Inch Millimeters Notes:

See Notes 10 & 11

/
14 / /
9 32 5 16
60 /
1 16 1.6 1. All dimensions U.S. customary unless
otherwise specified.
/
18 3.2 2. 3/8 thickness plain carbon steel
/
14 /
14 6.4 material.
3. The welder shall prepare a bill of
/
14 /
12 12.7 materials in U.S. customary units of
1 25.4 measure prior to cutting.
/
14
6 4. The welder shall convert the above bill
of materials to S.I. metric units of
measure.
5. All parts may be mechanically cut or
machine DFC unless indicated manual
OFC.
6. All welds GMAW-S, FCAW-G, or FCAW
11 as applicable.
1D 6 3 13/16 1E See Note 8 7. Fit and tack entire assembly on bench
/ TYP
34
before attaching to positioning fixture
arm.
2 2
2 8. Attach 2 2 extension tab of Part 1E
to positioning fixture arm. All welding
Manual OFC Manual done in position according to drawing
See / / 50
9 32 5 16
This Edge OFC- 1 2 orientation.
Note 10 6
9. Employ boxing technique where
1F applicable.
2
10. Partial penetration weld.
1C / TYP
12

1B 11. Weld joins Part 1C and 1D to 1E.

12. Weld joins Part 1C and 1E to 1A.
1A 5 /
14 2-4
8 See Notes 10 & 12
/ 2-4
/
14
/
9 32 5 16
50

Drawing Not to Scale

Part No. Reqd. Size S.I. Conversion
Tolerances:
1A Fractions: + or 1/16
Angles: +10, 5
1B
1C
1D
1E
1F

Fig. 23-25 Performance qualification test for FCAW-G or FCAW-S. Source: Modified from AWS S.E.N.S.E. Entry Level E62.0-95, Fig. 2.
767
 Flux Cored Arc
WeldingSelf-Shielded
The AWS-accepted term for this welding pro-
cess is flux cored arc weldingself-shielded
(FCAW-S). It is a semiautomatic welding pro-
cess. One form is known in the trade by the
Fig. 23-26 Square butt joint in 38-inch mild steel plate with a backup strip. name of Innershield, a process introduced by
The joint was welded in the flat position, and the weld was made with flux cored the Lincoln Electric Company. In this process
filler wire 332 inch in diameter. Welding required 450 amperes and 32 volts.
a vapor produced by a special electrode shields
the molten weld metal during the welding
operation. The flux cored electrode is a con-
tinuous wire that also serves as a filler wire,
Fig. 23-29.
The equipment needed to carry on this pro-
cess is essentially the same as that used for
other gas metal arc processes: constant volt-
age power source, and a continuous wire-feed
mechanism. The equipment can be fully auto-
matic or semiautomatic. Auxiliary gas shield-
Fig. 23-27 Lap joint in 38-inch mild steel plate welded in the flat position. The ing is not used.
horizontal fillet weld was made in a single pass with flux cored filler wire 332 inch
in diameter. Welding required 450 amperes and 32volts.
The tubular steel filler wire contains all the
necessary ingredients for shielding, deoxidiz-
ing, and fluxing. These materials melt at a lower
temperature than the steel electrode metal and
form a vapor shield around the arc and molten
weld metal. Also included in the electrode are
the alloying materials needed to provide high
grade weld metal. Electrodes are available for
welding in all positions, Fig. 23-30, page 770.
Process Advantages
The following information on the Innershield
process has been provided by the Lincoln
Fig. 23-28 T-joint in 38-inch mild steel plate. The horizontal fillet weld was Electric Company. These characteristics may
made in a single pass with flux cored filler wire 332 inch in diameter. Welding also be applied to all flux cored wire welding
required 450 amperes and 32 volts. without auxiliary gas shielding.
It offers much of the simplicity, adaptability, and
uniform weld quality that accounts for the continuing
Only minimal weld spatter shall be accepted, as
popularity of manual stick electrode welding.
viewed prior to cleaning. It is a visible arc process that allows the welder to
When using FCAW-G electrodes, gases may become place the weld metal accurately and to control the
trapped between the solidifying weld pool and the slag pool visually for maximum weld quality.
layer. This gas causes a longitudinal surface depression It operates in all positions including vertical-up,
in the face of the weld. This type of discontinuity is often vertical-down, and overhead.
referred to as worm tracking. If there is no evidence of a Welding can be done outdoors and in drafty locations
porosity worm hole at either end of a track depression, without wind screens because the shielding does not
these tracks need not be considered detrimental to the blow away.
overall joint efficiency. However, tracks do detract from The job needs only simple fixturing or none at all.
the appearance of the weld and if appearance is im- Often existing stick electrode fixtures can be used.
portant, corrective action may be required. Table23-4, Simple wire-feeding equipment is not encumbered by
page 760, lists some overall troubleshooting pointers. flux-feeding systems or gas bottles. Installation is

