1. FLUX CORED ARC WELDING FCAW - SS Innershield® Hobart Fabshield
FCAW - GS
Outershield®
Hobart FabCo 1

2. Principles of the FCAW-SS Process
Electric Arc Between Electrode & Work, Melts the Electrode & Fuses the Joint
Weld Metal & Slag Form
The Slag is Lighter than the Molten Metal & Rises to the Top
DC Polarity

3. Principles of the FCAW-GS Process
Electric Arc Between Electrode & Work, Melts the Electrode & Fuses the Joint
Weld Metal & Slag Form
The Slag is Lighter than the Molten Metal & Rises to the Top
DC Polarity

4. Minor Maintenance & Repair
Handle
FCAW-SS Gun Assembly
Conductor Tube
Thread Protector
Contact Tip
Trigger

5. FCAW-SS Electrodes

6. Electrodes Characterized by Long Electrical StickOut (E.S.O.)
Typically 3/4” - 3 3/4” with + 1/8” Tolerance
Too Long E.S.O. Causes an Unstable Arc, Increased Spatter, and Decreased Penetration
Too Short E.S.O. Causes Excessive Arc Length and Premature Melting & Activation of the Core Materials causing Porosity 6

7. Core Elements Common Core Elements & Their Function
Aluminum Deoxidize & Denitrify
Calcium Provide Shielding & Form Slag
Carbon Increase Hardness & Strength
Manganese Deoxidize & Increase Strength
Molybdenum Increase Hardness & Strength

8. Core Elements continued
Common Core Elements & Their Function
Nickel Improve Hardness, Strength, Toughness, & Corrosion Resistance
Potassium Stabilize the Arc & Form Slag
Silicon Deoxidize & Form Slag
Sodium Stabilize Arc & Form Slag
Titanium Deoxidize, Denitrify & Form Slag

9. Core Element Functions
Deep Penetration and High Deposition Rates
Even Out of Position
Mechanical & Metallurgical Properties
Refines the Metal in the Molten Pool with Deoxidizers and Denitrifiers
Provides a Slag Coverage to:
Protect the Weld
Shape the Weld Bead
Hold the Weld in Place for Out of Position Welding

10. FCAW-GS Electrodes

11. FCAW-GS - Shielding Gases
Carbon Dioxide
Argon/Carbon Dioxide Mix

12. CO2 Deeper Penetration Lower Cost Lower Strength Weld Metal
Less Susceptible to Gas Marks
Lower Cost
Less Spray Transfer
Less Radiated Heat

13. AR / CO2 Balances 75/80/85/90 Ar/CO2 Balance
Better Mechanical Properties
(Charpy, Tensile, Yield)
Lower Spatter
Better Arc Transfer
Lower Smoke Levels
Higher Deposition Rates
Especially Out of Position
Less Penetration

14. E7 X T- Y AWS Classification Electrode
70,000 psi Min. Tensile Strength
Welding Position
(0=Flat & Horizontal, 1= All Position)
Tubular (Flux Cored Electrode)
Usability & Performance Capabilities

15. E 7X T- Y AWS Classification Electrode
70,000 psi Min. Tensile Strength
Welding Position
(0=Flat & Horizontal, 1= All Position)
Tubular (Flux Cored Electrode)
Usability & Performance Capabilities

16. Metal Core - AWS Classification
E 70 C- Y
Electrode
70,000 psi Min. Tensile Strength
Metal Core Electrode
Usability & Performance Capabilities

17. Flux Cored Arc Welding
Summary

18. Flux Cored Arc Welding-SS
A Popular Welding Process in North America
Replacement for SMAW for Higher Productive Efficiency
Great for Outdoor Welding
Covers a Wide Variety of Material Types
Good on Dirty Steels and Off Analysis Steels
High Deposition Rates 37

19. The FCAW Process-SS

20. Flux Cored Arc Welding-GS
A Popular Welding Process in North America
High Efficiency and Deposition Rates
Covers a Wide Variety of Material Types
Provides Deep Penetration
Requires a Shielding Gas or a Gas Mixture
Deposits Low Hydrogen Welds 37

21. The FCAW Process-GS

22. Electrode Stickout

23. Contact Tip Position

24. Electrical Stick-Out vs Visible Stick-Out

25. Cross Section of a Fillet Weld

26. Cross Section of a Groove Weld

27. Flux Cored Arc Welding
Definitions

28. Alternating Current Alternating Current (AC): A current which reverses
at regularly recurring intervals of time (every 1/100 or
1/120 of a second) and which has alternately positive
and negative values. Modern power systems normally
generate a sinusoidal alternating current of either 50
or 60 Hertz (Hz).

29. Direct Current Electrode Negative
Direct Current Electrode Negative (DCEN):The
arrangement of direct current arc welding
cables/leads in which the electrode is the
negative pole and the workpiece is the positive pole
of the welding arc.
DCEN

30. Direct Current Electrode Positive
Direct Current Electrode Positive (DCEP): The
arrangement of direct current arc welding
cables/leads in which the electrode is the
positive pole and the workpiece is the negative pole
of the welding arc.
DCEP

31. Constant Voltage Power Source
Constant Voltage (CV) Power Source: An arc
welding power source with a volt-ampere relationship
yielding a large welding
current change from
a small arc
voltage change. 4

32. Constant Current Power Source
Constant Current (CC) Power Source: An arc
welding power source with a volt-ampere relationship
yielding a small welding
current change from
a large arc
voltage change.
Not Recommended for
FCAW-SS / FCAW-GS 4