Flux cored arc welding Principles

The flux-cored welding wire, or electrode, is a hollow tube filled with a mixture of deoxidizers, fluxing agents, metal powders, and ferro-alloys. The closure seam, which appears as a fine line, is the only visible difference between flux-cored wires and solid cold-drawn wire. Flux-cored electrode welding can be done in two ways: carbon dioxide gas can be used with the flux to provide additional shielding, or the flux core alone can provide all the shielding gas and slagging materials. The carbon dioxide gas shield produces a deeply penetrating arc and usually provides better weld than is possible without an external gas shield. Although flux-cored arc welding may be applied semi-automatically, by machine, or automatically, the process is usually applied semi-automatically. In semiautomatic welding, the wire feeder feeds the electrode wire and the power source maintains the arc length. The welder manipulates the welding gun and adjusts the welding parameters.

Flux-cored arc welding is also used in machine welding where, in addition to feeding the wire and maintaining the arc length, the machinery also provides the joint travel. The welding operator continuously monitors the welding and makes adjustments in the welding parameters. Automatic welding is used in high production applications.