FCAW BEST PRACTICES

Flux cored arc welding (FCAW) is a process that uses a continuous tubular electrode into which various alloying and fluxing ingredients are deposited. It is an efficient process readily adaptable to semiautomatic or automatic welding operations. Flux cored arc welding offers two major variations, self-shielded (FCAW-S) and gas shielded (FCAW-G). In the gas-shielded method, the shielding gas (CO2 or a mixture of argon/CO2) protects the molten metal from the oxygen and nitrogen present in the air by forming an envelope of gas around the arc and weld pool. With self-shielded flux cored arc welding, the high-temperature decomposition of some electrode core ingredients and their vaporization displace air around the arc to provide the shield. The core ingredients also contain scavengers that combine with undesirable elements that might contaminate the weld pool. Both variations can be used in most welding applications. The self-shielded method is sometimes chosen for field welding because it can tolerate air currents that might disrupt the shielding envelope of the gas-shielded variety. tive high cost of the equipment and complexity of setup, the significant fumes generated must be suitably exhausted, and added time and labor is required to remove the slag cover.

Equipment FCAW Advantages

High productivity is the chief advantage of FCAW. High travel speeds and deposition rates can be achieved with the process, especially when compared to shielded metal arc welding (SMAW). Flux cored arc welding is more forgiving of minor disparities than gas metal arc welding (GMAW), and it is more flexible and adaptable than submerged arc welding (SAW). The process is also noted for good sidewall fusion, deep penetration, and smooth weld profile. Some of the disadvantages are the relaThe recommended power source is the direct current (DC) constant-voltage type capable of operating at the maximum current required for the specific application. A wire feeder is required to supply the continuous electrode to the arc at a constant preset rate. If the electrode feed rate is changed, the welding machine automatically adjusts to maintain a preset arc voltage. The wire feeder requires drive rolls that will not flatten or distort the tubular electrode. Welding guns may be either gas cooled or water cooled. Water-cooled guns generally have higher current ratings (up to

Mandatory Classification Designators1 for FCAW Carbon Steel Electrodes Designates an electrode. Tensile strength designator. For A5.20 this designator indicates the minimum tensile strength (when multiplied by 10,000 psi) of the weld metal when the weld is made in the manner prescribed by this specification. For A5.20M two digits are used to indicate the minimum tensile strength (when multiplied by 10 MPa). Position designator. This designator is either 0 or 1. 0 is for flat and horizontal positions only. 1 is for all positions (flat, horizontal, vertical with downward progression and/or vertical with upward progression and overhead). This designator identifies the electrode as a flux cored electrode. Usability designator. This designator is some number from 1 through 14 or the letter G ( or GS). This designator refers to the usability of the electrode with requirements for polarity and general operating characteristics (see Table 2 in A5.20). The letter G indicates that the polarity and general operating characteristics are not specified. An S is used after the G to indicate that the electrode is suitable only for single pass welding. Shielding gas designator.2 Indicates the type of shielding gas used for classification. The letter C indicates that the electrode is classified using 100% CO2 shielding gas. The letter M indicates that the electrode is classified using 75-80% Argon/balance CO2 shielding gas. When no designator appears in this position, it indicates that the electrode being classified is self-shielded and that not external shielding gas was used.

E X X T -X X -J X HX
Optional Supplemental Designators3 Optional supplemental diffusible hydrogen designator (see Table 8 in A5.20). The letter D or Q when present in this position indicates that the weld metal will meet supplemental mechanical property requirements with welding done using low heat input, fast cooling rate procedures and using high heat input, slow cooling rate procedures as prescribed in Section 17 (see Tables 9 and 10 in A5.20). The letter J when present in this position designates that the electrode meets the requirements for improved toughness and will deposit weld metal with Charpy V-Notch properties of at least 20 ft.lbf at 40F [27J at 40C] when the welds are made in a manner prescribed by this specifications. Notes: 1. The combination of these designators constitutes the flux cored electrode classification. 2. See AWS A5.32/A5.32M. 3. These designators are optional and do not constitute a part of the flux cored electrode classification. Source: AWS A5.20/A5.20M: 2005, Specification for Carbon Steel Electrodes for Flux Cored Arc Welding.

