Today you're going to learn how to flux core weld from machine setup to the application of the welding process. Also, you'll learn about various welding machines, shielding gase, power sources, welding guns, and about the wire feeder.
Table of Contents
Key Takeaways
- Flux-cored arc welding is more diversely used than stick welding and any other process.
- For this process, you need a welding gun, protective equipment like an auto-darkening welding helmet and welding gloves, and a power source. No shielding gas needed.
- Flux core welding requires higher voltage and higher wire feed speeds for thicker material.
- FCAW requires lesser voltage and wire speeds for thin welds.
The process is ideal for welding outdoors because you don't need a shielding gas, and the filler metal moves from the welding gun. So, are you ready? Let's start with what you'll need once you learn what flux core welding is.
How to Flux Core Weld: The Welding Equipment
The equipment you need for FCAW includes the following.
A Welding Gun
There are two kinds of guns; air-cooled & water-cooled.
An advantage of cooling-welding guns is that they are lighter and are best for welds requiring fewer than 500 Amps. Welders find lighter guns better in more technical welding maneuvers.
Next is the water-cooled welding gun, ideal for welds requiring upwards of 500 Amps. Since flux-core welding is preferable for heavy-duty welding, the water-cooled gun is perfect, especially in continuous flux-cored welding.
That's because you'll expose the gun to high temperatures for extended periods. Also, the water-cooled gun allows water to flow around the gun's contact tube and nozzle, which reduces temperatures fast.
The Wire Feeder
The tubular electrode wire moves continuously through the action of the wire feed motor. It composes the filler metal. The trick of the wire feeder is configuring its speed to control the electrode delivery from the roller to your welding torch.
Your Power Source
On the power source, ensure you have access to direct current power because the method is done chiefly on ferrous materials. Moreover, a DC power supply offers a deeper weld penetration, creating a more stable welding arc in weld metals. Since this method is ideal for ferrous metals, the deeper penetration results in stronger joints.
A wire brush will help you brush off the flux after welding.
Flux Cored Welding: Self-Shielded
To flux core weld, we'll consider the example of the flux-cored wire. That means you'll learn how to do self-shielded flux-cored arc welding that doesn't need a shielding gas.
By the way, flux core welding aluminum doesn't work as we discussed before. You can successfully flux core weld other metals including stainless steel.
Preparation of the Welding Equipment for the Flux Core Process
- Look at the seller's description of the passes you can run using your wire feed. Some can run multiple passes, while some only have one.
- Load your flux-cored welding wire into your welding machine. Open your device and drop the wire on the spindle.
- Set your drive roll to the right. The drive roll is the tier that pushes the wire out. Its label is the size of the wire that it works with.
- Feed the wire into the guide past the drive roll in the liner.
- Crump down the drive roll idler and feed it through. Before feeding the wire through the tube to the welding torch, ensure you remove the contact tip; this is the copper tip at the end of the welding line. Its role is to conduct electricity from the wire inside the lead to the flux wire that comes out. Again, the contact tip has a number, so use the contact tip that matches your flux core wire diameter.
- Hold out straight the welding line (lead), which is the wire-like protrusion of the welding machine as you pull the trigger. Also, hold the feed button. That pushes the wire up and out. Then you can put back the contact tip on the end and tighten it.
- Regulate the tension in the drive roll idler by taking a scrap block of wood and coming at it at a 45-degree, feeding some flux-cored wire to ensure it doesn't slip. If you get a slippage, tighten the idler. If you aren't getting any slippage, you might be able to loosen it a little.
- Connect the torch to the negative side of your socket.
- Check your settings, so the wire feed unit and the voltage work together. It has two settings: the wire feed speed and the correct voltage. So if you have high wire feed, you'll need a higher voltage, giving you more heat and penetration. The lower voltage is ideal for thinner metals, while the high voltage is perfect for thicker materials. If you check the back of your welding machine, you'll see guidelines on setting the two depending on the thickness of the materials.
The Flux Cored Arc Welding Technique
Three welding parameters contribute to the effectiveness of your flux-cored arc welding project.
- The stick-out. That is the distance between the contact tip and the weld metal.
- The welding angle
- And your movement while welding, which is your welding position.
Now, you need half an inch stick-out. It's simple, but it can get hard to implement. But the secret is holding it consistently at a reasonable distance. You can do it like me; try holding it without turning on the machine and see how it goes.
The second is the welding angle. There are two of them, which include the traveling angle as you move along.
A drug angle of about 10-15 degrees is okay. What's critical is the working angle going in and out of your workpiece. So if you have two flat pieces welded together, go straight at 90 degrees into the weld joint. If it's one flat piece while the other one is straight, go to it at 45 degrees.
Next is the movement, so maintain a good consistent speed while moving. The best way to determine your welding speed is by watching the weld puddle as you weld. If you're moving slowly, the weld pool will be broad. If you're fast, your weld pool will be narrow. As far as manipulation goes, you can maneuver back and forth. But I would try to hold it in the center.
Pull up the Trick
Put on proper safety equipment. These include safety glasses, a welding jacket, a pair of gloves, and a welding mask. Then clear your welding area.
After that, it's welding. I like to make it easier by putting the dormant hand in a horizontal position and then passing the welding gun on the pointing finger while stretching all the fingers out. That helps in a smooth movement.
Frequently Asked Questions
Is Flux Core Welding Easy?
Yes, Flux core welding is easy with the right equipment and skills. But when pulling out the technique, most welders confessed to struggling when they started. A user-friendly welder like Forney Easy Weld 140 could be a good option to start with.
Do You Push or Pull Flux Core Welding?
You pull the nozzle to the pool during flux core welding. This technique is also called "drag".
Do You Need Gas for Flux Core Welding?
You don't need a shielding gas for flux core welding except in the gas-shielded technique. Generally, self-shielded is more common.
Can I Weld Flux Core as a MIG Welder?
Yes, you can flux core weld as a MIG welder. You only need the right equipment and skills and learn how flux core welding works.