

Pulse spray gas metal arc welding (GMAW) is a versatile welding process.
Sometimes welding suppliers and welding managers don't want to try it,
because they don't want to change the process they're using, train users,
adjust welding processes, or spend money on new equipment. While any
pulse spray machine can perform short-circuit transfer, each type of transfer
has distinct differences and benefits.

1.1

Three Common Types of Transfer for GMAW

Short-circuit ,spray transfer and pulse-spray are the three most common
types of GMAW metal transfer.

1.3

The short-circuit process

In the short-circuit process, when the wire touches the base metal, it causes a
short circuit. The base metal and wire become molten at the point where the
wire touches the base metal, and the wire is pinched off. Spatter, in the form
of round, molten balls that stick to the base metal, is a result of the sudden
separation, or transfer, of the wire.
The Short Circuit process can weld sheet metal and commonly is used for
joining materials 1/4 in. (6mm) thick or less. Its fast-freezing puddle
characteristic makes welding in all positions simple.

Short-circuiting is a low-heat-input process, generally less than 20 volts and

200 amps (4000 Volt-Ampere Apparent Power) using small-diameter
welding wires no larger than 0.045 in. (1mm) The short-circuit process can
weld materials that fit poorly. Besides shielded metal arc welding, it's probably
the least expensive GMAW process because of the low welding currents
involved, which require smaller, less expensive equipment.
Short-circuit also is the most abused process because welders use it
frequently for jobs that the process was not designed for, such as welding
metals thicker than the process reasonably allows.

The short-circuit process is not a deep-penetrating process and is not suited

for welding thick materials. It also lacks penetration at the toes of the weld,
especially in out-of-position welding, causing cold laps (lack of fusion).
Disadvantages of short-circuit include excessive spatter and low deposition
rates. It generally is not recommended for aluminum or other alloys, which
typically require higher heat input to obtain proper fusion.
short-circuiting can be beneficial because:
It can be used for welding sheet metal.
It can weld materials 1/4 in. (6mm) thick or less.
It can be used to weld in all positions.
It uses low heat input, generally less than 20 V and 200 amps, using
small-diameter welding wires no larger than 0.045 in. (1.2mm)
It can weld materials that fit poorly.

1.4

The Spray Transfer Mode

Spray transfer uses higher voltage and higher percentages of argon mixtures,
80 percent or better, mixed with carbon dioxide or small amounts of oxygen.
This high-energy output causes the droplets to be very small and burn off the
wire before short-circuiting occurs. This small stream of droplets creates a
fluid spray, which melts the base metal. Using higher operating parameters
results in deeper penetration. The biggest benefit of the spray transfer
process is its ability to make high-deposition welds on thick carbon steels,
stainless steels, aluminum, and other alloys using large-diameter welding
wires (0.052 in. and 0.062 in.) (1.3mm 1.6mm) with very little spatter and no
cleanup.

By using 0.035- and 0.045-in.-dia. (0.9mm 1.2mm) welding wires, you can
weld a range of thinner materials with the spray transfer process. It is not
recommended for metals 1/8 in. (3mm) or less. Other benefits include no
spatter, good fusion, a smooth bead, and weld appearance
The biggest drawback of spray transfer is that it can be used only in the flat
position because the puddle is so fluid. Both processes can be accomplished
with a basic constant-voltage welding power source.
Manufacturers have been able to design equipment that controls the weld
puddle. Amperage is pulsed from a specified high-low current at
predetermined frequencies to control the puddle better and thus allow for outof-position welding.

1.5

Pulse-Spray Transfer Mode

As with any welding process, short-circuit and spray transfer methods of

metal transfer in GMAW have their pros and cons. Pulse spray GMAW can be
useful for the following reasons:

It can weld a variety of metals.

It has good penetration.
It can weld a wide range of thicknesses.
It provides good fusion at the toes of the weld.
It can weld faster than short-circuit and globular transfer.
It has 90 percent less spatter than short-circuit transfer.
It can be used to weld in all positions.
It reduces the number of ASME and AWS certifications required.

1.6

Summary

Equipment for short-circuit welding can be less expensive than for spray
transfer. Any spray machine can perform short-circuit transfer as well, but
cost differences exist primarily in the type of gas used. Short-circuit uses less
argon and more carbon dioxide, while spray transfer requires more argon and
less carbon dioxide. Argon is one of the most expensive industrial welding
gases used in GMAW, while carbon dioxide is the least expensive. While any
pulse spray machine can perform short-circuit transfer, each type of transfer
has distinct differences and benefits.

