(EW-492) - Flux Cored Arc Welding-Hobart Institute of Welding Technology (Yasser Tawfik)

EW-492
TECHNICAL
GUIDE
Flux Cored Arc Welding
HOBART INSTITUTE OF WELDING TECHNOLOGY, 400 TRADE SQUARE EAST, TROY, OHIO 45373 U.S.A.
Table of Contents
Chapter
Page
1. Introduction to the Process . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Equipment for Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Shielding Gases and Electrodes . . . . . . . . . . . . . . . . . . . . . . 14
5. Welding Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. Cost of Flux Cored Arc Welding . . . . . . . . . . . . . . . . . . . . . . 32
7. Welding Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8. Weld and Joint Design . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9. Welding Procedure Variables . . . . . . . . . . . . . . . . . . . . . . . 59
10. Welding Procedure Schedules . . . . . . . . . . . . . . . . . . . . . . . 69
11. Preweld Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12. Welding Discontinuities and Defects . . . . . . . . . . . . . . . . . . . . 79
13. Postweld Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
14. Welder Training and Qualification . . . . . . . . . . . . . . . . . . . . . 87
15. Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Appendix: Sources for Standards . . . . . . . . . . . . . . . . . . . . .104
2012, 2002, 1994 Hobart Institute of Welding Technology

ISBN 978-1-936058-18-1
This publication includes information available at the time of production. The Hobart Institute of Welding Technology presents
this information as a guideline. Relevant standards may have been updated and should be reviewed together with this book
for accuracy. Federal or other laws and standards may govern different operations and facilities.
Hobart Institute of Welding Technology disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication,
use of or reliance on this book. Hobart Institute of Welding Technology makes no guarantee or warranty as to the accuracy
or completeness of any information published herein.
CHAPTER 1
INTRODUCTION TO THE PROCESS
Flux cored arc welding (FCAW) is an arc welding process in which the heat for welding is produced by an arc between a continuously fed tubular electrode wire and the work. Shielding is
obtained by a flux contained within the tubular
electrode wire or by the flux and an externally
supplied shielding gas. Some trade names for
this process are FabCO, Fabshield, Innershield, and Dual Shield. A diagram of the
process is shown in Illustration 1-1.
Gas
Molten Metal
Flux Cored
Electrode
Solidified
Weld Metal
Molten
Slag
Slag
Nozzle
(not required for
self-shielding wires)
Arc
Base
Metal
Flux cored arc welding is similar to gas metal

arc welding in many ways. The flux cored wires
used for this process give it different characteristics. Flux cored arc welding is widely used for
welding ferrous metals and is particularly good
for applications where high deposition rates are desirable. At high welding currents, the arc is smoother and
more manageable when compared to using large diameter gas metal arc welding electrodes with carbon dioxide.
The arc and weld pool are clearly visible to the welder.
A slag coating is left on the surface of the weld bead,
which must be removed. Since the filler metal transfers
across the arc, some spatter is created and some smoke
is produced.
The gas-shielded metal arc welding process had its beginning in the early 1920s. Experiments conducted at that
time proved that weld metal properties were improved
when the welding arc and welding puddle were protected
from atmospheric gases by an inert gas shield. However,
the development of coated electrodes in the late 1920s
reduced the interest in gas-shielded processes.
The gas tungsten-arc welding (GTAW) process became
available commercially in the early 1940s and was the
forerunner of the modern gas-shielded metal arc welding
processes which includes flux cored and metal cored arc
welding. In the GTAW process, a non-consumable electrode is used and the arc area is shielded by an inert gas.
This development was followed in the late 1940s by the
gas metal arc welding (GMAW) process when a consumable electrode wire replaced the tungsten electrode. The
gas metal arc or MIG (Metal Inert Gas) process was used
for nonferrous metals and employed an inert gas, usually
helium or argon. As gas metal arc welding developed,
engineers learned that mild carbon and low alloy steels
could be welded also. However, the high cost of inert
shielding gas prevented this process from competing
economically with the less costly manual shielded metal
arc welding.
Research work conducted on manual coated electrode
welds dealt with an analysis of the gas produced in
Direction of Travel
Illustration 1-1 Flux Cored Arc Welding
the disintegration of electrode coatings. Results of this

analysis showed that the predominate gas given off by
electrode coatings was carbon dioxide. This discovery
led quickly to the use of carbon dioxide gas for shielding
when welding carbon steel with the gas metal arc welding process. Early experiments with carbon dioxide gas
were not successful. However, continued research and
experimentation with electrode wire composition and
equipment did develop a practical gas metal arc process
for the welding of carbon steels.
CO2 shielded gas metal arc welding became very popular
during the mid-1950s. Its most successful applications
were for fully automatic welding installations in the automotive industry. High metal deposition rates and fast
travel speeds characterized the process. Because of the
extremely fluid weld puddle, the process was limited to
flat position and horizontal fillet welds. Also, the process
was so fast that it was difficult to do semiautomatic welding with manual travel. Weld spatter was a problem.
Flux cored or inside out coated electrode wires were
experimented with in the early 1920s but, as with the
gas-shielded systems, the development of covered electrodes reduced interest in the inadequately developed
flux cored electrode wires.
The joining of the CO2 gas shielding system to the flux
cored consumable wire development provided a process
that overcame many deficiencies. Operating characteristics were improved by the addition of the core materials and weld quality was improved by eliminating atmospheric contamination. The process was introduced
publicly at the American Welding Society Exposition held
at Buffalo, New York, in May 1954. The electrodes and
equipment were refined and introduced in essentially the
present form in 1957. Since the introduction, improvements have been made on the equipment and consumables for the process.
A major development in flux cored arc welding in the

early 1960s was the introduction of flux cored wires, not
requiring external gas shielding. These electrode wires
became popular for many field construction applications
because the need for a gas shielding system was eliminated, which made the equipment more portable.
Continuing work has been done on improving the mechanical properties, especially the impact toughness, of
welds made by flux cored arc welding. The electrodes
available today produce much better results than the
wires originally introduced in the late 1950s and early
1960s. More flux cored wires for welding higher alloy
steels have been developed. During the 1960s metal
cored wires were introduced. An important difference
between a flux cored wire and a metal cored wire is the
absence of heavy slag on the weld.
Other major improvements in flux cored wires include improving the welder appeal. This has been done by reducing the smoke and spatter levels produced and improving
the weld bead appearance characteristics. Development
on these and other aspects of flux cored arc welding is
continuing.
METHODS OF APPLICATION
ADVANTAGES AND LIMITATIONS

