Flux-Cored Arc Welding

The ux-cored arc welding (FCAW) process uses a gun, as in GMAW.

However, as the name implies, the ller wire is tubular, not solid,
containing a central core of ne granular ux. (See Figure 3.5.) FCAW
without shielding gas is said to be self-shielding and is designated as
FCAW-S. If an external gas is used, the process is designated as FCAW-G.
With the exception of needing slightly larger wire feed-drive rollers and
contact tips, FCAW equipment is essentially the same as that used in
GMAW.
Programmed Instruction Series: Ultrasonic Testing

Electric arc

Weld metal

Trigger Base metal

Gun Shielding gas

Figure 3.5: Flux-cored arc welding. Question 3.2

What sets GTAW apart from GMAW and FCAW?
• The type of electrode used.

• The ller wire is tubular.

• No shielding gas is required.

ÜAnswer is on p. 177.
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Electric Resistance Welding
The process of electric resistance welding (ERW) uses the effects of heat
and pressure to produce a weld joint. In the ERW process, the edges of two
metal parts are placed in contact with each other. Since the contact
resistance at the interface is much larger than the resistance in the bulk
metal, a large amount of heat is generated at the interface when a voltage is
applied to the two pieces due to the joule effect. The metal is heated to its
molten temperature or slightly below and the two pieces are pushed
against each other with pressure to form the joint.
While the resistance between the two pieces is used to produce the weld, it
is recommended to minimize the heat effect at the interface between the
electrode and the pieces. This is typically achieved by using a high-
conductivity copper alloy as the electrode and ushing water as the coolant
to remove the heat.
Volume II: Ultrasonic Evaluation and Advanced Techniques 125

126
ERW can be used to join two rods or plates, as well as to produce pipes
and tubes. It can be performed with a low-frequency or high-frequency AC
current. For pipes and tubes with smaller diameters, for example, below
100 mm (4 in.), a round coil is typically used surrounding the tube to be
welded. Eddy currents are induced in the material and signi cant heat is
generated at the position where the two edges touch each other because of
contact resistance.
An impeder is placed inside the tube to cool the weld with water. For
larger size pipes and tubes, copper electrodes are used in contact with or
close proximity to the edges of the formed skelp. Skelp is another name
for a plate, which is the iron or steel that has been rolled or forged and is
ready to be bent and welded into pipes or tubes. Heat is generated from the
current and resistance. The edge of the skelp is melted and pushed together
by the forming rollers to create a weld.
The ERW process can either be continuous or discrete. When it is used to
produce pipes and tubes, it is typically a continuous process at a speed
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varying from about 10 to 100 m/min. Subsequent processes may include
ID and OD weld bead trimming, quenching, annealing, forming, cutting,
grinding and coating to produce a nal product. ERW may also be a
discrete process, such as the welding process used to join two steel coils
before they enter the pickling tank for cleaning or the annealing oven for
heat treatment. The ERW process is also used to create spot welds when
the electrodes are placed on two overlapping sections of sheet metal.
ERW produces a very narrow weld seam, with the most common type of
discontinuity being lack of fusion. Hook cracks, named for their shape,
may occur near the weld line if nonmetallic inclusions are present at the
tube edges when the weld is made. Since ller metal and ux are not used
in these processes, slag inclusions will not form in electric-resistance and
high-frequency welds. Ultrasonic testing of electric resistance-welded pipe
involves multiple transducers on an automated system testing from both
sides of the weld to ensure full weld coverage.
Programmed Instruction Series: Ultrasonic Testing
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