768 Chapter 23 FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1
 quicker and more flexible. Welding rigs are more
portable.
Welder fatigue is minimized during sustained welding
operations because the guns are lightweight, flexible,
and easy to handle.
Compact guns fit into places where othersemiauto-
matic guns or stick electrode holders with the long
electrodes cannot go.
Uninterrupted wire feeding results from special elec-
trode lubrication, freedom from spatter-clogged guns,
and the ability to resist crushing of the tubular elec-
trode by high drive roll pressure.
Arc starts are quick and positive without sticking,
skipping, or excessive spatter. The process corrects
poor fitup and resists cracking in many crack-sensitive
applications.
Welding costs are cut because higher practical weld-
ing currents provide increased deposition rates and
travel speeds.
The process has been job-proven on many applica-
tions including repair welding, machinery fabrica-
tion, assembly welding, ship and barge building,
field welding of storage tanks, and erection of struc-
tural steel for small and large buildings.
Flux Cored Arc Welding
Self-Shielded Practice Jobs
Instructions for Completing
Practice Jobs
Complete the practice jobs according to the specifications
given in the Job Outline, Table 23-11, page 788, in the order
assigned by your instructor. Set up for welding as you did
when practicing with the FCAW-G process.
For video of an ironworker testing in
3G position with FCAW-S electrode, please visit
www.mhhe.com/welding.

Current Carrying These jobs should provide about 20 to 30 hours

Contact Tube
of practice, depending upon the skill of the in-
Insulated
dividual student. After completing these jobs,
Extension Tip you may wish to practice with other forms of
joints, various thicknesses of material, and dif-
Powdered Metal, ferent filler wire sizes. A wide range of current
Vapor or Gas Forming values should be employed. Develop a good
Materials, Deoxidizers
and Scavengers understanding of the results of changes in the
basic variables. Study Table 23-7, page 766,
carefully.
Arc Shield Composed
of Vaporized and Slag
Molten Slag Forming Compounds Power Sources
Protects Metal Transfer
Arc Through Arc Constant voltage (c.v.) d.c. power sources are
Solidified Slag used for the FCAW-S process and electrodes.
These machines can be of the transformer rec-
tifier type, inverter type, or engine-driven gen-
erator type. Many of these self-shielded type of
electrodes are very voltage sensitive. As little as
0.5 volt above or below their effective voltage
range can create problems such as weld appear-
ance, improper weld profile, and a reduction of
mechanical and/or physical properties.

Wire Feeders
Wire feeders are very similar to continuous
wire feeders for other gas metal arc processes.
Molten Weld
Metal They are generally of the push type. In some
Metal Droplets Covered cases the pull-push type of feeder can also be
with Thin Slag Coating
Solidified Weld Metal Forming Molten Pool used.
For portable work, the voltage sensing
Fig. 23-29 The self shielded, flux cored arc welding process. feeder is very popular. It operates off of the

FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1 Chapter 23 769

Fig. 23-30 An ironworker testing in the 3G position on 1-inch
plate with backing. Note the head position in relation to the fumes
and good body posture. This is a typical test that might be
conducted on a job site in a temporary structure. Miller Electric
Mfg. Co.
output voltage from the power source and does not re-
quire a separate power and power cord to run the feeder
motor. Controls are simplified, which reduces weight.
Because these electrodes are self-shielding, the feeder
does not require a gas solenoid valve. This feature also
eliminates the need for gas hoses and a shield gas supply
(cylinder).
The voltage sensing feeder may be equipped with a
weld contactor to turn power to the arc on and off.
The drive rolls should be of the V knurled type for the
hard sheath wires. For the soft sheathed wires, use a V or
U cogged-type drive roll. To determine if a hard or soft
sheath is provided on your specific wire, take a length
of wire and try bending it. If it has a hard sheath, it will
break in a few bends. If it has a soft sheath, it will bend
many times; in fact, it can be tied in a knot.
770 Chapter 23 FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1
Guns
Guns for semiautomatic FCAW-S welding should be light
and maneuverable to facilitate high speed work. They
should be equipped with a small guide tip for reaching
into deep grooves. Guns are made in light-, medium-, and
heavy-duty models to provide for different current ranges
and electrode diameters. The electrode in the gun is cold
until the trigger is pressed. If a voltage sensing feeder
is used, then a weld contacter is required. Medium- and
heavy-duty guns have a shield to protect the welders hand
from excessive heat.
Electrode Extension Electrode extension may range from
1
2 to 4 inches from the contact tip. (See Fig.23-23, p. 764.)
The visible extension is the length of electrode extending
from the end of the nozzle on the gun. A 2-inch elec-
trical extension may be only a 138-inch visible extension.
The specified electrode extensions are obtained by using
the proper guide tip and visible stickout on the welding
gun. When a long guide tip is used to provide a 4-inch
electrode extension, both the voltage and amperage must
be increased. When the electrode extension is 12 to 1 inch,
a guide tip is not used. Check the electrode manufacturers
requirements for the electrode extension to be used.
Welding Technique
Before starting, check all welding control settings. Direct
current electrode negative (DCEN) is very common on
self-shielded electrodes. Check the welding procedure or
the electrode manufacturer for correct polarity. Drive rolls
and wire guide tubes should be correct for the wire size and
type being used. Also, the gun, cable, and nozzle contact tip
should be correct for the wire size and electrode extension.
Starting the ArcAfter the proper electrode extension
has been set (cut the end of the electrode), the tip of the
electrode is positioned just above the work so that it is
lightly touching the work. The trigger is pressed to start
the arc. The mechanical feed will take care of advancing
the electrode. Welding is stopped by releasing the trigger
or quickly pulling the gun from the work.
Gun Angles Use a drag angle of about the same angle as
for stick electrode welding. The electrode-to-joint (work)
angle varies with the type of joint and thickness of material.
For horizontal fillets 516 inch and larger, the electrode points
at the bottom plate at about a 45 angle. The wire location
for most other positions and joints are to keep the weld size
and bead location appropriate. This causes the weld mate-
rial to be washed up on the vertical plate. For fillets 14 inch
and smaller, the electrode is pointed directly into the corner
of the joint at an angle of about 40.
 A stringer bead should be applied with steady travel
to avoid excess melt-through. Excess melt-through makes
the metal sag on the underside of the joint and causes weld
porosity. Joint fitup should be tight.
For out-of-position welding with E71T-G wire, the work
is positioned downhill (vertical-down). Stringer beads are
applied with settings in the middle to high range. The
drag angle is in the direction of travel so that the arc force
keeps the molten weld from spilling out of the joint.
In vertical-up and overhead welding, whipping, break-
ing the arc, moving out of the weld pool, or moving too
fast in any direction should be avoided. Currents are in
the low range.
Operating Variables
Four major variables affect the welding performance with
self-shielded electrodes: arc voltage, current (WFS), travel
speed, and electrode extension. These are all interdepen-
dent, and if one is changed, one or more of the others will
require adjustment. Review the material in Chapter 22
concerning the effects changing these variables has on
the weld bead. Also study Table 23-7, page 766, for an un-
derstanding of the corrections that you should make when
problems arise.
Inspection and Testing
After the weld is completed use the same inspection and
testing procedures that you have learned in previous weld-
ing practice. Examine the welds for bead formation and
appearance. It is impossible to determine the physical
characteristics of a weld by its appearance. However, a
weld that shows good fusion along the edges, has normal
convexity, is free of undercut and surface defects, and
has fine, smooth appearance usually meets the physical
requirements.
Fillet and Groove Welding
Combination Project with FCAW-S:
Job Qualification Test 2
This combination test project will allow you to demon-
strate your ability to read a drawing, develop a bill of
materials (SI conversions are optional), thermally cut, fit
components together, tack, and weld a carbon steel proj-
ect. You will be using the techniques developed in prior