Flux cored arc welding has many advantages for a wide
variety of applications. Flux cored arc welding often
competes with shielded metal arc welding, gas metal arc
welding, and submerged arc welding for many applications. Some of the advantages of this process are:
1) It has a high deposition rate and faster travel speeds
are often used
2) Using small diameter electrode wires, welding can be
done in all positions
3) Some flux cored wires do not need an external supply
of shielding gas which simplifies the equipment
4) The electrode wire is fed continuously so there is very
little time spent on changing electrodes
5) A higher percentage of the filler metal is deposited
when compared to shielded metal arc welding
6) Better penetration is obtained than from shielded
metal arc welding
Although flux cored arc welding may be applied semiautomatically, by machine, or automatically, the process
is usually applied semiautomatically. 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. In automatic welding, the welding operator
only starts the operation.
CHAPTER 2
PRINCIPLES OF OPERATION
The flux cored arc welding process uses the heat of an
electric arc between a consumable, tubular electrode and
the part to be welded. Electric current passing through an
ionized gas produces an electric arc. The gas atoms and
molecules are broken up and ionized by losing electrons
and leaving a positive charge. The positive gas ions then
flow from the positive pole to the negative pole and the
electrons flow from the negative pole to the positive pole.
About 95% of the heat is carried by the electrons and the
rest is carried by the positive ions. The heat of the arc
melts the electrode and the surface of the base metal.
The molten weld metal, heated weld zone, and electrode
are shielded by one of two methods. One is by the decomposition of the flux core of the electrode. The second method is by a combination of an externally supplied
shielding gas and the decomposition of the flux core of
the electrode wire. The flux core has essentially the same
purpose as the coating on an electrode for shielded metal
arc welding. The molten electrode filler metal transfers
across the arc and into the molten weld puddle. A slag
forms on top of the weld bead which can be removed
after welding.
The arc is struck by starting the wire feed which causes
the electrode wire to touch the workpiece and initiate the
arc. Arc travel is usually not started until a weld puddle is
formed. The welding gun then moves along the weld joint
manually or mechanically so that the edges of the weld
joint are joined. The weld metal solidifies behind the arc
which completes the welding process. A large amount of
flux is contained in the core of a self-shielding wire as
compared to a gas-shielded wire. This is needed to provide adequate shielding and because of this, a thicker
slag coating is formed. In these wires, deoxidizing and
denitrifying elements are needed in the filler metal and
flux core because some nitrogen is introduced from the
atmosphere. Most self-shielding wires also operate using

longer electrode extensions than gas-shielded wires.
ARC SYSTEMS
The flux cored arc welding process may be operated on
both constant voltage and constant current power sources. Any welding power source can be classified by its
volt-ampere characteristics as either a constant voltage
(also called constant potential) or constant current (also
called variable voltage) type, although there are some machines that can produce both characteristics. Constant
voltage power sources are preferred for a majority of flux
cored arc welding applications.
In the constant voltage arc system, the voltage delivered to the arc is maintained at a relatively constant level
which gives a flat or nearly flat volt-ampere curve, as
shown in Illustration 2-1. This type of power source is
widely used for the processes that require a continuously
fed wire electrode. In this system, the arc length is controlled by setting the voltage level on the power source
and the welding current is controlled by setting the wire
feed speed. As shown in Illustration 2-1, a slight change
in the arc length will produce a large change in the welding current.
Most power sources have a fixed slope that is built in for
a certain type of flux cored arc welding. Some constant
voltage welding machines are equipped with a slope control which is used to change the slope of the volt-ampere
curve. Illustration 2-2 shows different slopes obtained
from one power source. The slope has the effect of limiting the amount of short-circuiting current that the power
supply can deliver. This is the current available from the
power source on the short circuit between the electrode
40
36
35
D.C. VOLTS
D.C. VOLTS
30
25
20
HIGH
30
MEDIUM
25
LOW
20
200
300
400
500
LOAD CURRENT (D.C. AMPERES)
600
Illustration 2-1 Constant Voltage Volt-Ampere Curve
200
300
400
500
Illustration 2-2 Different Slope Obtained

from a Constant Voltage Power Source
600
wire and the work. This is not as important in flux cored

arc welding as it was in gas metal arc welding because
short-circuiting metal transfer is not encountered except
with alloy cored, low flux content wires.
A slope control is not required, but may be desirable,
when welding with small diameter, alloy cored, low flux
content electrodes at low current levels. The short-circuit
current determines the amount of pinch force available
on the electrode. The pinch force causes the molten
electrode droplet to separate from the solid electrode.
The flatter the slope of the volt ampere curve, the higher
the short-circuit and the pinch force. The steeper the
slope, the lower the short-circuit and pinch force. The
pinch force is important with these electrodes because it
affects the way the droplet detaches from the tip of the
electrode wire. When a high short-circuit and pinch force
are caused by a flat slope, excessive spatter is created.
When a very low short-circuit current and pinch force
are caused by a steep slope, the electrode wire tends to
freeze in the weld puddle or pile up on the work piece.
When the proper amount of short-circuit current is used,
very little spatter is created.
The inductance of the power supply also has an effect
on the arc stability. When the load on the power supply
changes, the current takes time to find its new level. The
rate of current change is determined by the inductance of
the power supply. Increasing the inductance will reduce
the rate of current rise. The rate of the welding current
rise increases with the current which is also affected by
the inductance in the circuit. Increased arc time or inductance produces a flatter and smoother weld bead as well
as a more fluid weld puddle. Too much inductance will
cause more difficult arc starting.
The constant current arc system provides a nearly constant welding current to the arc which gives a drooping
volt-ampere characteristic, as shown in Illustration 2-3.
This arc system is used with the shielded metal arc welding and gas tungsten arc welding processes. The welding
current is set by a dial on the machine and the welding
voltage is controlled by the arc length held by the welder.
This system is necessary for manual welding because
the welder cannot hold a constant arc length which
causes only small variations in the welding current.
When flux cored arc welding is done with a constant
current system, a special voltage sensing wire feeder is
used to maintain a constant arc length.
For any power source, the voltage drop across the welding arc is directly dependent on the arc length. An increase in the arc length results in a corresponding increase in the arc voltage and a decrease in the arc length
results in a corresponding decrease in the arc voltage.
Another important relationship exists between the welding current and the melt off rate of the electrode. With
low current, the electrode melts off slower and the metal
is deposited slower. This relationship between welding
current and wire feed speed is definite, based on the
wire size, shielding gas type and type of electrode. A
faster wire feed speed will give a higher welding current.
In the constant voltage system, instead of regulating the
wire to maintain a constant arc length, the wire is fed
into the arc at a fixed speed and the power source is designed to melt off the wire at the same speed. The selfregulating characteristic of a constant voltage power
source comes about by the ability of this type of power
source to adjust its welding current in order to maintain
a fixed voltage across the arc.
36
Open circuit voltage
VOLTS
VOLTS
D.C.VOLTS
VOLTS
30
25Arc
length:
Constant
voltage
power
source
Long
20Normal
Short
0
WELD
WELD CURRENT
CURRENT(AMPERES)
(AMPERES)
Constant
current
power
source
200
300
400
500
WELD CURRENT (AMPERES)