Equipment for short-circuit welding can be less expensive than for spray
transfer. Any spray machine can perform short-circuit transfer as well, but
cost differences exist primarily in the type of gas used. Short-circuit uses less
argon and more carbon dioxide, while spray transfer requires more argon and
less carbon dioxide. Argon is one of the most expensive industrial welding
gases used in GMAW, while carbon dioxide is the least expensive.
By considering the cost, the benefits of short-circuit and spray transfer
processes, and your product line, you can decide the best mode of transfer
for you.

2. Reading 2
Understanding transfer modes for GMAW
How they affect filler metal selection
PRACTICAL WELDING TODAY NOVEMBER/DECEMBER 2008
DECEMBER 14, 2008
BY: JERRY MATHISON
http://www.thefabricator.com/article/consumables/understanding-transfer-modes-for-gmaw

2.0

General

The gas metal arc welding (GMAW) process uses four basic modes to
transfer metal from the electrode to the workpiece. Each mode of transfer
depends on the welding process, the welding power supply, and the
consumable, and each has its own distinct characteristics and applications.
Several variables dictate the type of transfer you use, including the amount
and type of welding current, the electrode chemistry, electrode surface,
electrode diameter, shielding gas, and the contact tip-to-work distance.
Transfer mode also affects your choice of filler metal used. Choosing wisely
can greatly affect your efficiencies and productivity.

Short Circuit
Globular
Spray
Pulse-Spray

2.1

Short-circuit Transfer

In short-circuit transfer, the electrode touches the work and short circuits,
causing the metal to transfer as a result of the short. This happens at a rate of
20 to more than 200 times per second.
The advantage of the short-circuit transfer is its low energy. This method is
normally used on thin material (6.3mm) inch or less, and for root passes on
pipe with no backing. It can be used to weld in all positions.
This mode of transfer generally calls for smaller-diameter electrodes, such as
0.6mm,0.8mm, 0.9mm, 1.0mm, and 1.1mm. The welding current must be
sufficient to melt the electrode, but if it is excessive, it can cause a violent
separation of the shorted electrode, leading to excessive spatter. Using
adjustable slope and inductance controls can enhance the transfer to
minimize spatter and promote a flatter weld profile. Slope adjustment limits
the short-circuit amperage, while inductance adjustments control the time it
takes to reach maximum amperage. Proper adjustment of these two factors
can produce excellent bead appearance and is essential for short-circuit
transfer with stainless steel electrodes.

The most predominant solid stainless steel electrodes are ER 308L, ER 309L,
and ER 316L. These electrodes are also available in the Si type, such as
308LSi. The LSi types contain more silicon, which increases puddle fluidity
and helps the weld puddle to wet out better than the standard alloys. While
minor power source adjustments may be needed, both types can be used
successfully as long as the specification for the welding consumables permits.
For carbon steel electrodes, the electrode classification dictates the silicon
level. ER 70S-3 and ER 70S-6 are the most widely used. For pipe
applications, ER 70S-2, ER7 0S-4, and ER 70S-7 are sometimes used for
open-root work because they offer lower silicon levels. The lower silicon
produces a stiffer puddle and gives you more control of the back bead profile.
In an open-root weld, you may use an S-6 type electrode with less inductance
than an S-2 type electrode because the S-6 type has a higher level of silicon
and the puddle is more fluid.

Maintaining a constant contact tip-to-work distance in short-circuit transfer is

important to maintain a smooth transfer.
The most common shielding gas for the short-circuit transfer mode for carbon
steel electrodes is: 75 percent argon/25 percent CO2.
Numerous three-part shielding gas mixes are also available for carbon steel
and stainless steel for this mode of transfer.

2.2

Globular Transfer

Globular transfer means the weld metal transfers across the arc in large
droplets, usually larger than the diameter of the electrode being used.
This mode of transfer -generally is used on carbon steel only and uses 100
percent CO2 shielding gas.
The method typically is used to weld in the flat and horizontal positions
because the droplet size is large and would be more difficult to control if used
in the vertical and overhead positions compared to the short-circuit arc
transfer. This mode generates the most spatter; however, when higher
currents are used with CO2 shielding and a buried arc, spatter can be greatly
reduced. You must use caution with a buried arc because this can result in
excessive reinforcement if travel speed isn't controlled.

Stainless steel GMAW electrodes normally aren't used in this mode of

transfer because their nickel and chrome content (9 to 14 percent nickel and
19 to 23 percent chromium) creates a higher electrical resistance than carbon
steel electrodes. In addition to the electrical resistance differences, the use of
100 percent CO2 as a shielding gas could be detrimental to the corrosion
resistance of the stainless steel electrodes. Carbon steel ER 70S-3 and ER
70S-6 generally are the electrodes of choice.