jobs in this chapter using the FCAW-S process and elec-
trodes. Follow the instructions found in Table 23-11, Job
23-JQT2, page 788, and the notes on Fig. 23-25, page 767.
Inspection and Testing
After the project has been tacked, have it inspected for
compliance to the drawing. After the project has been
FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1 Chapter 23 771
completely welded, use the same inspection and testing
methods that you have used in previous welding practice.
On multiple-pass welds have your instructor inspect after
each weld unless otherwise instructed. Use the following
acceptance criteria to judge your welds. Look for surface
defects. Keep in mind that it is important to have good ap-
pearance and uniform weld contour. These characteristics
usually indicate that the weld was made properly and that
the weld metal is sound throughout. Only visual inspec-
tion will be used on this test project to the following ac-
ceptance requirements:
There shall be no cracks or incomplete fusion.
There shall be no incomplete joint penetration in
groove welds except as permitted for partial joint pen-
etration groove welds.
Your instructor shall examine the weld for acceptable
appearance and shall be satisfied that you are skilled
in using the process and procedure specified for the
test.
Undercut shall not exceed the lesser of 10 percent of
the base metal thickness or 132 inch.
Where visual examination is the only criterion for
acceptance, all weld passes are subject to visual
examination, at the discretion of your instructor.
The frequency of porosity shall not exceed one in each
4 inches of weld length, and the maximum diameter
shall not exceed 332 inch.
Welds shall be free from overlap.
Large spatter shall be unacceptable, as viewed prior to
cleaning.
Automatic or Mechanized
Welding Applications
Industry is continually finding new applications for au-
tomatic/mechanized welding applications, Fig. 23-31,
page 772. These applications have economically replaced
many other joining methods such as rivets, bolts, resis-
tance welding, and castings. The difference between au-
tomatic and mechanized applications of welding is that
in mechanized applications an operator must guide the
electrode in the joint. In automatic applications, sensors
are used to guide the electrode in the joint.
Automatic or mechanized arc welding has many char-
acteristics that are highly desirable for manufacturing:
Repeatability
High quality
High production
Low welding costs
Uniform welds
Desirable weld appearance
Fig. 23-31 Welds being made on a vessel with the SAW pro-
cess. The manipulator is equipped with flux delivery and recovery
systems. The traveler car and rails allow for making longitudinal
welds while the turning rolls allow for making the circumferential
welds. Note the operator catwalk and ladder for convenience and
safety. Pandjiris
Continuous output
Ability to conform to various welding conditions
Almost 100 percent duty cycle
Each company needs to study the individual job and
the general plant conditions in making the decision to use
automatic/mechanized welding. A few considerations:
Can the job be redesigned for automatic or
mechanized welding?
How does the cost compare with the costs of other
processes?
Are new work processes, such as handling the
material, introduced that will offset the saving in
welding time?
Which automatic or mechanized system is best for
the job?
Are there sufficient floor space and power available
for the new equipment?
Is skilled labor available to operate the automatic/
mechanized system?
Is the work repetitive enough to gain the full
advantage of automatic/mechanized welding?
Submerged Arc Welding (SAW)
Submerged arc welding may be applied via automatic,
mechanized, or by semiautomatic means. Welding takes
place beneath a blanket of granular, fusible flux. A bare
filler wire electrode is fed continuously into the arc and
is completely hidden by a mound of flux. Equipment
includes the power source, an automatic wire-feeding
772 Chapter 23 FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1
Fig. 23-32 A side beam carriage is set up with the SAWpro-
cess. The digital readout control panel, electrode supply coil, wire
drive head, and flux hopper are clearly visible.
device, a flux-feed system, a gun in semiautomatic weld-
ing, and flux pickup, Fig. 23-32.
The filler wire is not in actual contact with the work-
piece. The current is carried across the arc gap through the
flux. The weld pool is completely covered at all times, and
the welding operation is without sparks, spatter, smoke, or
flash, Fig. 23-33. Thus protective shields and helmets are
not needed. Goggles should be worn, however, for safety.
Some smoke and fumes are created that require proper
ventilation.
Welds made under the protective layer of flux have un-
usually good ductility, impact strength, uniformity, density,
corrosion resistance, and low hydrogen content. Physical
properties are equal or better than the base metal when the
base metal is free from rust, scale, moisture, and other sur-
face impurities. In heavy sections, cracking can be mini-
mized by the use of multipass welding and preheating.
Automatic/mechanized submerged arc welding is used
extensively in the welding of carbon steel, chromium-
molybdenum alloy steel, and stainless-steel piping. Ap-
plications include the longitudinal seam welding of rolled-
plate piping, circumferential welds on large piping, and
straight fillet welds on fabricated plate attachments. The
process can be used to make groove welds, fillet welds, and
plug welds in both production and repair work, Figs. 23-34
and 23-35, page 774. It is also suitable for hard-surfacing
and the welding of castings.
Because the bed of flux must be supported, welding
is performed in the flat position. In special situations the
 To Automatic Wire Feed