Illustration 2-4 Volt-Ampere Curves
Illustration 2-3 Constant Current

Volt-Ampere Curve
600
With the constant current arc system, the welder would

change the wire feed speed as the gun is moved toward
or away from the weld puddle. Since the welding current remains the same, the burn-off rate of the wire is
unable to compensate for the variations in the wire feed
speed, which allows stubbing or burning back of the wire
into the contact tip to occur. To lessen this problem, a
special voltage sensing wire feeder is used, which regulates the wire feed speed to maintain a constant voltage
across the arc. The constant voltage system is preferred
for most applications, particularly for small diameter wire.
With smaller diameter electrodes, the voltage sensing
system is often not able to react fast enough to feed at
the required burn-off rate, resulting in a higher instance of
burn-back into the contact tip of the gun.
Illustration 2-4 shows a comparison of the volt ampere
curves for the two arc systems. This shows that for these
particular curves, when a normal arc length is used, the
current and voltage level is the same for both the constant current and constant voltage systems. For a long
arc length, there is a slight drop in the welding current for
the constant current machine and large drop in the current for a constant voltage machine. For constant voltage power sources, the volt-ampere curve shows that
when the arc length shortens slightly, a large increase in
welding current occurs. This results in an increased burnoff rate, which brings the arc length back to the desired
level. Under this system, changes in the wire feed speed,
caused by the welder, are compensated for electrically
by the power source.
METAL TRANSFER
Metal transfer, from consumable electrodes across
an arc, has been classified into three general modes
of transfer. These are spray transfer, globular transfer,

and short-circuiting transfer. The metal transfer of most
flux cored electrodes resembles a fine globular transfer,
sometimes referred to as small droplet transfer. Some
flux cored electrodes have a spray transfer. Only the alloy cored, low flux content wires can produce a shortcircuiting metal transfer similar to gas metal arc welding.
On flux cored electrodes, the molten droplets build up
around the periphery or outer metal sheath of the electrode. By contrast, the droplets on solid wires tend to
form across the entire cross section at the end of the
wire. A droplet forms on the cored wire, is transferred,
and then a droplet is formed at another location on the
metal sheath. The core material appears to transfer independently to the surface of the weld puddle. Illustration
2-5 shows the metal transfer in flux cored arc welding.
At low currents, the droplets tend to be larger than at
higher current levels. If the welding current using a 3/32
in. (2.4 mm) electrode wire is increased from 350 to 550
amps, the metal transfer characteristics will change.
Transfer is much more frequent and the droplets become
smaller as the current is increased. At 550 amperes some
of the metal may transfer by the spray mode, although
the globular mode prevails. There is no indication that
higher currents cause a transition to a spray mode of
transfer, unless an argon-oxygen shielding gas mixture
is used.
The larger droplets at the lower currents cause a certain
amount of splashing action when they enter the weld
puddle. This action decreases with the smaller droplet
size. This explains why there is less visible spatter, the arc
appears smoother to the operator, and the deposition efficiency is higher, when a wire is used with a high current
density rather than at the low end of its current range.
Illustration 2-5 Metal Transfer in Flux Cored Arc Welding
CHAPTER 3
EQUIPMENT FOR WELDING
The equipment used for flux cored arc welding is very
similar to that used for gas metal arc welding. The basic
arc welding equipment consists of a power source, controls, wire feeder, welding gun and welding cables. A major difference between the gas-shielded electrodes and
self-shielded electrodes is that the gas-shielded wires
also require a gas shielding system. This may also have
an effect on the type of welding gun used. Fume extractors are often used with this process. For machine and
automatic welding, several items, such as seam followers
and motion devices, are added to the basic equipment.
Illustration 3-1 shows a diagram of the equipment used
for semiautomatic flux cored arc welding.
POWER SOURCES
The power source or welding machine provides the electric power of the proper voltage and amperage to maintain a welding arc. Most power sources operate on 230 or
460 volt input power, but machines that operate on 200
or 575 volt input are available as options. Power sources
may operate on either single phase or three-phase input
with a frequency of 50 to 60 Hz.
Power Source Duty Cycle
The duty cycle of a power source is defined as the ratio
of arc time to total time. Most power sources used for
flux cored arc welding have a duty cycle of 100%, which
indicates that they can be used to weld continuously.
Some machines used for this process have duty cycles
of 60%, which means that they can be used to weld six
of every ten minutes.
With Gas
Types of Current
Flux cored arc welding uses direct current. Direct current can be connected in one of two ways, which are
electrode positive (reverse polarity) or electrode negative
(straight polarity). The electrically charged particles flow
between the tip of the electrode and the work as shown in
Illustration 3-2. Flux cored electrode wires are designed
to operate on either DCEP or DCEN. The wires designed
for use with an external gas shielding system are generally designed for use with DCEP. Some self-shielding flux
cored wires are used with DCEP while others are developed for use with DCEN. Electrode positive current gives
better penetration into the weld joint. Electrode negative
current gives lighter penetration and is used for welding
thinner metal or where there is poor fit-up. The weld created by DCEN is wider and shallower than the weld produced by DCEP.
Types of Power Sources
The power sources generally recommended for flux cored
arc welding are direct current constant voltage types.
Both rotating (generator) and static (single or three-phase
transformer-rectifiers) are employed. Any of these types
of machines are available to produce constant current or
Shielding
Gas Source
(Optional)
Control System
Wire Feed Control
Without Gas
In general, these lower duty cycle machines are the

constant current type, which are used in plants where
the same machines are also used for shielded metal
arc welding and gas tungsten arc welding. Some of the
smaller constant voltage welding machines have a 60%
duty cycle.
Gas
Out
Gun
Control
Feeder Contactor Control
Wire
Feed
Drive
Motor
Electrode
Voltage
Control
Electrode Lead
Workpiece Lead
Base Metal
Illustration 3-1 Equipment for Flux Cored Arc Welding
Power
Source
constant voltage output, or both. The same power sources used with gas metal arc welding are employed with
flux cored arc welding. Flux cored arc welding generally
uses higher welding currents than gas metal arc welding, which sometimes requires a larger power source.
It is important to use a power source that is capable of
producing the maximum current level required for an application.
Generator Welding Machines
The generator welding machines used for this process
can be powered by an electric motor, for shop use, or
an internal combustion engine, for field applications. The
gasoline or diesel engine driven welding machines have
either liquid or air-cooled engines and many of them provide auxiliary power for emergency lighting, power tools,
etc. Many of the engine driven generators used for flux
cored arc welding in the field are combination constant
current-constant voltage types. These are popular for applications where both shielded metal arc welding and flux
cored arc welding can be accomplished using the same
power source. Illustration 3-3 shows an engine driven
generator machine used for flux cored arc welding. The
motor driven generator welding machines are gradually being replaced by transformer-rectifier welding machines. Motor-driven generators produce a very stable
arc, but they are noisier, more expensive, consume more
power and require more maintenance than transformerrectifier machines.
Transformer-Rectifier Welding Machines
The most widely used welding machines for flux cored
arc welding are the transformer-rectifiers. A method of
supplying direct current to the arc, other than the use
of a rotating generator, is by adding a rectifier to a basic
+ +
+
-
- +
+
+
-
DCEP
DCEN
Illustration 3-2 Particle Flow for DCEP and DCEN
Illustration 3-3 Gas Powered Welder/Generator

