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Weld Design and Joining
Published in Zainul Huda, Manufacturing, 2018
Flux Core Arc Welding: The FCAW process involves the uses of a tubular wire that is filled with a flux. Direct current, electrode positive (DCEP) is commonly employed, which results in the striking of an arc between the continuous wire electrode and the workpiece. The flux melts during welding and shields the weld pool from the atmosphere.
Design of Connections for Steel Members
Published in John F. Unsworth, Design and Construction of Modern Steel Railway Bridges, 2017
The flux cored arc welding (FCAW) process is often semiautomatic and uses a continuous wire as the consumable electrode. The wire is annular with the core filled with the flux material‡. In this manner, the flux material at the core behaves similarly to the coating in the SMAW or granular flux in the SAW process.
Steel Connections
Published in Paul W. McMullin, Jonathan S. Price, Richard T. Seelos, Steel Design, 2018
Common welding methods today include: Shielded Metal Arc Welding (SMAW)—commonly called “stick” welding, utilizes a flux-coated metal wire that acts both as an electrode and as the filler metal (Figure 8.5). The flux melts with the wire in the heat of the welding arc. The shielding gas and slag that are created protect the weld. Additional alloying elements are added to the flux to provide specific operating and metallurgical characteristics. It is the most versatile and accessible arc welding process.Submerged Arc Welding (SAW)—employs a continuous wire electrode that melts in the arc beneath a bed of granular flux. SAW is a high-deposition, automatic welding process for welding thick sections, Figure 8.5.Gas–Metal Arc Welding (GMAW)—consumes a continuous wire electrode protected by shielding gas only, shown in Figure 8.7. Some wires are tubular and contain additional alloying elements to improve operating and metallurgical characteristics. This process is very versatile and commonly used for welded fabrication.Flux-Cored Arc Welding (FCAW)—consists of a tubular, continuous wire electrode. Flux is formed into the tube creating shielding gas and slag in the welding arc, illustrated in Figure 8.8. It is like a “stick” electrode turned inside out. Some variations incorporate a secondary shielding gas for precision arc control and increased toughness.Electroslag Arc Welding (ESG)—uses highly specialized welding equipment and copper cooling “shoes”, schematically shown in Figure 8.9. The process deposits large amounts of weld metal, joining base metals as thick as 4 in (100 mm) in a single pass. The cooling shoes pull the massive amount of heat out of the connection, mold the weld bead, and maintain the dimensional integrity of the connection.
Study of arc welding stability in flux cored arc welding process and pulsed continuous current
Published in Welding International, 2021
Alisson Caetano Neves, João Roberto Sartori Moreno, Celso Alves Corrêa, Emillyn Ferreira Trevisani Olívio
Flux Cored Arc Welding (FCAW) is a process that uses a continuous electric arc between a constant wire and the melting pool. The process is used for the protection of elements contained within the tubular wire, adapted from [1]. Figure 1(a) shows FCAW-S process, where the welding zone is protected by the gases generated by the burning of the elements contained in the tubular wire, in addition to the generated slag. Figure 1(b) shows FCAW-G process, where protection is provided by gases externally assigned by the welding nozzle, in addition to the protection provided by the tubular wire elements.