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FCAW
INDEX
1. Principles of Flux-cored arc welding (FCAW)
6. Defects in Welding
Flux-cored arc welding (FCAW or FCA) is a semi-automatic or automatic arc welding process.
FCAW requires a continuously-fed consumable tubular electrode containing a flux and a constant-
voltage or, less commonly, a constant-current welding power supply. An externally supplied
shielding gas is sometimes used, but often the flux itself is relied upon to generate the necessary
protection from the atmosphere. The process is widely used in construction because of its high
welding speed and portability.
FCAW was first developed in the early 1950s as an alternative to shielded metal arc welding
(SMAW). The advantage of FCAW over SMAW is that the use of the stick electrodes used in
SMAW is unnecessary. This helped FCAW to overcome many of the restrictions associated with
SMAW.
2. Machine Welding - uses a gun that is connected to a manipulator of some kind (not hand-
held). An operator has to constantly set and adjust controls that move the manipulator.
3. Automatic Welding - uses equipment which welds without the constant adjusting of
controls by a welder or operator.On some equipment, automatic sensing devices control
the correct gun alignment in a weld joint.
2. Wire Feeders (Constant Speed And Voltage-Sensing) - controls supply of wire to welding
gun.
Constant Speed Feeder - Used only with a constant voltage (CV) power source. This type of
feeder has a control cable that will connect to the power source. The control cable supplies power
to the feeder and allows the capability of remote voltage control with certain power source/feeder
combinations. The wire feed speed (WFS) is set on the feeder and will always be constant for a
given preset value.
Voltage-Sensing Feeder - Can be used with either a constant voltage (CV) or constant current
(CC) - direct current (DC) power source. This type of feeder is powered off of the arc voltage and
does not have a control cord. When set to (CV), the feeder is similar to a constant speed feeder.
When set to (CC), the wire feed speed depends on the voltage present. The feeder changes the
wire feed speed as the voltage changes. A voltage sensing feeder does not have the capability of
remote voltage control.
4. Welding Gun - delivers electrode wire and shielding gas to the weld puddle.
Defects in Welding:
Porosity
Porosity − small cavities or holes
resulting from gas pockets in weld
metal.
Excessive Spatter
Excessive Spatter − scattering of
molten metal particles that cool to
solid form near weld bead
Incomplete Fusion
Incomplete Fusion − failure of weld
metal to fuse completely with base
metal or a preceeding weld bead.
Possible Causes Corrective Actions
Remove all grease, oil, moisture, rust,
paint, coatings, and dirt from work
Workpiece dirty. surface before welding.
Select higher voltage range and/or
Insufficient heat input. adjust wire feed speed.
Place stringer bead in proper
Improper welding technique. location(s) at joint during welding.
This document is the property of L&T-MHI BOILERS PRIVATE LIMITED
and must not be copied or lent without their permission in writing.
SPECIFICATION No: LMB-COI-TRG-001 REV. No. R0 Page of
Lack Of Penetration
Excessive Penetration
Burn-Through
Waviness Of Bead
Distortion