Photo courtesy of Miller Electric Manufacturing Co.
transformer circuit. A rectifier is an electrical device which

changes alternating current into direct current. These
machines are more efficient electrically than motor-generator welding machines and they provide quieter operation. There are two basic types of transformer-rectifier
welding machines; those that operate on single phase
input power and those that operate on three-phase input
power.
The single phase transformer-rectifier machines provide
DC current to the arc and a constant current volt-ampere characteristic. These machines are not as popular
as three-phase transformer-rectifier welding machines
for flux cored arc welding. When using a constant current power source, a special variable speed or voltage
sensing wire feeder must be used to maintain a uniform
current level. A limitation of the single phase system is
that the power required by the single phase input power
may create an unbalance of the power supply lines which
is objectionable to most power companies. These machines normally have a duty cycle of 60%.
The most widely used type of power source for this process is the three-phase transformer-rectifier. These machines produce DC current for the arc and, for flux cored
arc welding, most have a constant voltage volt ampere
characteristic. When using these constant voltage machines, a constant speed wire feeder is employed. This
type of wire feeder maintains a constant wire feed speed
with slight changes in welding current. The three-phase
input power gives these machines a more stable arc
than single phase input power and avoids the line unbalance that occurs with the single phase machines. Many
of these machines also use solid state controls for the
welding. A 650 amp solid state controlled power source

is shown in Illustration 3-4. This machine will produce
the flattest volt-ampere curve of the different constant
voltage power sources. Most three-phase transformerrectifier power sources are rated at a 100% duty cycle.
CONTROLS
The controls for this process are located on the front of
the welding machine, on the welding gun, and on the wire
feeder or a control box.
The welding machine controls for a constant voltage machine include an on-off switch, a voltage control, and often a switch to select the polarity of direct current. The
voltage control can be a single knob, or it can have a tap
switch for setting the voltage range and a fine voltage
control knob.
Other controls are sometimes present, such as a switch
for selecting CC or CV output on combination machines,
or a switch for a remote control. On the constant current welding machines there is an on-off switch, a current
level control knob, and sometimes a knob or switch for
selecting the polarity of direct current.
The trigger or switch on the welding gun is a remote control that is used by the welder in semiautomatic welding to stop and start the welding current, wire feed, and
shielding gas flow.
For semiautomatic welding, a wire feed speed control is
normally part of, or close by, the wire feeder assembly.
The wire feed speed sets the welding current level on
a constant voltage machine. For machine or automatic
Illustration 3-4 Three phase Power Source

with Multi-Process Capability
welding, a separate control box is often used to control

the wire feed speed. On the wire feeder control box, there
may also be switches to turn the control on and off and
gradually feed the wire up and down.
Other controls for this process are used for special applications, especially when a programmable power source
is used. An example is a timer for spot welding. Controls
that produce a digital read-out are popular because more
concise control is easier.
4-Roll Gear Box

Photo courtesy of Miller
Electric Manufacturing Co.
2-Roll Gear Box
Illustration 3-7 Wire Feeder Assembly
Illustration 3-5
Constant Speed
Wire Feeder
WIRE FEEDERS
The wire feed motor provides the power for driving the
electrode through the cable and gun and to the work.
There are several different wire feeding systems available.
The selection of the best type of system depends on the
application. Most of the wire feed systems used for flux
cored arc welding are the constant speed type, which are
used with constant voltage power sources. This means
that the wire feed speed is set before welding. (See Illustration 3.5.) The wire feed speed controls the amount of
welding current. Variable speed or voltage sensing wire
feeders are used with constant current power sources.
With a variable speed wire feeder, a voltage sensing circuit is used to maintain the desired arc length by varying
the wire feed speed. Variations in the arc length increase
or decrease the wire feed speed. (See Illustration 3.6.)
A wire feeder consists of an electrical motor connected
to a gear box containing drive rolls. The gear box and
wire feed motor shown in Illustration 3-7 has four feed
rolls in the gear box. Many systems have only two. In a
four roll system, the lower two rolls drive the wire. Because of their structure, flux cored wires can be easily
flattened. The type of drive roll used is based on the size
of the tubular wire being fed. The three basic types of
drive rolls are the U-groove, V-knurled and the U-cogged
(gear type), as shown in Illustration 3-8. U-groove drive
rolls are only used on small diameter wires. These can be
used because small diameter tubular wires are less easily
Illustration 3-6 Variable Speed

(Voltage Sensing) Wire Feeder
flattened. V-knurled drive rolls are most commonly used

for wire sizes 1/16 in. (1.6 mm) and greater. These drive
rolls are lightly knurled to prevent slipping of the wire. The
U-cogged (geared) drive rolls are used for large diameter
flux cored wires. A groove is cut into both rolls. Different
gear ratios are used, depending on the wire feed speed
required. Illustration 3-9 shows the wire feed speeds that
can be obtained from different gear ratios.
Wire feed systems may be of the pull, push, or pushpull, type depending on the method of application and
the distance between the welding gun and the coil or
U groove
for soft wires
or soft-shelled
cored wires
V knurled
for hard-shelled
cored wires
U cogged
for extremely
soft wires
or soft-shelled
cored wires
Illustration 3-8
Common Types of Drive Rolls and their Uses
Gear
Ratio
15:1
Wire Feed Speed

in/min
(mm/s)
500-2000
212-846
37.5:1
60-1000
25-423
46:1
50-825
21-349
75:1
30-500
13-212
90:1
25-400
11-169
150:1
15-250
6-106
300:1
8-125
3-53
600:1
4-63
2-27
1200:1
2-30
1-13
Illustration 3-9 Wire Feed Speeds obtained

