A

Seminar Report
on
FLUX-CORED ARC WELDING
Submitted By:
Patil Rohit Gajmal
T.E. [MECHANICAL]

Guided By:
Prof. N. A. Patil

Department of Mechanical Engineering

R. C. Patel Institute of Technology,
Shirpur-425405
2018-19
 R. C. Patel Institute of Technology,
Shirpur, Dist-Dhule

CERTIFICATE

This is to certify that Patil Rohit Gajmal of T.E [Mechanical] has

satisfactorily carried out seminar work on“FLUX-CORED ARC

WELDING” and submitted the report in the premises of Department

of MECHANICAL under the guidance of Prof. N. A. Patil dur-

ing year 2018-2019.

Date:
Place: Shirpur

Seminar Guide Coordinator

Head of Department Principal

 APPROVAL SHEET

The seminar report entitle “Flux-Cored Arc Welding” by Patil Rohit Gaj-

mal is approved for the partial fulfilment of award for the course in Third Year of

the Department of Mechanical.

Date:
Place: Shirpur

Prof. P. L. Sarode Prof. N. A. Patil

(Head of Department) (Seminar Guide)

EXAMINERS:

1)
2)

1
 Acknowledgement

I take this opportunity to express my heartfelt gratitude towards the Department

of Mechanical RCPIT, Shirpur that gave me an opportunity for presentation of my
seminar in their esteemed organization.

It is a privilege for me to have been associated with Prof N. A. Patil, my guide

during seminar work. I have been greatly benefited by his valuable suggestion and
ideas. It is with great pleasure that I express my deep sense of gratitude to him for
his valuable guidance, constant encouragement and patience throughout this work.

I express my gratitude to Prof P. L. Sarode [HOD Mechanical] for his constant

encouragement, co-operation and support and also thankful to all people who have
contributed in their own way in making this seminar success.

I take this opportunity to thank all the classmates for their company during the
course work and for useful discussion I had with them.

Under these responsible and talented personalities I was efficiently able to com-
plete my seminar in time with success.

Patil Rohit Gajmal

 Abstract

This seminar is about “The Welding Technique adopted by many Industries to get
higher productivity”. That is Flux-cored arc welding (FCAW).
Flux-cored arc welding is a semi-automatic or automatic 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. An
externally supplied shielding gas is sometimes used, but often the flux itself is relied
upon to generate the necessary protection from the atmosphere, producing both
gaseous protection and liquid slag protecting the weld. The process is widely used
in construction because of its high welding speed and portability.
Contents

List of Figures ii

1 INTRODUCTION 1

2 LITERATURE SURVEY 2

3 CONCEPT AND WORKING PRINCIPLE 4

3.1 Concept: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Welding Equipments Description: . . . . . . . . . . . . . . . . . . . . 4
3.3 Block Diagram: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Working Principle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 PRODUCTIVITY BENEFITS OF FCAW PROCESS 7

5 PROCESS VARIABLES 9
5.1 Weldable Metals: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Joint Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Welding Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.4 Flux-Cored Electrode Wire: . . . . . . . . . . . . . . . . . . . . . . . 11

6 ADVANTAGES, LIMITATIONS AND APPLICATIONS OF FCAW 13

6.1 Advantages: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Limitations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Applications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 FUTURE SCOPE 15

8 CONCLUSION 16

REFERENCES 17

i
List of Figures

3.1 Block Diagram of FCAW . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Schematic Illustration of the FCAW Process . . . . . . . . . . . . . . 6
3.3 Photograph of FCAW Machine . . . . . . . . . . . . . . . . . . . . . 6

4.1 Deposition rate of FCAW process compared with SMAW and GMAW
processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Various Types of Welded Joints . . . . . . . . . . . . . . . . . . . . . 10

5.2 Flux-Cored Wire Reel . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Chapter 1

INTRODUCTION

At present, shielded metal arc welding (SMAW) and gas tungsten arc welding
(GTAW) are the most commonly used welding processes in the fabrication industries,
but because they are manual processes, productivity is limited. There are other
processes available to improve welding deposition rate and duty cycle. For welding
positions and components where mechanised welding is applicable, submerged arc
welding (SAW) is a generally preferred and most productive process. However, for
all-positional welding and particularly for fixed pipe or site welding, the ideal high
productivity process is tubular flux-cored arc welding (FCAW).
This seminar describes the potential productivity benefits of using FCAW for
manufacturing industries and presents joint completion rates and time savings in
comparison to other arc welding processes. FCAW is the process in which solid wire
is replaced by a flux-cored electrode wire that is called as tubular wire.
This process is growing in popularity. Some FCAW still uses CO2 shielding, but
use of flux-cored wire alone is increasing.

