Flux Cored Arc Welding: An Overview

Flux-cored arc welding, or FCAW, is a common welding technique that has existed since the 1950s. Arc welding uses an electric arc to generate heat that melts and ultimately binds metal. Since flux-cored welding is taught in welding training programs, here is a brief overview of this welding method.

What is fluxed cored welding?

Flux-cored arc welding is a semi-automatic or automatic arc welding process. This arc welding technique creates an electronic arc through a continuously fed consumable tubular electrode containing a flux (flow) and a constant voltage welding power supply. It is similar to MIG welding, only that the electrode is shielded from air by the flux core. ¹ There are two types of flux-cored arc welding, with and without shielding gas.

Flux cored welding advantages and disadvantages

The advantages of flux-cored arc welding include:

• Has high efficiency and productivity
• Can be used with many types of metal with different thickness range
• Requires less pre-cleaning than MIG
• Arc is easy to see and use
• No need for gas apparatus
• Can be used outdoors
• Doesn’t require high skill level

However, this welding technique also has some downsides:

• Limited to ferrous metals and nickel-based alloys
• Produces slag that must be removed
• Equipment is more expensive
• Produces more fume than MIG welding ²

Flux cored welding applications and industries

Because of its many advantages, flux-cored arc welding is used in industries that require a high number of welds or involves outdoor welding. It is also used in areas where gas cylinder and gas shielding cannot be readily used, and a useful method for welding material that has some scale, rust, or other contaminants. Flux-cored arc welding is commonly used in the following jobs:

• Ship building
• Construction
• Shop fabrication
• Maintenance

Flux-cored arc welding has been an efficient and reliable welding method for decades. As a professional welder, it is important to know the advantages and disadvantages of each welding method. This knowledge can help determine which techniques to choose for what application.