from Different Gear Ratios
spool of wire. Pull type wire feeders have the drive rolls
attached to the welding gun. Most machine and automatic welding stations use this type of system. Pull type
wire feeders are rarely used in semiautomatic welding.
Pull wire feeders have the advantage for welding small
diameter aluminum and soft nonferrous metals with gas
metal arc welding because it reduces wire feeding problems. Since most flux cored wires are steel, this is not
an advantage for flux cored arc welding. The push type
system, which has the drive rolls mounted near the coil
or spool of wire is the most commonly used in semiautomatic welding. The wire is pulled from the coil or spool
and then pushed into a flexible conduit and through the
gun. The relatively large diameter wires used in flux cored
arc welding are well suited to this type of system. The
length of the conduit can be up to about 12 feet (3.7 m).
Another advantage of this push type system is that the
wire feed mechanism is not attached to the gun, which
reduces the weight and makes the gun easier to handle.
Some wire feed systems contain a two-gun, two-wire
feeder arrangement connected to a single control box,
which is connected to a single power source. Both wire
feeders may be set up and there is a switch on the control to automatically select which of the two systems will
be used. One advantage to this system is that the second wire feeder and gun can provide backup in case of
breakdown, gun maintenance or electrode change. Another advantage is that two different electrodes for different applications can be set up. For example, a gas
metal arc welding electrode and gun can be set up on
one schedule for welding a root pass. The second schedule can be set up with flux cored wire to weld the rest of
Illustration 3-10 600 Ampere Air-Cooled Gun

for Flux Cored Arc Welding
Illustration 3-11 Gun for Self-Shielded

10
the joint. This eliminates the need for two power sources
or the need to change the electrode wire and gun. The
liner is made of flexible metal and is available in sizes
compatible with the electrode size. The liner guides the
electrode wire from the wire feeder drive rolls through the
cable assembly and prevents interruptions in the travel.
Heavy duty welding guns are normally used because of
the large size electrode wires used and the high welding
current levels required. Because of the intense heat created by this process, heat shields are usually attached to
the gun in front of the trigger to protect the welders hand.
Both air-cooled and water-cooled guns are used for flux
cored arc welding. Air-cooled guns are cooled primarily
by the surrounding air, but when a shielding gas is used,
this will have an additional cooling effect. Air-cooled guns
are lighter and easier to manipulate. Illustration 3-10
shows a 600 ampere air-cooled welding gun.
Some self-shielded flux cored wires require a specific
minimum electrode extension to develop proper shielding. These welding guns have guide tubes with an insulated extension tube. This guide supports the electrode
and insures minimum electrode extension as shown in
Illustration 3-12. A gun for self-shielded flux cored wire
welding is shown in Illustration 3-11.
and duty cycles required. The welding gun is mounted

directly below the wire feeder. Illustration 3-13 shows
a machine welding head with concentric nozzle for flux
cored arc welding. Gas can also be supplied to the arc by
a side delivery tube. If a gas-shielded wire is to be used,
the gas can be supplied by a nozzle that is concentric
around the electrode or by a side delivery tube. The side
shielding permits the welding gun to be used in deep,
narrow grooves and reduces spatter buildup problems
in the nozzle. Side shielding is only recommended for
welding using carbon dioxide. When using argon-carbon
dioxide and argon-oxygen mixtures, a concentric nozzle
is preferred. Concentric nozzles provide better shielding
and are sometimes recommended for CO2 at high current
levels when a large weld puddle exists.
FUME EXTRACTORS
Fume extractors are often used to help to reduce the
smoke levels produced by flux cored electrodes. This
Machine Welding Guns

Machine and automatic welding guns use the same basic design principles and features as the semiautomatic
welding guns. These guns often have very high current
carrying capacities and may also be air-cooled or watercooled. Large diameter wires up to 1/8 in. (3.2 mm) are
commonly used with high amperages. Machine welding
guns must be heavy duty because of the high amperages
FCAW gun with

side delivery
gas nozzle
FCAW gun
with concentric
gas nozzle
Electrode
Guide Tube
Insulated Nozzle
Contact Tube
Flux Cored
Electrode
FCAW Gun
for robotic
applications
Electrode
Extension
Visible Extension
Work
Illustration 3-12 An Insulated Extension Guide

to Ensure a Minimum Electrode Extension
for Self-Shielded Electrodes
Illustration 3-13 Automatic Welding Guns

Photos courtesy of Tregaskiss
11
The purpose of a gas flow regulator is to reduce the pressure from the gas supply source and maintain a constant
delivery pressure. The gas flowmeter is then used to control the flow of gas from the regulator to the welding gun.
The gas flow rate is adjusted by a valve at the flowmeter
outlet. The flowmeter is often attached to the regulator
as shown in Illustration 3-15. Regulators and flowmeters
are designated for use with specific shielding gases and
should only be used with the gas that they were designed
for.
The hoses are normally connected to solenoid valves on
the wire feeder to turn the gas flow on and off with the
welding current. A hose is used to connect the flowmeter
to the welding gun. The hose is usually part of the welding gun assembly.
Illustration 3-14 Fume Extractor Nozzle
reduces air pollution and gives better visibility. Welding

guns can be equipped with a fume extractor which consists of an exhaust nozzle that encircles the gun nozzle,
as shown in Illustration 3-14. The nozzle is connected to
a filter and an exhaust pump. The fume extraction nozzle
should be located at a distance far enough from the arc
to draw in the rising fumes without disturbing the shielding gas flow.
The major advantage of this fume extraction system is
that it is always close to the point of welding. A portable
fume exhaust fan cannot be positioned as close to the
arc and requires repositioning for every change in welding position.
The major disadvantage of the fume extractor is that it
makes the gun bulkier and more difficult to manipulate.
Fume extractors are generally not necessary in a welding
booth that is well ventilated.
Illustration 3-15 Flowmeter and Regulator

for Argon/CO2
Photo courtesy of Smith Equipment
SHIELDING GAS EQUIPMENT
WELDING CABLES
The shielding gas equipment used for gas-shielded flux

cored wires consists of a gas supply hose, a gas regulator, control valves, and supply hose to the welding gun.
The welding cables and connectors are used to connect

the power source to the welding gun and to the work.
These cables are normally made of copper or aluminum
with copper being the most common. The cable consists
of hundreds of wires that are enclosed in an insulated
casing of natural or synthetic rubber. The cable that connects the power source to the welding gun is called the
electrode lead. In semiautomatic welding, this cable is
often part of the cable assembly, which also includes the
shielding gas hose and the conduit that the electrode
wire is fed through. For machine or automatic welding,
the electrode lead is normally separate. The cable that
connects the work to the power source is called the work
lead. The work leads are usually connected to the work
by pincher clamps or a bolt.
The shielding gases are supplied in liquid form when they

