Flux-cored
arc welding (FCAW) is a common arc welding process. FCAW requires a continuously
fed consumable tubular electrode containing a flux and a constant voltage or,
less commonly, a constant current welding power supply. The use of an externally
supplied shielding gas is optional creating the primary process variation:
FCAW–S (self-shielded or “open-arc”)
FCAW–G (gas-shielded)
FCAW key process variables
Wire feed speed (and current)
Arc voltage
Electrode extension
Travel speed
Electrode angles
Electrode wire type
Shielding gas composition (if required)
FCAW applications
FCAW may be an “all-position” process with the right filler metals
A high-deposition rate process in the 1G/1F/2F
Some “high-speed” (e.g., automotive applications)
Used on the following alloys:
Mild and low alloy steels
Stainless steels
Some high nickel alloys
Some wearfacing/surfacing alloys
References and further reading
American Welding Society, Welding Handbook, Vol 2 (9th ed.)