Stick and flux core welder10/3/2023 The flux used in flux-core wire comes in many varieties. A side effect of smoothing and stabilizing the welding arc is reducing the spatter. Stabilize the arc – The flux can stabilize and control the welding arc.The slag protects the weld metal from the atmosphere as it cools it slowly and helps shape the weld. Slag protection – Another important job of the flux is the creation of a thin layer of slag over the weld.Along with these alloys, flux has deoxidizers added to prevent the weld puddle from oxidizing. Adds alloys – The flux also adds alloys into the weld metal to improve certain aspects of the finished weld.Some wires need an external shielding gas to give enough gas coverage for this protection. When burned, it produces a shielding gas that protects the weld area from atmospheric contamination. It protects the weld – The most important job of the flux is protecting the weld.The flux at the core of the welding wire serves several purposes. The metal shell of the wire serves three purposes: conducting electricity, providing filler metal, and protecting the flux from moisture or contamination. These dies turn the flux-filled U channel into a tubular wire of the correct diameter.įiller metal makes up the outer shell of the wire, also known as a ‘sheath’, and the hollow center contains tightly-packed flux. Flux pours into the center of this profile before feeding into a series of dies. GMAW Differences ComparedĬarbon steel, stainless steel, or alloy-steel, flux-core wires are in compositions to suit many base metals.Ī thin strip of metal feeds through a machine to make flux-core wire, turning it into a “U” shape. GMAW also uses the filler metal composition to add alloy elements to the weld metal, where the flux in FCAW wire contains these elements. Other wire-feed processes like GMAW don’t use flux but rely on external shielding gas. The major difference is that the hollow center contains flux. The wire used in flux core is the electrode and filler metal, like the wires used in GMAW. The Science Behind Flux-Core Welding: How It Worksįlux-core welding is like other wire-fed welding processes like GMAW and SAW but uniquely uses a special tubular wire filled with flux. The arc melts the base metals and the wire to form a weld puddle.Īs the wire melts, the flux inside burns, providing a shielding gas to protect the weld from the atmosphere.įor gas-shielded wires, an external shielding gas and the flux inside the wire add to the gas shielding. When the wire contacts the base metal, a welding arc forms and remains as long as nothing breaks the welding circuit. While the power supply controls the voltage, the speed of the wire feeder determines the amperage for the welding circuit.Ī wire feeder feeds the flux-core wire through the welding cable to the welding gun.
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