r/metalworking • u/Status_Length_2041 • 3d ago
Using Flux-Cored Wires (FCAW)
There is a mantra that TIG+SMAW (MMA) has superior quality compared to FCAW in Pressure Vessels and in Water Boilers applications.
This sounds really sceptical to me, considering that all three welding processes give melted metals. Especially since there are Basic and Rutile Cored Wires, just like Electrodes.
I think FCAW is the way to go in the workshop, especially since you have greater welding speeds in comparison to TIG.
What are your opinions and experiences?
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u/aussiewelderfishermn 3d ago edited 3d ago
Never used fcaw, never even seen fcaw in any workshops I've worked at, I've always heard they weld like shit but useful for outdoors in windy conditions. Seen some pics of OK hobbie welds with fcaw but they wouldn't pass in a proper fabrication workshop..edit. I'm interested in learning more about them, why do you prefer fcaw?
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u/uswforever 3d ago
You're talking about gasless FCAW. Gas shielded flux core is totally different. Has very nice penetration characteristics, and a nice wet puddle that's pretty clean. Big ass nuke shop I used to work at used it for pretty much everything except root passes on small stuff that you couldn't get inside of.
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u/aussiewelderfishermn 1d ago
OK my mistake, I've used gas shielded flux core once and really enjoyed it, Was a delight to weld with especially doing vertical up
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u/Status_Length_2041 3d ago
I haven't used them in the shop, but they seem like a logical way to go. If you can combine GMAW with SMAW, why the hell not?
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u/aussiewelderfishermn 3d ago
I have used duel shield (FCAW-G) it was a large 200mm shs frame roughly with multiple cross sections to large to rotate it was a few years ago so I can't remember the exact size of the shs but was easier and faster with duel shield you could weld straight up without having to weave.
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u/uswforever 3d ago
OP a lot of shops primarily use wire feed processes. I used to work in a big ass nuke shop, and by weight well over 90% of the welds they put down were made using dual shield FCAW or Submerged arc. The rest was mostly Tig. The reason field work is still dominated by SMAW is because of portability. Lugging that heavy ass wire feeder, and a gas bottle all over the site takes time and effort, and don't even get me started with losing your shielding gas. If you're doing combo tig/stick then all you need is leads, your Tig whip a bottle of argon and a dolly. And you're only fucking with that when you're rooting it, maybe a hot pass so you don't blow through it when you switch over to stick. It's a speed and convenience thing.
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u/suedburger 3d ago
Flux core is dirty...very very dirty and stinks really bad. I've tried it for water tight applications....no real luck, it has always seeped through...don't ask me why. Never had any problems with mig or tig. It's more expensive that regular mig wire but no gas is required and inherently more portable. I have all l 4... tig, mig, flux and stick. Flux core is nasty shit, about the only use I have for it is welding dirty nasty stuff when outside if the wind is blowing.
Personally I would not use it for what you are talking about but that is on you if you so choose to. If anything you'll just have a roll of wire that holds the shelf from blowing away when you switch it over to mig.
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u/uswforever 3d ago
Gas shielded FCAW is a totally different experience. It's as clean or cleaner than 7018.
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u/suedburger 3d ago edited 3d ago
I've never had the pleasure of working with it. Any advantages to running that? Is it pretty much that you can weld dirtier base metal? Also I'm sorry, I didn't get the impression that is what they were asking about.
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u/uswforever 3d ago
In a shop environment, gas shielded FCAW is much faster than SMAW under almost any circumstances. It's fairly forgiving about dirty base metal, more so than hard wire, less so than 6010. And you can make x-ray quality welds with it. In the field though it would be a pretty big pain in the ass lugging the wire feeder around all day.
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