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Chapter 2

LITERATURE SURVEY

D. Katherasan, Jiju V. Alias, P. Sathiya

(Journal of Intelligent Manufacturing 25 (1), 67-76, 2014):
Flux cored arc welding (FCAW) process is a fusion welding process in which the
welding electrode is a tubular wire that is continuously fed to the weld area. It is
widely used in industries and shipyards for welding heavy plates. Welding input
parameters play a very significant role in determining the quality of a weld joint.
This paper addresses the modeling of welding parameters in FCAW process using
a set of experimental data and regression analysis, and optimization using Particle
Swarm Optimization (PSO) Algorithm. The input process variables considered here
include wire feed rate (F); voltage (V); welding speed (S) and torch Angle (A) each
having 5 levels. The process output characteristics are welded bead width, reinforce-
ment and depth of penetration. The Taguchi method and regression modeling are
used in order to establish the relationships between input and output parameters.
In the next stage, the proposed model is embedded into PSO algorithm to optimize
the FCAW process parameters. In this study the objectives considered are maxi-
mization of depth of penetration, minimization of bead width and minimization of
reinforcement. A comparative study on the effectiveness of the two algorithms on
the optimization of the weld bead geometry is done.

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RCPIT, Shirpur Department of Mechanical Engineering

T. Kannan, N. Murugan
(Journal of Materials Processing Technology 176 (1-3), 230-239, 2006):
The main problem faced in duplex stainless steel cladding is the selection of the
optimum combination of process parameters for achieving the required quality of
clad. This paper highlights an experimental study carried out to analyse the ef-
fects of various flux cored arc welding (FCAW) process parameters on important
clad quality parameters in duplex stainless steel cladding of low carbon structural
steel plates. The experiments were conducted based on four-factor five levels central
composite rotatable design with full replications technique and having mathematical
models developed using multiple regression method. The effects of the input pro-
cess parameters on clad quality parameters have been presented in graphical form,
which helps in selecting welding process parameters to achieve the desired clad qual-
ity quickly.

H. R. Ghazvinloo, A. HonarbakhshRaouf
(Journal of Applied Science 10 (8), 658-663, 2010):
Generally, the quality of weld joint is strongly influenced by process parameters
during the welding process. In order to achieve high quality welds, the bead geom-
etry and mechanical properties of the weldments should be provided accuracy. The
present study highlights an experimental study carried out to analyze the effects
of various FCAW welding parameters on weld width and tensile properties of weld
metal extracted of a butt joint. The welding current, arc voltage and welding speed
were chosen as variable parameters and due to high application in industry; welding
assemblies were chosen as 26, 30 and 34 V and welding speeds were chosen as 40,
50 and 60 cm min-1 for all experiments. The result of this study helps in selecting
welding process parameters to achieve the desired geometry and tensile properties
for weld quickly.

Flux-Cored Arc Welding 3

Chapter 3

CONCEPT AND WORKING

PRINCIPLE

3.1 Concept:
The FCAW is a process in which coalescence is produced by heating with an
electric arc between a continuous tubular consumable electrode and the work. The
electrode is flux-cored that is the flux is contained within the electrode which is hol-
low. In addition to flux, minerals and Ferro-alloys in the core can provide additional
protection and composition control. The flux-cored electrode is coiled and supplied
to the arc as a continuous wire.

3.2 Welding Equipments Description:

1. A motor is used to control the feed of the wire which drive the electrode at a
present and uniform rate.
2. A Trigger for control of electrode feed and flows of gas which gives electric current
also.
3. A mount for the spooled electrode.
4. A control station containing the relays, solenoids and timers needed to integrate
the system.

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5. A power supply to provide current.

6. A water supply for cooling if necessary.

3.3 Block Diagram:

Figure 3.1: Block Diagram of FCAW

3.4 Working Principle:

1. FCAW utilizes the heat of an arc between a continuously fed consumable flux-
cored electrode and the work.
2. The heat of the arc melts the surface of the base metal and the end of the
electrode.
3. The melted electrode is transferred through the arc to the work piece.
4. Shielding is obtained due to the disintegration of the cored flux contained in the
electrode.
5. The ingredients contained in the electrode form a glass like slag, which is lighter

Flux-Cored Arc Welding 5

RCPIT, Shirpur Department of Mechanical Engineering

in weight than the deposited weld metal and which floats on the surface of the weld
as a protective cover.
6. The flux-cored electrode is automatically fed in to the arc from a coil.
7. The arc is maintained automatically and arc travel can be manual or by machine.

