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4.2 FCAW Basic Welding Technique
FLUX CORED ARC WELDING(FCAW):This is an electric arc welding process which fuses
together the parts to be welded by heating them with an arc between a continuous flux filled
electrode wire and the work. Shielding is obtained through decomposition of the flux within the
tubular wire. Additional shielding may or may not be obtained from an externally supplied gas or
gas mixture. The process is normally applied semi automatically; however the process may be
applied automatically or by machine. It is commonly used to weld large diameter electrodes in the
flat and horizontal position and small electrode diameters in all position. The process is used to a
lesser degree for welding stainless steel and for overlay work.
Weld at a Steady Pace do not weave the arc, neither forward,backward,of sideways remove slag
with the Chipping Hammer to expose weld for Horizontal Weld Joins.
Remember:Drag if there’s Slag ,Refer to manual for Troubleshooting Poor Weld Quality.
Adjustable Variables
1) Stick-out (distance between the end of the contact tube (tip) and the end of the electrode
2) wire). Maintain at about 10mm stick-out.
3) Wire Feed Speed. Increase in wire feed speed increases weld current ,Decrease in wire feed
4) speed decreases weld current.
5) Nozzle Angle. This refers to the position of the welding gun in relation to the joint. The transverse
angle is usually one half the included angle between plates forming the joint. The longitudinal angle
is the angle between the center line of the welding gun and a line perpendicular to the axis of the
weld. The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling)
or leading (pushing). Whether the operator is left handed or right handed has to be considered to
realize the effects of each angle in relation to the direction of travel.
Establishing the Arc and Making Weld Beads
1) Before attempting to weld on a finished piece of work, it is recommended that practice welds be
made on a sample metal of the same material as that of the finished piece.
2) The easiest welding procedure for the beginner to experiment with MIG welding is the flat
position. The equipment is capable of flat, vertical and overhead positions.
3) For practicing MIG welding, secure some pieces of 1.5mm or 2.0mm mild steel plate 150X
150mm. Use 0.8mm flux cored gas less wire or a solid wire with shielding gas.
4.3 Basic MIG Welding
Good weld quality and weld profile depends on gun angle, direction of travel, electrode extension
(stick out), travel speed, thickness of base metal, wire feed speed (amperage) and arc voltage. To
follow are some basic guides to assist with your setup.
1) Gun Position -ravel Direction, Work Angle
Gun position or technique usually refers to how the wire is directed at the base metal, the angle and
travel direction chosen.Travel speed and work angle will determine the characteristic of the weld
bead profile and degree of weld penetration.
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