2.3

Spray Transfer Mode

Spray transfer is named for the spray of tiny molten droplets across the arc,
similar to spray coming out of a garden hose when the opening is restricted.
Spray transfer usually is smaller than the diameter of the wire and uses
relatively high voltage and wire feed speeds or amperage. Unlike short-circuit
transfer, once the arc is established, it is on at all times. This method
produces very little spatter and is most often used on thick metals in the flat
and horizontal positions.

Spray Transfer Mode

Shield Gas & Transition
Current

Spray transfer is achieved with high percentages of argon in the shielding gas,
generally a minimum of 80 percent.
Also called axial spray, this mode uses a current level above what is
described as the transition current. The transition current will vary depending
on the electrode diameter, shielding gas mixture percentages, and contact tipto-work distance. When the current level is higher than the transition current,
the electrode transfers to the work in very small droplets that can form and
detach at the rate of several hundreds per second. Sufficient arc voltage is
required to ensure that these small droplets never touch the work, achieving a
spatter-free weld. Spray transfer also produces a fingerlike penetration profile.

This transfer mode is used mostly in the flat and horizontal positions because
it produces a large weld puddle. High deposition rates can be achieved
compared to the other transfer modes.
Because of the arc length used, it is also more easily influenced by magnetic
fields. If this is not controlled, penetration profile, bead appearance, and
spatter levels can be negatively affected.

The major factor in choosing a carbon steel electrode is sometimes the

amount of silicate islands that remain on the weld bead surface. This is
especially the case if you need to minimize postweld cleaning time or if the
finished product will be painted. For this reason, you might choose an ER
70S-3, ER 70S-4, or ER 70S-7 electrode. With stainless steel electrodes,
there is little difference in the bead appearance in the Si types because of the
higher energy used in this mode of transfer. The wetting action advantage of
the Si types is not necessary, and if they are used it usually is a matter of
preference. The effect of the chemistry on the transition current is minimal,
but a higher voltage may be required with one alloy compared to another to
achieve a true spray.

2.4

Pulse-Spray Transfer Mode

In the pulse-spray transfer mode, the power supply cycles between a high
spray transfer current and a low background current. This allows for super
cooling of the weld pool during the background cycle, making it slightly
different than a true spray transfer. Ideally, in each cycle one droplet transfers
from the electrode to the weld pool. Because of the low background current,
this mode of transfer can be used to weld out of position on thick sections
with higher energy than the short-circuit transfer, thus producing a higher
average current and improved side-wall fusion. Additionally, it can be used to
lower heat input and reduce distortion when high travel speeds are not
needed or cannot be achieved because of equipment or throughput
limitations.

Generally, the same shielding gases used for spray transfer are also used for
pulsed-spray mode.
The electrodes you can use include all the standard carbon steel and
stainless steel types, along with some of the specialty alloys such as
INCONEL (625), duplex (2209), and superduplex (2509). With a
programmable pulse power supply, most solid-wire alloys can be used with a
customized pulse waveform.
With all modes of transfer, the wire type will have some effect on the machine
settings. In addition, the wire surface will affect the transfer. Manufacturers
use different types of arc stabilizers on the wire surface to enhance a smooth
transfer. This is why small adjustments must be made when welding with the
same type of electrode from different manufacturers.

3. CV Transfer Mode
A CV power source delivers constant voltage by varying the current to
maintain a constant arc length. In this mode, the operator is able to adjust
wire feed speed and arc voltage. CV is considered the conventional way to
weld aluminum, and fabricators today still choose CV for its simplicity and
lower capital cost over other GMAW methods. Welding aluminum with either
CC or CV power sources requires high-energy axial spray transfer to melt the
base metal and ensure good fusion.
To obtain spray arc transfera steady stream of molten metal that sprays
across the arcthe welding current must be above a certain minimum
transition current. For example, using CV spray transfer with 364-inch
aluminum GMAW wire requires a minimum of 135 amps.

http://www.thefabricator.com/article/aluminumwelding/tackling-aluminum-gmaw

CV/CC Current Transfer Modes:

Constant Voltage
Power Source

Constant Current
Power Source

Operating
point

Current, A

Voltage, V

Voltage, V

Operating
point

Current, A

http://www.lincolnelectric.com/en-us/support/process-and-theory/Pages/constant-current-vs-constant-coltage-output.aspx

Current Transfer Modes: CC

http://www.lincolnelectric.com/en-us/support/process-and-theory/Pages/constant-current-vs-constant-coltage-output.aspx

4. Other Interesting Reading:

3.1
Choosing the right shielding gas and supply system for GMAW
WWW.THEFABRICATOR.COM JANUARY 2002
July 26, 2001
By: David Bell
http://www.thefabricator.com/article/consumables/choosing-the-right-shielding-gas-and-supply-system-for-gmaw