Figure 3.2: Schematic Illustration of the FCAW Process

Figure 3.3: Photograph of FCAW Machine

Flux-Cored Arc Welding 6

Chapter 4

PRODUCTIVITY BENEFITS OF
FCAW PROCESS

Deposition rate is often used as a measure of potential productivity, although

many other factors contribute to operator duty cycle and hence productivity. A
graph of comparative deposition rates of different welding processes is shown in
Figure 4.1.

Figure 4.1: Deposition rate of FCAW process compared with SMAW and GMAW
processes

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RCPIT, Shirpur Department of Mechanical Engineering

It should be pointed out that, although compared here, the solid wire gas metal
arc welding (GMAW) process has not found widespread use in the power generation
industry mainly due to concerns over lack-of-fusion, sensitivity to welder error and
demands for more sophisticated power sources.
Flux-cored wire, 1.2mm diameter, is capable of a deposition rate which is com-
petitive with all other arc welding processes except SAW [5]. This advantage is
particularly notable for positional welding, where the ease of use and high effective
operating currents come into their own. Compared with solid wire gas metal arc
welding (GMAW), a faster burn-off rate for tubular FCAW is also promoted by
higher current density at the wire tip and I2R resistance heating of the wire ex-
tension from the contact tip. Moreover, the flux-cored wire process, which utilises
spray transfer, produces reliable fusion and penetration in all welding positions.
The duty cycle possible with the FCAW process is also higher than for the GTAW
and SMAW processes, which further improves potential productivity compared to
these processes. The better duty cycle can be attributed to two main factors: The
continuous nature of the process and the all-positional capability of the process
without the need for a change in welding parameters. For some applications, espe-
cially numerous short welds, the duty cycle of the FCAW process may also compete
with SAW if the set-up times and positioning of the joints into the flat position
contribute a significant proportion of the time. The ability of the FCAW to weld
thick section joints relatively quickly in all position may allow the FCAW process
to compete with SAW in these situations.
The FCAW process is expected primarily to replace the SMAW process; the
GTAW process will still be required for pipe roots and other small diameter or thin
wall pipe, and the SAW process will be preferred for very thick section welds that
can be rotated or manipulated into the flat position.

Flux-Cored Arc Welding 8

Chapter 5

PROCESS VARIABLES

5.1 Weldable Metals:

1. Low to medium carbon steels.
2. Low alloy high strength steels.
3. Quenched and tempered steels.
4. Cast Iron.

5.2 Joint Design:

With edge preparation, welds can be made with a single pass on materials from
6mm through 19mm.
With multipass technique and with joint preparation the maximum thickness is
practically unlimited. Horizontal fillets can be made up to 9.5mm in a single pass,
and in the flat position fillet welds can be made to 19mm.
For maximum utilization and efficiency, different joint details are suggested:
(a) For groove welds, the square groove design can be used up to 16 mm thickness.
Beyond this thickness, bevels are required; however, the included angle of bevel
groove welds can be reduced 35-50 percent over that normally used for shielded
metal arc welding. This is because the smaller size electrode wire can get deeper

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RCPIT, Shirpur Department of Mechanical Engineering

into the joint.

(b) Open root can be used; however, a root face is normally required to avoid burning
through. In many structural applications the weld is made with a tight root opening
and the back side is gouged and rewelded.
(c) When welding fillets welds using CO2 shielding also, the fillet size can be smaller,
yet will have the same strength as shielded metal arc welds.

Figure 5.1: Various Types of Welded Joints

Flux-Cored Arc Welding 10

RCPIT, Shirpur Department of Mechanical Engineering

5.3 Welding Parameters:

The FCAW process normally used direct current with electrode positive i.e.,
DCEP or DCRP. Direct current with constant voltage power is normally employed.
When AC type specially formulated flux-cored electrodes are used, the drooping
characteristic type power source and voltage sensing feeders are employed.
The welding current for Flux-cored arc welding can vary from as low as 50
amperes to as high as 750 amperes. Most flux-cored arc welding is done in the range
of 350-500 amperes when the 2.4mm electrode wire is used.

