FCAW (Flux Cored Arc Welding) Mode of Metal Transfer

Thanks for the info. Yes, GMAW-S is another form of SMAW and FCAW-G is another form of GMAW. In SMAW, mode of metal transfer is not an issue, so FCAW-S also free from metal transfer mode.However, I found one research article in internet and it says FCAW-S mode of metal transfer is predominantly globular repelled mode.

FCAW-G is already in globular mode and already entered in the WPS.however, just for confirmation only I asked this question.

"In order to achieve spray transfer, higher current and large diameter electrode wire is needed. A shielding gas of CO2 (Carbon Dioxide), a mixture of carbon dioxide and argon or an argon - oxygen mixture is needed."

Pardon me, but if your job is writing the WPS, shouldn't you know the answer to this?

Maybe ask your welders?

Mechanical testing also over.My management told me to proceed and no need to bother about welders.

You can achieve "spray" with smaller diameter wires as well by reducing the amperage and increasing the voltage. And also remember, that when FCAW is used, you will likely have to reverse the polarity of the welding machine as compared to using solid wire.

"Metal transfer modes (short circuit, globular and spray) are applicable to SMAW in general,"
WHAT?

Sorry, what are you asking what about??

I am confused as well. How is it that mode of transfer applies to SMAW?

I'm still trying to figure why you would use shielding gas with flux cored welding wire.

Sometimes it's necessary, depending on what (and especially where) you're welding. Apart from that I agree completely.

Fabrication industry is wide.

1. general grill and gate, mild steel ladder and other general house hold equipments.

2. pressure and temperature containing equipments

3. piping networks, pipelines

4. ships, boats and other marine equipments

5. aircraft,space shuttle and other space related equipments

6. medical related equipments

and other equipments missed in the above list. welding process selection is based on the quality requirement of the product. that is why FCAW-G is used in this project.

You can get flux cored wire in both gasless type and with gas type. Depends usually on where the welding is taking place. If in shop, the gas shielded type is usually preferred, but in the field, where getting shielding gas to the machine may be difficult, gasless may be preferred, trust me, when you are making field welds up on the 30th floor, you don't want to have to handle any bottles, or run a pipeline.

All I've ever done is build exhaust systems and weld fencing. I use flux core if I'm doing fence welding and usually gas shielding for pretty welds.

Yup, on the more architectural stuff where appearance is more important than weld strength(welds are usually way overdesigned anyway) making them pretty is the most important.

My back ground is varied from farm implements(again appearance is important) to machine design to structural where welds are really "designed". You want really "pretty" welds SAW is the way to go. Not only pretty, but you can get some very high deposition rates using up to 3/16" diameter welding wire using tandem head machines. Even faster is iron powder welding.

Unfortunately, sub arc is a bit beyond most people's budget- definitely mine!

True yes. I only ever used it in large fab shops, but Lincoln used to make what they called a "squirt" gun, a hand held sub arc. Haven't seen one of those in the last 2 or 3 decades though, but back then I had a satelite shop that used them almost exclusively on structural products.

I used my Lincoln HD 100 for the first time on 3 years last week to weld some hinges.

I've got to bring it to work next week to weld some 304 SS grating together.

That'll be the first MIG welding I've done in, forever.

Now where did I put that tank?????

Yes, FCAW-G is selected to weld carbon steel plate (SA 516 Gr. 70) at shop. SMAW, GTAW, GMAW (Manual and Semi automatic) and SAW also available in our workshop. Sometimes I have to visit site to monitor site welding activity. At site, preferred welding processes are GTAW and SMAW.Our clients are not interested in FCAW-S though it is a good process. Root pass and hot pass welding of pipes at the top of the furnace and at the top of vertical column are carried out by GTAW. We will provide adequate wind shield by polyethylene tarpaulins (Blue and Orange colour).Argon gas cylinder movement from ground to top of furnace or piperacks are not a major problem as we have plenty of mammoth cranes and adequate manpower. SMAW is the preferred method for us to finish structural welds (eg: - pipe supports).