A wire feeder configured for .052 inch (1.3 mm) FCAW-G

Flux-cored arc welding (FCAW) is a common 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. The use of an externally supplied shielding gas is optional creating the primary process variation: Welding is a fabrication process that joins materials, usually metals or thermoplastics, by causing coalescence. ... An electrode is a conductor used to make contact with a nonmetallic part of a circuit (e. ... The flux visualized. ... A high output constant current welding power supply for use with GTAW and SMAW A welding power supply is an electrical device that provides an electrical current to perform welding procedures which require electricity. ...

• FCAW–S (self-shielded or “open-arc”)
• FCAW–G (gas-shielded)

FCAW key process variables

• Wire feed speed (and current)
• Arc voltage
• Electrode extension
• Travel speed
• Electrode angles
• Electrode wire type
• Shielding gas composition (if required)

FCAW applications

• FCAW may be an “all-position” process with the right filler metals
• A high-deposition rate process in the 1G/1F/2F
• Some “high-speed” (e.g., automotive applications)

Used on the following alloys:

• Mild and low alloy steels
• Stainless steels
• Some high nickel alloys
• Some wearfacing/surfacing alloys

References and further reading

American Welding Society, Welding Handbook, Vol 2 (9th ed.)

See also

• Gas Metal Arc Welding or MIG welding
• Gas Tungsten Arc Welding or TIG welding
• Shielded Metal Arc Welding or stick welding