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Mandatory Classification Designators1 for FCAW Low-Alloy Steel Electrodes Designates an electrodes. Tensile strength designator. For A5.29 this designator indicates the minimum tensile strength (when multiplied by 10 ksi) of the weld metal when the weld is made in the manner prescribed by this specification. Two digits are used for weld metal of 100 ksi minimum tensile strength and higher. Two digits are used to indicate the minimum tensile strength (when multiplied by 10 MPa). See Table 1M in A5.29. Positionality designator. This designator is either 0 or 1. 0 is for flat and horizontal positions only. 1 is for all positions (flat, horizontal, vertical with downward progression and/or vertical with upward progression and overhead). This designator identifies the electrode as a flux cored electrode. Usability designator. This designator is the number 1, 4, 5, 6, 7, 8, or 11 or the letter G. The number refers to the usability of the electrode (see Section A7 in Annex A in A5.29). The letter G indicates that the polarity and general operating characteristics are not specified. Deposit composition designator. Two, three or four digits are used to designate the chemical composition of the deposited weld metal (see Table 7 in A5.29). The letter G indicates that the chemical composition is not specified. Shielding gas designator.2 Indicates the type of shielding gas used for classification. The letter C indicates a shielding gas of 100% CO2. The letter M indicates a shielding gas of 7580 % Argon/balance CO2. When no designator appears in this position, it indicates that the electrode being classified is self-shielded and that no external shielding gas is used.

E X X T X -X X -J HX
Optional Supplemental Designators3 Optional supplemental diffusible hydrogen designator (see Table 9 in A5.29). The letter J when present in this position designates that the electrode meets the requirements for improved toughness and will deposit weld metal with Charpy V-Notch properties of at least 20 ft.lbf (27J) at a test temperature of 20F [10C] lower than the temperature shown for that classification in Table 1U (Table 1M)in the specification A5.29. Notes: 1. The combination of these designators constitutes the flux cored electrode classification. Note that specific chemical compositions are not always identified with specific mechanical properties in the specification. A supplier is required by the specification to include the mechanical properties appropriate for a particular electrode in the classification of the electrode. Thus, for example, a complete designation is E80T5-Ni3. EXXT5-Ni3 is not a complete classification. 2. See AWS A5.32/A5.32M, Specification for Welding Shielding Gases. 3. These designators are optional and do not constitute a part of the flux cored electrode classification. Source: AWS A5.29/A5.29M: 2005, Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding.

700 A). Current ratings for gas-cooled guns are based on using CO2. If argonbased gas is used, the gun current rating should be decreased 30%.

Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding.

Polarity
Polarity is one of the variables that must be considered when selecting FCAW electrodes. Some FCAW electrodes are designed to be used with direct current electrode positive (DCEP) and others are designed for direct current electrode negative (DCEN). Less base metal penetration results from using DCEN. Determine which polarity the electrode is recommended for before using.

Electrode Classifications
The American Welding Society has developed a system of classifications for the various FCAW electrodes. The system is based on electrode type, minimum tensile strength, welding position, chemical composition, usability, impact properties, and diffusible hydrogen tests. Mild steel electrodes are classified according to AWS A5.20, Specification for Carbon Steel Electrodes for Flux Cored Arc Welding; low-alloy electrodes are classified in AWS A5.29, Specification for LowAlloy Steel Electrodes for Flux Cored Arc Welding; and stainless steel flux cored electrodes are classified by the standard AWS A5.22, Specification for Stainless Steel Electrodes for Flux Cored Arc Welding and

too long an extension produces an unstable arc with excessive spatter, and too short an extension may cause excessive arc length at a particular voltage setting. Most manufacturers recommend 34 to 112 in. (19 to 38 mm) for gas-shielded electrodes and 3 4 to 334 (19 to 95 mm) for self-shielded electrodes.

Gas Shielding
Carbon dioxide (CO2) and mixtures of argon and CO2 are the preferred shielding gases for FCAW-G. Carbon dioxide usually provides a globular transfer, good penetration, and low cost in contrast to mixed gases. Carbon dioxide is relatively inactive at room temperature, but when heated to high temperature by the arc, it dissociates to form carbon monoxide and oxygen. The gas mixture commonly used in FCAW is 75% argon and 25% CO2. There can be some variations to the percentages,

Electrode Extension
The unmelted electrode that extends beyond the contact tube is the electrode extension. This portion of the electrode is resistance heated, which can have an effect on arc energy, deposition rate, and weld penetration. All things being equal,

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Table 1 Shielding and Polarity Requirements for Mild Steel FCAW Electrodes AWS Classification EXXT-1 EXXT-1M EXXT-2 EXXT-2M EXXT-3 EXXT-4 EXXT-5 EXXT-5M EXXT-6 EXXT-7 EXXT-8 EXXT-9 EXXT-9M EXXT-10 EXXT-11 EXXT-12 EXXT-12M EXXT-13 EXXT-14 EXXT-G EXXT-GS Notes:
a. Mixed gas normally refers to 75% to 80% argon/balance CO2 b. As agreed upon by supplier and user c. Direct current electrode positive d. Direct current electrode negative

Recommended Weld Passes Multiple Multiple Single Single Single Multiple Multiple Multiple Multiple Multiple Multiple Multiple Multiple Single Multiple Multiple Multiple Single Single Multiple Single

