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Flux-cored welding, also known as flux-cored arc welding (FCAW), is a welding process that is suitable for the outdoors, enabling welders to meld metals and other materials together by applying heat and pressure.
If you’ve wondered, “What is flux-cored welding, and how does it differ from other types?” know that during flux-cored welding a continuous hollow wire electrode is fed through the welding gun. It is similar to gas metal arc welding (also known as GMAW or metal inert gas [MIG] welding) in the type of power supply it uses. But unlike GMAW, FCAW does not require an external shielding gas.
This is because a flux compound within the wire protects the weld pool by forming a gas as it reacts with the welding arc. This makes FCAW an ideal type of welding for dirty, rusty and contaminated materials.
Keep reading if you would like to learn more about FCAW.
FCAW is a good technique to use on materials that are no thinner than 20 gauge, including carbon steel, low-alloy steels, high-nickel alloys, cast iron and stainless steels. The flux-cored wire is powerful and able to penetrate into thick weld joints.
FCAW is often used in the construction industry, since this semi-automatic type of welding can be used outdoors, has a high welding speed and is easily portable.
FCAW can be used for jobs like:
When a welder needs to work outdoors or on contaminated materials, FCAW can produce high amounts of welds in a short amount of time.
Several advantages make FCAW a popular welding choice, including:
While there are many pros to FCAW, there are still some cons to consider:
Wondering more about the specific process and other details of flux-cored welding? We have you covered.
In FCAW, an electric arc unites a continuous filler metal electrode with the base material. As the welding process happens, the shield gas provided by the flux protects the weld pool from oxidation and other atmospheric elements.
After the weld is completed, there is slag that must be removed. Welders need to account for time to remove slag to make the weld look clean.
There are a few different processes a welder can use when performing flux-cored welding. These variants include self-shielded FCAW and gas-shielded FCAW.
There are different fluxing agents with each that provide different benefits to the welder. Self-shielded FCAW is typically used outdoors because FCAW using a separate gas shield would have issues with wind potentially blowing it away.
Flux agents used in gas-shielded processes are designed to help deliver deeper penetration and work with out-of-position welds. Gas-shielded welds are also known as dual shields because flux-cored welds already rely on the electrode for shielding.
There are a variety of welding patterns that can be achieved with flux-cored welds. High and narrow welds, for example, can be achieved by using a backhand welding method.
There is a stringer bead method that deposits weld beads in a straight line, as well as a weave bead technique that forms a zigzag pattern.
Wires for flux-cored welding differ depending on whether the process is self-shielded or gas-shielded. Self-shielded wires, or FCAW-S, don’t need an external gas cylinder. They are often used for portable jobs but do tend to produce more smoke and spatter.
Gas-shielded wires, or FCAW-G, require external shielding gas. They are easier to control and produce welds that are aesthetically pleasing. Typically they are used in shop settings, as outside the gas could blow around.
FCAW-G wires tend to be less expensive than FCAW-S wires. Both wires are typically available in diameters ranging from .035 to 7/64 of an inch.
The polarity for flux-cored welding processes depends on whether they are self-shielded or gas-shielded. The majority of gas-shielded welds work the best with a direct-current electrode positive (DCEP) polarity. When using a self-shielded process, direct-current electrode negative (DCEN) polarity is used.
Stick welding and flux-cored welding are extremely similar. Both use flux to protect the weld pool from contaminants. The difference is that with FCAW flux is at the center of the electrode, whereas in stick welding flux coats the entire electrode.
The main difference between MIG welding and flux-cored welding is how the electrode gets sheltered from the air. FCAW receives shielding from the flux core. MIG welding relies on an outside shielding gas.
Flux-cored welding and MIG welding are considered to deliver the same weld strength.
FCAW is one of the main components of the Welding Technology program at Universal Technical Institute (UTI). In the program, students are introduced to welding tools including hand grinders, pedestal grinders, plasma cutters, CNC pipe cutters and more. State-of-the-industry equipment is provided by Lincoln Electric, a leading brand in welding equipment.
Students learn about subjects including general safety and safe operation, math that’s practical to welding industry fabrication, welding theory, metallurgy, advanced welding machine functions, the science behind welding and hands-on welding applications. Students take a specific FCAW course, which builds upon stick-welding skills, so that they learn how to perform overhead, vertical and horizontal welding operations.
Students will then apply those skills in Welding Applications I, where they’ll use blueprinting and project planning skills to fabricate specific projects using FCAW welding.
“Students choose this program because they like to work with their hands,” says Edward Lopez, welding technical team leader at UTI Rancho Cucamonga. “They want to choose an industry that pays very well and will be in demand for many years to come.”6
FCAW is just one of the welding processes students learn in the UTI program. They also learn about other types of welding, which you can read about here. For more information on the UTI welding program, contact us.
Discover what gas metal arc welding is, the industries it's used in and how you can prepare for a career in welding at UTI.
Learn how GMAW welding, also known as TIG welding, works as well as how it's used.
Learn how SMAW works, what it's used for, the benefits of SMAW welding and more.
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