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L&T-MHI BOILERS PRIVATE

LIMITED
HAZIRA
Welding Engineering

TITLE
FCAW

R0

First issue

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NO.

REVISION DETAILS

DATE

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ASAN
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PREP. BY

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INDEX
1. Principles of Flux-cored arc welding (FCAW)
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2. Typical Flux-cored arc welding (FCAW) Setup

3. Conditions That Affects Weld Bead Shape
4. Gun Movement During Welding
5. Weld Bead Characteristics
6. Defects in Welding

Principles of Gas Metal Arc Welding (GMAW)

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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 constantvoltage 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.
FCAW can be done in three different ways:
1. Semiautomatic Welding - equipment controls only the electrode wire feeding. Movement of
welding gun is controlled by hand. This may be called hand-held welding.
2. Machine Welding - uses a gun that is connected to a manipulator of some kind (not handheld). 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.

Basic equipment for a typical FCAW semiautomatic setup:

1. Welding Power Source - provides welding power.
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.
3. Supply of Electrode Wire.
4. Welding Gun - delivers electrode wire and shielding gas to the weld puddle.
5. Shielding Gas Cylinder - provides a supply of shielding gas to the arc.

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Typical Gas Metal Arc Welding (FCAW) Setup

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Conditions That Affects Weld Bead Shape:

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Gun Movement during Welding:

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Weld Bead Characteristics:

Poor

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Weld Bead Characteristics:

Good

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Activities to be done prior to welding

Clean the surface to be welded

Check seam no
Check that machine is properly calibrated
Get the preheat and interpass temperature sticks
See that that the welder is qualified in the position in which joint is to be welded
Refer WPS, shop weld plan for the respective joints.
Check earthing lug is tightly fitted to prevent arc strike on the base metal
Ensure proper set-up of the joint

Activities to be done while Welding

Set welding parameters within the range as specified in WPS

Ensure the temperature is between preheat and interpass temperature as specified in WPS
Maintain preheat and interpass temperature as per WPS

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Defects in Welding:
Porosity
Porosity small cavities or holes
resulting from gas pockets in weld
metal.

Possible Causes

Inadequate
shielding gas
coverage.
Wrong gas.
Dirty welding
wire.

Workpiece dirty.
Welding wire
extends too far
out of
Inadequate
shielding gas
coverage.

Corrective Actions
Check for proper gas flow rate.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Eliminate drafts near welding arc.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Use welding grade shielding gas; change to different gas.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work
surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Check for proper gas flow rate.
Remove spatter from gun nozzle.

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Excessive Spatter
Excessive Spatter scattering of
molten metal particles that cool to
solid form near weld bead

Possible Causes
Wire feed speed
too high
Voltage too high.

Corrective Actions
Select lower wire feed speed

Electrode
extension
(stickout) too
long
Workpiece dirty

Use shorter electrode extension (stickout).

Insufficient
shielding gas at
welding a
Dirty welding
wire.

Select lower voltage range

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work
surface before welding
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near
welding arc
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Incomplete Fusion
Incomplete Fusion failure of weld
metal to fuse completely with base
metal or a preceeding weld bead.
Possible Causes
Workpiece dirty.
Insufficient heat input.
Improper welding technique.

Corrective Actions
Remove all grease, oil, moisture, rust, paint,
coatings, and dirt from work surface before
welding.
Select higher voltage range and/or adjust wire
feed speed.
Place stringer bead in proper location(s) at joint
during welding.
Adjust work angle or widen groove to access
bottom during welding.
Momentarily hold arc on groove side walls
when using weaving technique.

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Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

Lack Of Penetration
Lack Of Penetration shallow
fusion between weld metal and
base metal
Possible Causes
Improper joint penetration

Improper weld technique

Insufficient heat input.

Corrective Actions
Material too thick. Joint preparation and
design must provide access to bottom of
groove while maintaining proper welding
wire extension and arc characteristics.
Maintain normal gun angle of 0 to 15
degrees to achieve maximum
penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more
than 1/2 in (13 mm) beyond nozzle.
Select higher wire feed speed and/or
select higher voltage range.
Reduce travel speed.

Excessive Penetration
Excessive Penetration weld metal
melting through base metal and hanging
underneath weld.
Possible Causes
Excessive heat input.

Corrective Actions
Select lower voltage range and reduce
wire feed speed
Increase travel speed.

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Burn-Through
Burn-Through weld metal melting completely
through base metal resulting in holes where
no metal remains

Possible Causes
Excessive heat input.

Corrective Actions
Select lower voltage range and reduce wire feed
speed.
Increase and/or maintain steady travel speed.

Waviness Of Bead
Waviness Of Bead weld metal that is not
parallel and does not cover joint formed by base
metal

Possible Causes
Unsteady hand.

Corrective Actions
Support hand on solid surface or use two hands.

Distortion
Distortion contraction of weld met al during
welding that forces base metal to move.

Possible Causes
Excessive heat input

Corrective Actions
Use restraint (clamp) to hold base metal in
position
Make tack welds along joint before starting
welding operation
Select lower voltage range and/or reduce wire
feed speed

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Increase travel speed..

Weld in small segments and allow cooling
between welds.

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