CAMPARISON OF FCAW & GMAW FOR SS

E 308 T1-1 AWS 5.22 SL.NO FCAW 1 FCAW is versatile process & weld metal is protected by Slag from flux & also external Gas used. 2 FCAW consumables are normally available in 1.2mm & 1.6mm Size.Can be supplied in 1.0mm size in specific cases. 3 Because of smooth operation , the spatter level is nil/very low. 4 FCAW can operate with CO2 gas to give radiographic quality welds.In specific cases ,also can be used with 80:20 Argon /CO2 Mix also 5 Because of the flux covering, the positional capability is very high. 6 In view of the Transfer mode i.e Spray transfer, FCAW has better wetting action in deeper grooves/Thicker joints 7 In view of higher Current carrying capacity, the deposition rate is at least 20% higher in flat position. In vertical up position the productivity is 100% higher & weld beads are of good quality. With FCAW Overhead welding can be done with ease by skilled welder FCAW has great advantage when welding of SS of special grade as smaller quantity to required specification can be manufactured in required lot size. In general FCAW is much superior & productive process capable of giving better bead finish & quality as campared to GMAW. ER308 AWS 5.9 GMAW GMAW is restricted process where in weld pool is protected by external shielding Gas only GMAW Consumables are available in 0.8mm/1.2mm/1.6mm Size. With Argon gas spatter level is high. To reduce spatter ,may have to use Argon Plus O2 Mix. Operates only with Argon/Argon Plus 2% O2 .Hence use of inert gas is must for Solid SS wires . Most suited for flat /horizontal position of welding. T he transfer mode depends on Current level employed & may vary from Globular to Spray. The higher level of welder skill is called for to achieve proper side wall fusion. In view of increase in level of spatter, set welding current is fixed in narrow band. In vertical position ,the weld bead is Convex & normally requires grinding. The situation can be improved to limited extent with Mixed Gas With GMAW overhead welding can not done Satisfactorily as GMAW operates in Drop transfer mode in low Currents . GMAW is limited by availability of custom made consumables. Normally, for special purpose steels If special lot of consumables are required, the minimum quantity will be specified as 2 to 3 Tonnes.

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