External Shielding Medium CO2 Mixed gasa CO2 Mixed gasa None None CO2 Mixed gasa None None None CO2 Mixed gasa None None CO2 Mixed gasa None None Note b Note b

Current and Polarity DCEPc DCEP DCEP DCEP DCEP DCEP DCEP DCEP DCEP DCENd DCEN DCEP DCEP DCEN DCEN DCEP DCEP DCEN DCEN Note b Note b

Table 2 Typical Parameters for Mild Steel and Low-Alloy Steel Electrodes (EX1T-1 Types) for Welding in All Positions Diameter mm (in.) 0.9 (0.035) Position Wire Feed Speed cm/min (in./min) Flat 1829 (720) Uphill 813 (320) Overhead 813 (320) Flat 953 (375) Uphill 660 (260) Overhead 660 (260) Flat 914 (360) Uphill 610 (240) Overhead 610 (240) Flat 762 (300) Uphill 406 (160) Overhead 406 (160) Flat 635 (250) Flat 457 (180) Flat and horizontal 381 (150) Flat and horizontal 318 (125) Current, A 250 150 150 250 200 200 300 225 225 350 225 225 400 450 550 600 Volts, V 32 26 26 28 25 26 28 25 26 29 25 26 30 30 30 33

1.2 (0.045)

1.3 (0.052)

1.6 (116)

2.0 (564) 2.4 (332) 2.8 (764) 3.2 (18)

but this is the most popular. This mixture produces a spray-like transfer and better arc characteristics than straight CO2. When gas mixtures are used with electrodes designed for CO2 shielding, the weld deposit may accumulate excessive amounts of silicon, manganese, and deoxidizing elements since these elements are more readily transferred when high percentages of argon or other inert gases are used. Consult the electrode manufacturer for the recommend shielding gas for a particular electrode. Inadequate gas flow will result in poor shielding of the weld pool, and excessive gas flow can result in turbulence and mix56 NOVEMBER 2006

ing in air. Either extreme will increase weld metal impurities. The correct gas flow depends on the type and diameter of gun nozzle, distance of the nozzle to the work, and air movement in the immediate area of the arc.

Handling of Gas Cylinders

Compressed gas cylinders should be handled carefully and should be adequately secured when stored or in use. Cylinders caps should be kept in place (hand tight) to protect the valves unless a regulator is attached to the cylinder. Before connecting a regulator, the

cylinder valve should momentarily be opened slightly then closed immediately to clear the valve of dust or dirt. The valve operator should stand to one side of the regulator gauges, never in front of them. After the regulator is attached, the pressure adjusting screw should be released by turning it counterclockwise. Open the valve slowly to prevent a surge of high-pressure gas into the regulator. Turn the adjusting screw clockwise until the proper pressure is attained. The cylinder valve should be turned off if the cylinder is to be left unattended, and the adjusting screw should be in the open position.

Table 3 Typical Welding Parameters for Mild and Low-Alloy Steel Self-Shielded FCAW Electrodes AWS Classification EXXT-3 Diameter, mm (in.) 2.4 (332) 3.0 (0.120) 4.0 (532) 2.0 (564) 2.4 (332) 3.0 (0.120) 2.0 (564) 2.4 (332) 2.0 (564) 2.4 (332) 2.8 (764) 2.0 (564) 2.4 (332) 2.4 (332) 0.9 (0.035) 1.2 (0.045) 1.6 (116) 2.0 (564) 2.4 (332) 1.2 (0.045) 1.6 (116) 2.0 (564) 0.8 (0.030) 0.9 (0.035) 1.2 (0.045) Welding Position Flat Flat Flat Flat Flat Flat Flat Flat Flat Flat Flat Flat Flat Flat Flat Uphill Flat Uphill Flat Uphill Flat Flat All All All Flat Uphill Flat Uphill Flat Uphill Wire Feed Speed cm/min (in./min) 610 (240) 508 (200) 330 (130) 508 (200) 483 (190) 406 (160) 762 (300) 762 (300) 508 (200) 381 (150) 318 (125) 305 (120) 254 (100) 636 (250) 330 (130) 254 (100) 305 (120) 241 (95) 305 (120) 241 (95) 305 (120) 254 (100) 254 (100) 178 (70) 152 (60) 572 (225) 432 (170) 635 (250) 635 (250) 483 (190) 406 (160) Volts, V 24 24 23 31 31 30 28 28 26 24 26 21 22 26 17 16 17 16 17 16 20 20 16 16 18 16 15 18 18 17 17 Current, A 510 700 780 275 355 500 450 480 300 350 400 280 340 570 140 90 150 110 230 175 290 365 145 185 210 125 100 150 150 200 175