Welding Wire
Welding Composition
Feed Table AC or DC
Finished Weld
Solidified Fused Surface
Granulated Welding
Composition
Composition
Composition
Retaining Fused Welding
Plates Composition

Welding Vee

Weld
Metal

Plate Metal

Molten Weld
AC or DC
Metal

Weld Backing Direction of Weld

Fig. 23-33 Cutaway view of the welding zone in a single V-groove welded with the submerged arc
welding process.

flux can be supported to aid weld positioning (Fig. 23-36,
p. 774). Welds can be made in one or two passes in any
thickness of steel from 16 gauge to 3inches or more. High
welding speeds are possible, and the current may be as high
as 4,000 amperes at 55volts. Backing rings are often used
for groove welds. When fitup is poor, the first pass should
be made by manual shielded metal arc welding or semiau-
tomatic GMAW or FCAW processes.
S H OP TAL K
IIW
The International Institute of Welding (IIW)
offers a searchable on-line research database. This
group of organizations from 40 countries began in
1947. It presents conferences and exhibitions regard-
ing the science and application of joining technology. Its
journal, Welding in the World, examines welding, brazing,
soldering, thermal cutting, thermal spraying, adhesive
bonding, and microjoining.
When a backing ring is not used, the first pass may
be made by these same processes or the gas tungsten arc
welding process. In the welding of alloy pipe, the alloying
elements should be contained in the filler wire and not in
the flux.
Power SourceWelding power may be provided by a
d.c. rectifier, or an a.c. transformer. Welding with direct
current provides versatile control over the bead shape,
penetration, and speed, and arc starting is easier. DCEP
provides the best control of bead shape and maximum
penetration. DCEN provides the highest deposition rates
and minimum penetration. Alternating current provides
penetration that is less than DCEP but greater than
DCEN. It minimizes arc blow at high amperage, and it is
preferred for single-electrode welding with high currents
and for multiple-wire, multiple-power welding. The cost
of producing current with transformers is less than with
generators.
Both constant current (variable voltage) and constant
voltage power supplies are used for submerged arc weld-
ing. In the constant current welding machine, a voltage
sensing wire control system maintains a constant welding

FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1 Chapter 23 773

Fig. 23-34 Mechanized Submerged Arc Weld Made on a Bridge
Pile Casing. Note the starting and or run off tab. These tabs assure
good weld soundness at the ends of the production joint. American
Welding Society
Flux Hose
Flexible
Noncombustible
Flux Dams Flux Support Flux Support
Edge Weld Roundabout 3 Oclock Welds
Fig. 23-36 Various types of flux supports for submerged arc welding.
current. The wire feeder varies the wire-feed speed to
produce a constant arc voltage and keep the desired arc
length. This system is generally used for welding with
high currents and large electrodes (532 inch and over). It is
also a good choice for hard-surfacing and welding alloys.
The constant voltage welding machine is used with
the constant speed wire-feed control system. This system
maintains a constant speed wire feed. Voltage is selected
at the machine and is held constant regardless of current
demand. Constant voltage, constant speed systems are
774 Chapter 23 FCAW (Plate), SAW, and Related Processes: FCAW-G Jobs 23-J1J11, FCAW-S Jobs 23-J1J12; SAW Job 23-J1
Fig. 23-35 A side beam carriage and turning rolls set up
to do both longitudinal and circumferential welds on a vessel.
The SAW process is being used on this project. It could have
been easily set up for the FCA or GMAW as well. This setup is
being used to develop the WPSs for welding on stainless-steel
vessels. Pandjiris
preferred for small diameter filler wires and for high
speed welding of thin materials.
Wire and Flux ClassificationsWire and flux
specifications for the submerged arc welding
process are covered in the AWS A5.17 for car-
bon steel and AWS A5.23 for low alloy steel
specifications. These specifications list multiple
welding wires and fluxes.
The wires are divided into three groups ac-
cording to manganese content. The low man-
ganese steel wires are EL8, EL8K, and EL12.
In the medium manganese steel category are
EM11K, EM12, EM12K, EM13K, and EM15K.
The high manganese wires are EH10K, EH11K,
EH12K, and EH14.
The classification system follows the stan-
dard AWS pattern for filler metal specifications.
For example, let us consider the classification EL8K. The
prefix E designates an electrode as in other specifica-
tions. The letter L indicates that this is an electrode that
has a comparatively low manganese content (0.60 per-
cent maximum). The letters M and H indicate a medium
(1.50 percent maximum) and high (2.20 percent maxi-
mum) manganese content, respectively. The number 8 in
the designation indicates the nominal carbon content of
the electrode. The letter K, which appears in some desig-
nations, indicates that the electrode is made from a heat of
steel that has been silicon killed.