Metallurgical and Materials Eng.

Department
Faculty of Petroleum and Mining Engineering, Suez University

Welding Metallurgy,
MTE 452 A1

‫ميتالورجيا اللحام‬
FLUX CORE ARC WELDING
8/12/2015

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Content
1- Introduction
2- Power supply
3-Electrode Feeding
4-FCAW Electrode classification
5- Guns
6-Smoke Extraction Nozzles
7-the advantage of the system
8-operation
9-process paramter
10-travel speed
11-gun angle
12-advatage and disadvantage
13- Discontinuity
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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Introduction
• Flux cored arc welding (FCAW) is fusion
welding process.
• weld heating is produced from an arc
between the work and a continuously fed
filler metal electrode.
• Atmospheric shielding is provided by the
flux sealed within the tubular electrode.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Power supply
• The FCA welding power supply is
called constant-voltage (CP, CV(

• FCAW machines can be much more

powerful than GMAW
• machines are available with up to 1500
amperes of welding power.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

• Flux-cored arc welding (FCAW or FCA) is

a semi-automatic or automatic arc welding
process.
• FCAW requires a continuously-fed consu-
mable tubular electrode containing a flux
and a constant-voltage or, less commonly,
a constant-current welding power supply.
• An externally supplied shielding gas is
sometimes used

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Flux Cored Arc Welding - S

INSULATOR

MOLTEN SLAG -~CONTACT TUBE

FLUX-FIUEO TUBULAR W RE ELECTRODE

---,,POWDERED METAL FLUX AND

SLAG-FORMING MATER ALS
----=-~~ARC SHIELDING COMPOSED OF
~VAPORIZED COMPOUNDS

___.......MOLTEN WELD POOL

B) SELF-SHIELDED FLUX CORED ARC WELDING (FCAW-S( 7

Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Flux Cored Arc Welding - G

GAS NOZZL.E
WIRE GUIDE AND
CONTACT TUBE

MOLTEN SLAG SHIELDIN G

GAS
FLUX-FILLED TUBULAR
SLAG WIRE ELECTRODE

POWDERED METAL FLUX A

SLAG-FORMING MATERIAL

MOLTEN
WELD POOL
BASE METAL

A) GAS-SHIELDED FLUX CORED ARC WELDING (FCAW-G( 8

Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Electrode feeding
• Many feed systems are designed with dual
feeders so that solid wire and flux core run
in sequence.
• FCAW feeders are designed to use large-
diameter wire and most often have two
sets of feed rollers.
• The two sets of rollers help reduce the
drive pressure on the electrode.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

FCAW Electrode Classification

E70 T - 1
Electrode
Type Gas, Usability
Minimum UTS and Performance
70,000 psi
Flux Cored /Tubular
Position Electrode

American Welding Society Specification

AWS A5.20 and AWS A5.29.
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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Guns
• Gun : FCA welding guns are available as water-
cooled or air-cooled.
• Industry needs water-cooled gun because of the
higher heat caused by longer welds made at
higher currents.
• The air-cooled gun is more portable because it
has fewer hoses, and it may be made lighter so
it is easier to produce than the water-cooled gun

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

12
Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Smoke Extraction Nozzles

• Because of the large quantity of smoke
that can be generated, systems for smoke
extraction that fit on the gun have been
designed.
• These systems use a vacuum to pull the
smoke back into a specially designed
smoke extraction nozzle on the welding
gun.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

The advantages of the system

• Cleaner air for the welder to breathe
because the smoke is removed before it
rises to the welder’s face.

• Reduced heating and cooling cost beca-

use the smoke is concentrated , so less
air must be removed with the smoke.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Operation

• the heat generated by a DC electric arc to

fuse the metal in the joint area , the arc
being struck between a continuously fed
consumable filler wire and the work piece,
melting both the filler wire and the work
piece in the immediate vicinity. The entire
arc area is covered by a shielding gas that
protects the molten weld from atmosphere.
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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Flux Cored Arc Welding (FCAW)

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Process parameters
• Wire feed speed and current
• Arc voltage
• Travel speed
• Gun angles
• Electrode wire type

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Travel speed
• travel speed is the linear rate at which the
arc is moved along the weld joint.

• Fast travel speed deposit less filler metal.

• If the rate of travel increases , filler metal

cannot be deposited fast enough to fill the
path melted by the arc.
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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Cont.
• This causes the weld bead to have groove
melted into the base metalnext to weld so
left unfilled by the weld.
• This condition is undercut.
• Slower travel speeds will at first increase
penetration and increase the filler weld
metal deposited.
• As the filler metal increases, the weld
bead will build up in the weld pool.
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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Gun angle
• The gun angle , work angle , and travel angle
are used to refer to the relation of the gun to
the work surface.
• gun angle can be used to control the weld pool
• The electric arc produces an electrical force
known as the arc force. The arc force can be
used to counteract the gravitational pull that
tends to make the liquid weld pool sag or run
ahead of the arc.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Cont.
• By manipulating the electrode travel angle
for the flat and horizontal position of
welding to a 20to 45° angle from the
vertical the weld pool can be controlled.

• )40to 50°) angle from the vertical plate is

recommended for fillet welds.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Welding gun Angles

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

High Quality

• The addition of the flux gives the process

the high level of reliability needed for
welding on boilers, pressure vessels, and
structural steel.

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University Arc Welding
Flux-Cored

Advantages
• High deposition rates
• Deep penetration
• High-quality
•
pre-cleaning
•
Slag covering helps with larger
out-of-position welds
• Self-shielded FCAW is draft
tolerant.
• Stick electrode unnecessary.
• Closed shop environment.
•
Better mechanical properties
• It allows a higher production rate

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University Arc Welding
Flux-Cored

Limitations

• Slag must be
removed

• Spatter
• FCAW wire is expensive

• Equipment is
expensive and
complex
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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Discontinuity
• Slag inclusions
• Porosity
• Incomplete fusion
• Incomplete joint penetration

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Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

27
Welding Metallurgy 4th Year Students 2015/2016
 Metallurgical and Materials Eng. Department
Faculty of Petroleum and Mining Engineering, Suez University

Thanks for Attention

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Welding Metallurgy 4th Year Students 2015/2016