EXXT-4

EXXT-6 EXXT-7

EXXT-8 EXXT-10 EXXT-11

EXXT-14

EXXT-GS

Table 4 Typical Parameters for Gas-Shielded Stainless Steel FCAW Electrodes AWS Classification EXXXT0-1/-4 EXXXT0-1/-4 EXXXT1-1/-4 EXXXT1-1/-4 EXXXT1-1/-4 Diameter, mm (in.) 1.2 (0.045) 1.6 (116) 0.9 (0.035) 1.2 (0.045) 1.6 (116) Welding Position Flat & horizontal Flat & horizontal Flat Uphill Flat Uphill Flat Uphill Wire Feed Speed cm/min (in./min) 991 (390) 635 (250) 1016 (400) 699 (275) 546 (215) 406 (160) 660 (260) 521 (205) Current, A 190 250 140 95 390 250 300 250 Volts, V 26 29 24 23 29 26 29 26

Ventilation
The welding fumes generated by FCAW can be hazardous, but they can be controlled by general ventilation, local exhaust ventilation, or by respiratory protective equipment. Consult ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes. Ozone, nitrogen dioxide, and carbon monoxide are toxic gases associated with FCAW. Phosgene gas could also be present as a result of thermal or ultraviolet decomposition of chlorinated hydrocarbon cleaning agents located in the vicinity of welding. Two such solvents are trichlorethylene and perchlorethylene.

Welding with Gas-Shielded FCAW

Joint designs with relatively narrow grooves, small groove angles, and narrow root openings can be used with FCAW-G. The groove angle is properly designed when it provides accessibility for the appropriate gas nozzle and electrode extension. Adequate gas shielding is required to obtain sound welds. Welding in still air may require gas flow rates of 30 to 40 ft3/h (14 to 19 L/min). Welding in moving air may require flow rates up to 55 ft3/h (26 L/min). Regular cleaning of the inside of the gas nozzle and contact tip is recommended to prevent obstruction of gas flow. If there is brisk air movement in the

welding area, curtains could be used to restrict the movement and protect the gas shielding.

Welding with Self-Shielded FCAW

The somewhat shallower penetration with FCAW-S means the groove angle needs to be more open than with FCAWG. Electrode extension introduces a variable that may influence joint design. In making flat position groove weld without backing, care must be taken to obtain sufficient fusion and penetration in the root. Similarily, in grooves with backing, the root opening must be sufficient to permit complete fusion. WELDING JOURNAL 57

Table 5 Flux Cored Arc Welding Troubleshooting Problem Porosity Corrective Action Increase gas flowmeter setting. Clean spatter-clogged nozzle. Decrease to eliminate turbulence. Shield weld zone from draft or wind. Check gas source. Check for leak in hoses and fittings. Contaminated base metal Clean weld joint faces. Contaminated filler wire Remove drawing compound on wire. Clean oil from rollers. Avoid shop dirt. Rebake filler wire. Insufficient flux in core Change electrode. Excessive voltage Reset voltage. Excess electrode stickout Reset stickout and balance current. Insufficient electrode stickout (self-shielded electrodes) Reset stickout and balance current. Excessive travel speed Adjust speed. Improper manipulation Direct electrode to the joint root. Improper parameters Increase current. Reduce travel speed. Decrease stickout. Reduce wire size. Increase travel speed (self-shielded electrodes). Improper joint design Inccrease root opening. Reduce root face. Excess joint restraint Reduce restraint. Preheat. Use more ductile weld metal. Improper electrode Check formulation and content of flux. Insufficient deoxidizers or inconsistent flux-fill in core Check formulation and content of flux. Excessive contact tip wear Reduce drive roll pressure. Melted or stuck contact tip Reduce voltage. Adjust backburn control. Replace worn liner. Dirty wire conduit in cable Change conduit liner. Clean out with compressed air. Possible Cause Low gas flow High gas flow Excessive wind drafts Contaminated gas

Incomplete fusion or penetration

Cracking

Electrode feeding

When welding in the flat position, techniques similar to those used with lowhydrogen covered electrodes can be followed. When making vertical welds on plates 34 in. (19 mm) and thicker, the root pass may be deposited downhill for joints without backing and uphill for joints with backing. Subsequent passes are deposited uphill.

Weld Quality
Several types of discontinuities can result from improper procedures or practices. Minor discontinuities may be permitted if they are not objectionable from a design or service standpoint. A few mild steel FCAW electrodes are designed to tolerate a certain amount of mill scale and rust on the base metals. Some deterioration of weld quality should be expected when welding dirty materials. These electrodes are usually designed for single-pass applications. When they are used for multipass welding, cracking caused by accumulated deoxidizing agents in the weld may occur. The causes and remedies of some discontinuities are listed in the troubleshooting table (Table 5). Excerpted from Welding Handbook, Ninth Edition, Vol. 2, Part 1. 58 NOVEMBER 2006