Flux-Cored Arc Welding: Its Process? - weldingcrew.net Flux-Cored Arc Welding: Its Process? - weldingcrew.net

Flux-Cored Arc Welding: Its Process?

A vintage photo of a man

Flux-cored arc welding (FCAW) is a fusion welding process that involves the use of a continuously fed consumable wire electrode. The heat necessary to melt the metals is provided by the electrode, which creates an electric arc. The electrode wire employed in flux-cored arc welding is filled up with flux.

Though, the arc starts through the electrode to work. But, the welding process melts the flux filled in the electrode. Further, it protects the welded area from the atmosphere.

DCEP (direct current, electrode positive) is used in flux-cored arc welding.

Flux-Cored Arc Welding: Its Process?
Flux-Cored Arc Welding: Its Process?

Equipment Used In The Process

Power Source

The power sources used in the process usually operate on 230 or 460 volts. Though, machines running on 200 to 575 volts are also present. Moreover, the power may work on a single or three-phase frequency of 50-60 hertz. Further, it is proven that the power sources used have a 100% duty cycle. Therefore, they can be used continuously in the process.

Wire Feed Motor

A wire feed motor used for imparting power to ease the movement of the electrode through the cable. Moreover, wire feed motor used in FCAW is constant in their speed. Further, the voltage power used is consistent.

Air And Water Cooled Guns Used In The Process

Air Cooled Guns

The surrounding air cools air-cooled welding guns, but a shielding gas when used provides a better cooling effect.

Water Cooled Guns

Water-cooled welding gun has ducts that help in the circulation of water around the contact tube and the nozzle. However, the guns which are suitable for the process are:

 When above 500 Amp: Water-cooled gun is used

When below 500 Amp: Air-cooled gun is used

Shielding Gases

Shielding gas pieces of equipment used in shielding the flux-cored wires consist of a gas supply hose, a gas regulator, and control valve. Thus, protection is given to the welded area from gases like oxygen and carbon dioxide and the atmosphere.


The electrodes which are used in the process provide the filler metal to the weld puddle.

 Flux-Cored Arc Welding: Its Process?
Flux-Cored Arc Welding: Its Process?

Working Process Of Flux Cored Arc Welding

In the arc welding process, the arc provides the heat between a continuously fed electrode and the workpiece.

Further, the flux contained inside an electrode provides shielding.

Two types of FCAW are:

Self-Shielded FCAW

Self-shielded FCAW is applying to outdoor conditions where there is a probability that the wind may take the shielding gas away.

Gas Shielded FCAW

The de-oxidation of the weld pool is in much smaller degree as in comparison to that in gas shielded FCAW.

Advantages Of Flux-Cored Arc Welding

In this process, less cleaning is required.

Moreover, a high deposition rate is involved.

Disadvantages Of Flux-Cored Arc Welding

However, it releases more smoke as compared to other processes like GMAW and SAW.

Further, the wire is expensive.

Also, it is essential that the slag is removed.

Applications Of Flux-Cored Arc Welding

FCAW is used in shipbuilding as this saves enormous cost.

Further, construction companies use this for welding.

I hope that this article was helpful to you all, and you got your required information.

Subscribe to our monthly Newsletter