Flux-Cored Arc Welding (FCAW), also known as Flux-Cored Wire Welding, and the welding process 136.

Flux Cored Welding Torch

It consists of Nozzle, Contact Tip, Insulation, and Gas Diffuser.

Flux Core Welding Machine (Similar to GMAW)

It operates with constant voltage (Constant Voltage-CV), typically using DCEP welding current. The arc voltage (V) setting depends on the size of the welding wire, the thickness of the workpiece, and the welding position. Adjusting the voltage (V) higher will result in a longer arc distance and higher power. Adjusting the voltage (V) lower will result in a shorter arc distance and lower power.

Adjusting the Wire Feed Speed (S)

If the feed speed is fast, the welding current (A) increases, and the rate of melting the welding wire increases. If the feed speed is slow, the welding current (A) decreases, and the rate of melting the welding wire slows down.

Flux Core Wire Electrode

Steel welding wire according to AWS A5.20, types E70T-1C (using SG-C gas), E70T-1M (using a mixed SG-AC-20 gas), and E70T-6 (no external shielding gas required). Stainless steel welding wire according to AWS A5.22, types E308LT1-1 (using SG-C gas), E308LT1-4 (using SG-AC-20 gas). These wires come in spool sizes ranging from 0.8 mm to 4.0 mm.

FCAW uses argon gauge-valve CGA-580, or for carbon dioxide gauge-valve CGA-320.

Gas Shielding Tubes for FCAW Welding are according to AWS A5.32.

Steel and stainless steel welding wires use carbon dioxide (CO2) SG-C gas (black tube with a white stripe) and argon + carbon dioxide SG-AC-20 gas (Ar+20%CO2, blue-mist tube with a black shoulder).

FCAW Welding Cable

It consists of welding current-carrying cable, gas delivery cable, welding wire feeder tube, control switch cable, and water cooling system (if available).

Ground Cable connected to the workpiece

For example, use copper welding current-carrying cable, AWG size 1/0.

Base Metal commonly welded

Workpieces with a thickness of 10-25 mm, such as:

1. Carbon steel plates ASTM A-36
2. Seamless steel pipes ASTM A-53
3. Stainless steel plates, chromium, and chromium-nickel, for use in high-pressure and heat-resistant applications, ASTM A-240
4. Seamless austenitic stainless steel pipes for use in high-pressure and heat-resistant applications, ASTM A-312

On behalf of Worachart Group, we would like to express our sincere gratitude to Teacher Thares Taping for generously sharing valuable knowledge, which will be beneficial to those who wish to continue their studies in the future.