1. Flux Core Arc Welding
FCAW

2. 5 Essentials of Arc Welding
Arc Length
Travel Speed
Electrode Angle
Electrode
Machine Setting

3. FCAW Machine Settings Machine setting depends on thickness of metal.
Voltage/Arc heat (see chart on machine)
Wire speed (see chart on machine)

4. Electrode (wire)
Tubular welding electrode(wire) with flux in the center.
Type of wire depends on base metal.
Mild steel base metal = mild steel wire.
Various sizes (.030”, .035”, .045”)
All machines in our shop are set up with .030” mild steel wire.

5. Electrode Angle Work angle (front to back)
Flat welds = 90
T – Joint = 45
Travel angle (right to left)
Always 90

6. Travel Speed
Resulting weld should be 1/8” – 3/16” wide.

7. Arc Length
Stickout: Length of wire sticking out from the welding tip. Should be around 1/2”.
Listen carefully to your weld, should have a constant sizzle, no cracking or popping.

8. Welding Gun
When you pull the trigger on the welding gun 2 things happen simultaneously:
Wire-feed starts
Arc starts

9. FCAW Related Terms
Cold lap: Non-penetrating weld; weld sits on top of or overlaps base metal.
Causes: Improper machine setting, low heat, improper arc length(stickout).
Slag: Layer of impurities that form around the resulting weld.
After each weld always:
Chip slag with a chipping hammer.
Clean weld with a wire brush.