5.4 Flux-Cored Electrode Wire:

Most of the Flux-cored electrode wire is manufactured by passing low-carbon
steel strip through contour-forming rolls that bends the strip into a U-shape cross-
section, which is then filled with flux through a filling device. Then, the flux-filled U-
shape strip passes through closing rolls that form it into a tube and tightly compress
the core materials. The tube is then pulled through drawing dies that reduce its
diameter and further compress the core materials.
The finished electrode wire is wound into a continuous coil or on to spools, as
required.
The functions of Flux-cored are:
(a) To act as deoxidizers or scavengers to help purify the weld metal and produce a
sound deposit.
(b) The form slag to float on the molten weld metal and protect it from the atmo-
sphere during solidification.
(c) To Act as act stabilizers to produce a smooth welding arc and reduce weld spat-
ter.
(d) To add alloying elements to the weld metal to increase weld strength and to
provide other required weld metal properties.
(e) To provide shielding gas.

Flux-Cored Arc Welding 11

RCPIT, Shirpur Department of Mechanical Engineering

Figure 5.2: Flux-Cored Wire Reel

Flux-Cored Arc Welding 12

Chapter 6

ADVANTAGES, LIMITATIONS
AND APPLICATIONS OF FCAW

6.1 Advantages:
1. High deposition rate - nearly three to four times higher compared to other manual
welding processes.
2. High quality of weld metal at lower cost.
3. Low operator skill required than SMAW.
4. More flexible and adaptable than SMAW.
5. Smooth and Uniform welds, less liable to porosity.
6. High travel speed and considerably reduced spatter.
7. It can be easily mechanized.
8. Less pre-cleaning required than SMAW.
9. Reduced distortion over SMAW.
10. All position capability.

6.2 Limitations:
1. Used only to weld ferrous metals.
2. Equipment is more expensive, however the increased productivity compensates

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RCPIT, Shirpur Department of Mechanical Engineering

for this.
3. It cannot be used easily in confined spaces and spaces with limited access.

6.3 Applications:
1. FCAW is widely used on medium thickness steel fabrication where the fine wire
GMAW process would not apply and where the fit-up is such that SAW would not
apply.
2. FCAW is also used for surfacing and for buildups.
3. FCAW has been widely used for welding in bridges, high rise buildings, Ship
building and Offshore drilling platforms.
4. FCAW with Co2 gas shielding gives deeper weld penetration and can weld thick-
ness from 1.6mm to 13mm with no edge preparation. When Co2 is not used, the
maximum thickness welded is only about 6mm.

Flux-Cored Arc Welding 14

Chapter 7

FUTURE SCOPE

There’s an old saying that goes, “No one wants a quarter-inch drill bit, they
want a quarter-inch hole.” By that same token, a farmer doesn’t want a welder;
they simply want to join two pieces of metal.
For most farmers, that has meant relying on an old “buzz box” Stick welder a
standard piece of equipment found on farms across Canada for the last 75 years.
But just as seed, breeding and harvesting technologies have changed over that
period to make farming an easier, more productive process, welding technologies
have likewise improved to offer similar benefits.
Although certainly capable of meeting the demands of most farm welding ap-
plications, Stick welders also have limitations that can be overcome by the use of
other welding methods, particularly wire welding, which includes Gas Metal Arc
Welding (GMAW) also known as MIG (Metal Inert Gas) and flux cored arc welding
(FCAW).
Both MIG and FCAW are performed with the same welder and differ only in the
way the weld is protected from contamination by the surrounding air environment.

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Chapter 8

CONCLUSION

Today’s Flux Cored Arc Welding is the high productivity welding solution for
many applications. High productivity Flux Cored Arc welding fills the gap between
Submerged Arc welding and conventional SMAW with excellent all position capa-
bilities.
The reality of Flux-cored arc welding is using a typical MIG welding machine
and mostly the same equipment, with a few small exception! Although they are con-
sidered two different types of welding processes, it is only the electrode type, and
shielding type, that separate them. Learning and understanding flux core welding is
about learning to use a different type of electrode in a MIG welding machine. That
is all there really is to flux-core arc welding.

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 REFERENCES
Papers:
1. “Flux Cored Welding”. Welding Procedures and Techniques. 23 June 2006.
American Metallurgical Consultants. 13 Sep 2006.
2. Groover, Mikell P. Fundamentals of Modern Manufacturing. Second. New York
City: John Wiley and Sons, INC, 2002
3. “Solid Wire Verses Flux-cored Wire When to Use them and Why”. Miller
Electric Mfg. Co. 13 Sep 2006.

Books:
1. Dr R. S. Parmar, “Welding Process Technology”.
2. A. Banerjee, “Welding Procedures Applications”.
3. L. M. Gourd, “Principles of Welding Technology”.
4. Dr O.P. Kanna, “A text book of Welding Technology”.
5. Richard L. Little, “Welding Welding Technology”.

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