are in storage tanks with vaporizers or in a gas form in
high pressure cylinders. An exception to this is carbon
dioxide. When put in high pressure cylinders, it exists in
both the liquid and gas forms. The bulk storage tank system is used when there are large numbers of welding stations using the same type of shielding gas in large quantities. For applications where there are large numbers of
welding stations but relatively low gas usage, a manifold
system is often used. This consists of several high pressure cylinders connected to a manifold, which then feeds
a single line to the welding stations. Individual high pressure cylinders are used when the amount of gas usage is
low, when there are few welding stations, or when portability is required.
The size of the welding cables used depends on the output capacity of the welding machine, the duty cycle of
the machine, and the distance between the welding ma-
12
Weld
Type
Manual
(Low
Duty
Cycle)
Weld
Current
Length of Cable in Feet Cable Size A.W.G.
100
60'
4
100'
4
150'
4
200'
2
300'
1
400'
1/0
150
2/0
3/0
200
1/0
3/0
4/0
250
1/0
2/0
300
2/0
3/0
350
1/0
1/0
3/0
4/0
400
1/0
1/0
3/0
450
2/0
2/0
4/0
500
2/0
2/0
4/0
Note: Length of cable circuit equals total electrode and work cable
Illustration 3-16 Suggested Copper Welding Cable Sized for Flux Cored Arc Welding
chine and the work. Cable sizes range from the smallest
at AWG No. 8 to AWG No. 4/0 with amperage ratings of
75 amperes on up. Illustration 3-16 shows recommended
cable sizes for use with different welding currents and
cable lengths. A cable that is too small may become too
hot during welding
Motion Devices
OTHER EQUIPMENT
Motor driven carriages that run on tracks or directly on the

workpiece are commonly used. Carriages can be used
for straight line, contour, vertical, or horizontal welding.
Side beam carriages are supported on the vertical face
of a flat track and they can be used for straight line welding. Multiple electrode welding heads can be used to obtain higher deposition rates. Welding head manipulators
may be used for longitudinal welds and, in conjunction
with a rotary weld positioner, for circumferential welds.
These welding head manipulators come in many boom
sizes and can also be used for semiautomatic welding
with mounted welding heads.
Water Circulators
When a water-cooled gun is used, a water supply must
be included in the system. This can be supplied by a
water circulator or directly from a hose connection to
a water tap. The water is carried to the welding torch
through hoses that may or may not go through a valve in
the welding machine. A typical water circulator is shown
in Illustration 3-17.
Motion devices are used for machine and automatic

welding. These motion devices can be used to move the
welding head, workpiece, or gun, depending on the type
and size of work and the preference of the user.
Oscillators are optional equipment that are used to oscillate the gun for surfacing, vertical-up welding, and other
welding operations that require a wide bead. Oscillators
can either be mechanical or electromagnetic devices.
Accessories
Accessory equipment for flux cored arc welding consists
of items for cleaning the weld bead and cutting the electrode wire. Because of the slag coating that is formed,
chipping hammers and wire brushes are usually required
to remove the slag. A grinder is often used for final cleaning and for removing spatter. Wire cutters or pliers are
used to cut the end of the electrode wire between stops
and starts.
Illustration 3-17 Water Circulator
Photo courtesy of Smith Equipment
13
CHAPTER 4
SHIELDING GASES AND ELECTRODES
The electrodes used for flux cored arc welding provide
the filler metal to the weld puddle and shielding for the
arc. A shielding gas is required for some electrode types.
The purpose of the shielding gas is to provide protection,
from the atmosphere, to the arc and molten weld puddle.
The chemical composition of the electrode wire and flux
core in combination with the shielding gas will determine
the weld metal composition and mechanical properties of
the weld.
SHIELDING GASES
The primary purpose of shielding gas, in any gas-shielded
arc welding process, is to protect the arc and weld puddle
from contaminating effects of the atmosphere. The nitrogen and oxygen of the atmosphere, if allowed to come in
contact with the molten weld metal, cause porosity and
brittleness.
In shielded metal arc welding, protection is accomplished
by placing an outer coating on the electrode which produces a gaseous shield as the coating disintegrates in the
welding arc. In flux cored arc welding, the same effect is
accomplished by decomposition of the electrode core or
by a combination of this and surrounding the arc area with
a shielding gas supplied from an external source.
A shielding gas displaces air in the arc area. Welding is
then accomplished under a blanket of shielding gas. Since
the molten weld metal is exposed only to the shielding
gas, it is not contaminated by the atmosphere.
Oxygen, which makes up 21% of air, is a highly reactive
element which, at high temperatures, combines readily
with other elements in the steel to form undesirable oxides and gases. Oxygen combines with iron to form compounds which can lead to inclusions in the weld metal
and also lower its mechanical properties. On coating, free
oxygen in the molten metal combines with the carbon of
the steel to form carbon monoxide. If gas is trapped in the
weld metal as it cools, it collects in pockets and causes
pores in the weld deposit.
Nitrogen, which makes up 78% of air, causes the most
serious problems when welding steel. When steel is molten, it can take a relatively large amount of nitrogen into
solution. At room temperature, the solubility of nitrogen in
steel is very low. Therefore, in cooling, nitrogen precipitates or comes out of the steel as nitrites. These nitrites
cause high yield strength, tensile strength, hardness, and
a pronounced decrease in the ductility and impact resistance of the steel. The loss of ductility due to the presence
of iron nitrites often leads to cracking of the weld metal.
Excessive amounts of nitrogen can also lead to extensive
porosity in the weld deposit.
Hydrogen may come from water in the atmosphere or

from moisture on surfaces welded and is also harmful to
welds. Hydrogen is also present in oils, paints, and some
protective coverings. Even very small amounts of hydrogen in the atmosphere produce an erratic arc. Of more
importance is the effect that hydrogen has on the properties of the weld deposit. As in the case of nitrogen, steel
can hold a relatively large amount of hydrogen when it is
molten but, upon cooling, it has a low solubility for hydrogen. As the metal starts to solidify, it rejects the hydrogen.
The hydrogen entrapped in the solidifying metal collects
at small discontinuities and causes pressure stresses to
occur. This pressure can lead to minute cracks in the weld
metal, which can later develop into larger cracks. Hydrogen also causes defects known as fish eyes and underbead cracks. Underbead cracking is caused by excessive
hydrogen that collects in the heat affected zone.
Inert and active gases may be used for flux cored arc
welding. Active gases such as carbon dioxide, argonoxygen mixtures and argon-carbon dioxide mixtures are
used for almost all applications, with carbon dioxide being the most common. Active gases are not chemically
inert and can form compounds with the metals. Since almost all flux cored arc welding is done on ferrous metals,
this is not a problem. The choice of the proper shielding
gas for a specific application is based on:
1) Type of metal to be welded
2) Arc characteristics and metal
transfer
3) Availability
4) Cost of the gas
5) Mechanical property requirements
6) Penetration and weld bead shape
GAS
Carbon Dioxide
Carbon dioxide is manufactured
from fuel gases which are given off
by the burning of natural gas, fuel
oil, or coke. It is also obtained as a
by-product of calcining operations in
lime kilns, from the manufacturing of
ammonia, and from the fermentation
of alcohol. The carbon dioxide given
off by the manufacturing of ammonia
and the fermentation of alcohol is almost 100% pure. Carbon dioxide is
made available to the user in either
cylinder or bulk containers, with the
cylinder being more common. With
the bulk system, carbon dioxide
is usually drawn off as a liquid and
14
LIQUID
Illustration 4-1
Carbon Dioxide
Gas Cylinder
welding steel. These are deep penetration and low cost.

Carbon dioxide promotes a globular transfer.
Illustration 4-2 Manifold System for Carbon Dioxide

Photo courtesy of Rexarc International, Inc.
heated to the gas state before going to the welding torch.

The bulk system is normally only used when supplying
a large number of welding stations. In the cylinder, the
carbon dioxide is in both a liquid and a vapor form, with
the liquid carbon dioxide occupying approximately two
thirds of the space in the cylinder as shown in illustration
4-1. By weight, this is approximately 90% of the content of the cylinder. Above the liquid, it exists as a vapor
gas. As carbon dioxide is drawn from the cylinder, it is
replaced with carbon dioxide that vaporizes from the liquid in the cylinder and therefore the overall pressure will
be indicated by the pressure gage. When the pressure
in the cylinder has dropped to 200 psi (1.4 MPa) the cylinder should be replaced with a new cylinder. A positive
pressure should always be left in the cylinder in order to
prevent moisture and other contaminants from backing
up into the cylinder. The normal discharge rate of the CO2
cylinder is about 10 to 50 cubic feet per hour (4.7 to 24
liters per minute). However, a maximum discharge rate of
25 cfh (12 L/min.) is recommended when welding using
a single cylinder. As the vapor pressure drops from the
cylinder pressure to discharge pressure through the CO2
regulator, it absorbs a great deal of heat. If flow rates are
set too high, this absorption of heat can lead to freezing of the regulator and flowmeter which interrupts the
shielding gas flow. When flow rates higher than 25 cfh (12
L/min.) are required, normal practice is to manifold two
CO2 cylinders in parallel or to place a heater between the
cylinder and gas regulator, pressure regulator and flow
meter. Illustration 4-2 shows a manifold system used for
connecting several cylinders together. Excessive flow
rates can also result in drawing liquid from the cylinder.
Argon only is not used for FCAW, only the mixtures with
CO2. Most active gases cannot be used for shielding, but
carbon dioxide provides several advantages for use in
The carbon dioxide shielding gas breaks down into components such as carbon monoxide and oxygen. Because
carbon dioxide is an oxidizing gas, deoxidizing elements
are added to the core of the electrode wire to remove
oxygen. The oxides formed by the deoxidizing elements
float to the surface of the weld and become part of the
slag covering. Some of the carbon dioxide gas will break
down to carbon and oxygen. If the carbon content of the
weld pool is below about .05%, carbon dioxide shielding will tend to increase the carbon content of the weld
metal. Carbon, which can reduce the corrosion resistance of some stainless steels, is a problem for critical
corrosion applications. Extra carbon can also reduce the
toughness and ductility of some low alloy steels. If the
carbon content in the weld metal is greater than about
10%, carbon dioxide shielding will tend to reduce the
carbon content. This loss of carbon can be attributed to
the formation of carbon monoxide, which can be trapped
in the weld as porosity deoxidizing elements in the flux
core, reducing the effects of carbon monoxide formation.
Argon-Carbon Dioxide Mixtures
Argon and carbon dioxide are often mixed for use with
flux cored arc welding. A high percentage of argon gas in
the mixture tends to promote higher deposition efficiency
due to the creation of less spatter. This mixture also creates less oxidation and lower fumes. The most commonly
used argon-carbon dioxide mixture contains 75% argon
and 25% carbon dioxide. This gas mixture produces a
fine globular metal transfer that approaches a spray. It
also reduces the amount of oxidation that occurs, compared to pure carbon dioxide. The weld deposited in an
argon-carbon dioxide shield generally has higher tensile
and yield strengths. Argon-carbon dioxide mixtures are
often used for out-of-position welding, achieving better
arc characteristics and welder appeal. This mixture also
improves arc transfer on smaller diameters. Argon/CO2 is
often used on low alloy steels and stainless steels.
Electrodes that are designed for use with CO2 may cause
an excessive build-up of manganese, silicon, and other
deoxidizing elements if they are used with shielding gas
mixtures containing a high percentage of argon. This will
have an effect on the mechanical properties of the weld.
Argon-Oxygen Mixtures
Argon-oxygen mixtures containing 1 or 2% oxygen are
used for some applications. Argon-oxygen mixtures tend
to promote a spray transfer which reduces the amount of
spatter produced. A major application of these mixtures
is the welding of stainless steels where carbon dioxide
can cause corrosion problems.
15
ELECTRODES
Sheath
Core
Alloying Materials
Flux
Slag Formers
Illustration 4.3 Cross-Section of a Flux Cored Wire
The electrodes for flux cored arc welding consist of a

metal sheath surrounding a core of fluxing and/or alloying compounds as shown in Illustration 4-3. The core of
carbon steel and low alloy electrodes contain primarily
fluxing compounds. Some of the low alloy steel electrode
cores contain high amounts of alloying compounds with
a low flux content. Most low alloy steel electrodes require gas shielding. The sheath comprises approximately
75 to 90% of the weight of the electrode. Self-shielded
electrodes contain more fluxing compounds than gasshielded electrodes. The compounds contained in the
electrode perform essentially the same functions as the
coating of a covered electrode used in shielded metal arc
welding. These functions are:
1) To form a slag coating that floats on the surface of
the weld metal and protects it during solidification.
2) To provide deoxidizer and scavengers which help
purify and produce solid weld metal.
3) To provide arc stabilizers which produce a smooth
welding arc and keep spatter to a minimum.
4) To add alloying elements to the weld metal which will
increase the strength and improve other properties in
the weld metal.
5) To provide shielding gas. Gas-shielded wires require
an external supply of shielding gas to supplement
that produced by the core of the electrode.
signed machinery. Illustration 4-4 shows one simplified

version of the apparatus for producing tubular type cored
electrodes on continuous production. A thin, narrow,
flat, low-carbon steel strip passes through forming rolls
which form the strip into a U-shaped cross-section. This
U-shaped steel passes through a special filling device
where a measured amount of the specially formulated
granular core material is added. The flux-filled U-shaped
strip then flows through special closing rolls which form
it into a tube and tightly compress the core materials.
This tube is then pulled through draw dies to reduce its
diameter and further compress the core materials. Drawing tightly seals the sheath and additionally secures the
core materials inside the tube under compression thus
avoiding discontinuities in the flux. The electrode may or
may not be baked during, or between, drawing operations. This depends on the type of electrode and the type
of elements and compounds enclosed in the sheath.
Additional drawing operations are performed on the wire
to produce various electrode diameters. Flux cored electrode wires are commonly available in sizes ranging from
.035-5/32 inch.
The finished electrode is wound into a continuous coil,
spool, reel or drum. These are available as 10 Ib., 15 Ib.,
or 50 Ib. spools, 60 Ib. (27 kg) coils, 250 or 500 Ib. (113225 kg) reels, or a 600 Ib. drum. Electrode wires are generally wrapped in plastic to prevent moisture pick-up.
Classification
The classification system used for tubular wire electrodes
throughout industry in the United States was devised by
the American Welding Society (AWS). There are several
different specifications covering flux cored arc welding
electrodes for steels which are shown in illustration 4-5.
The manufacture of a flux cored electrode is an extremely

technical and precise operation requiring specially de-
Illustration 4.4 Manufacturing

of Flux Cored Wire
16
The AWS specification for carbon steel and low-alloy

steel electrodes uses two classification systems.
AWS
Specification Specification Title / Metal
The fixed classification system includes electrodes that

have gained wide acceptance over the years, and they
are classified by their specific mechanical properties. Illustration 4-6 shows the electrodes that are included in
the fixed classification system.
Source
Specification for
Electrode
Classification
& Requirements
Stainless Steel Flux Cored and

Metal Cored Welding Electrode and Rods
A5.36
Carbon and Low Alloy Steel Flux Cored Electrodes for

Flux Cored Arc Welding and Metal Cored Electrodes for
Gas Metal Arc Welding
Illustration 4-5 AWS Filler Electrodes

Specifications for Flux Cored Arc Welding
Weld Deposit Requirements

Classification
Designationb,c
Shielding
Gasd
E7XT-1Cg
C1
E7XT-1Mg
M21
E7XT-5C
C1
E7XT-5M
E7XT-6g
AWS
A5.20/A5.20M
A5.22
Tensile Strength: 70-95 ksi

Minimum Yield Strength: 58 ksi
Min Charpy Impact: 20 ftlbf @ 0 F
Minimum % Elongation: 22% j
M21

Min Charpy Impact: 20 ftlbf @ -20 F
None
E7XT-8g
E7XT-9Cg
C1
E7XT-9M
M21
E7XT-12Cg
C1
E7XT-12Mg
M21
Weld
Depositf
CS1
CS3
CS1
E70T-4g
E7XT-7h
Mechanical
Propertiese
None

Min Charpy Impact: 20 ftlbf @ -20 F
CS2

Min Charpy Impact: Not Specified
CS3
a) These multiple pass electrodes are classified according to the fixed classification system utilized in AWS A5.20/A5.20M as applicable, which has been carried over for these
specific electrodes as a part of AWS A5.36/A5.36M. The mechanical property and weld deposit requirements are as defined in this table. These same electrodes may also be
classified to the same requirements or to different requirements using the open classification system introduced in this specification. In this case, the classification designations
are as described in AWS A5.20/A5.20M, Figure 1. See Table A.1 or Table A.3, as applicable, in Annex A for comparisons of the fixed classification designations and equivalent
open classification designations for the above electrodes when both are classified to the requirements listed in this table.
b) Under AWS A5.20/A5.20M, the E at the beginning of the classification designates an electrode. The 7 is the tensile strength designator. The X indicates the electrodes
position of welding capability. A 0 is used to indicate flat and horizontal only. A 1 is used to indicate all position capability. The T identifies the electrode as a flux cored
electrode The one or two digit number after the dash indicates the electrodes usability characteristics as defined in AWS A5.20/A5.20M. For the open classification system
introduced in this specification, the T identifies the electrode as either a flux cored or a metal cored electrode. The T is combined with a one or two digit number as a part
of the alpha-numeric designator for usability. See Illustration 4-11. Under AWS A5.18/A5.18M for classification E70C-6M, the E designates an electrode. The 70 indicates that
the weld deposit will have a minimum tensile strength of 70 ksi. The C indicates that the electrode is a composite (metal cored) electrode. The 6 indicates the composition of
the weld metal the composition produced with this electrode. The M indicates the type of shielding gas used.
c) The electrodes shown in the darker blue panels are self-shielded.
d) See Illustration 4-8.
e) Mechanical properties are obtained by testing weld metal from the groove weld shown in Figure 2 of AWS A5.36/A5.36M. Welding and testing shall he done as prescribed in this
specification. The requirements for welding and testing are the same as those given in A5.20/A5.20M. All mechanical property testing for the classifications listed in this table
shall be done in the as-welded condition.
f) See Illustration 4-12.
g) The D, Q, and H optional designators which are not part of the electrode classification designation, may be added at the end of the designation as established in
AWS A5.20/A5.20M, i.e., E7XT-XXD, E7XT-XXQ, E7XT-XXHX, E7XT-XXDHX, or E7XT-XXQHX as applicable. The J optional, supplemental designator listed in A5.20/A5.20M is
no longer required. The open classification system introduced in this A5.36/A5.36M specification eliminates the need for this designator.
h) The H optional, supplemental designator, which is not part of the electrode classification designation, may be added to the end of the designation as established in
AWS A5.18/A5.I8M, i.e., E70C-6MHZ. Provisions for the D and Q optional, supplemental designators have not been established in A5.18/A5.18M and, as a result, may not
be used with the E70C-6M designation. However, that does not preclude their use with metal core electrodes classified utilizing the open classification system under the
A5.36/A5.36M specification.
i)Yield strength at 0.2% offset.
J Percent elongation in 2 in. (50 mm) gauge length when a 0.500 (12 mm) nominal diameter tensile specimen and nominal gauge length to diameter ratio of 4:1 is used.
Illustration 4-6 Flux Cored Electrode Classifications with Fixed Requirementsa

(Source: AWS A5.36)
17
The open classification system is designed to better

define the performance capabilities of advanced electrodes that are being developed.
strength in units of 10,000 ksi (69 MPa). Illustration

4-7 shows the tension test requirements.
3) The third digit indicates the welding position. A 0
indicates flat and horizontal positions only, and a 1
indicates all positions.
4) The T stands for a tubular (flux cored) wire classification and the 5 designates the usability characteristics of the electrode. See Illustration 4-11.
An example is E80T5-M21P6-Ni2 where:

1) The E indicates an electrode.
2) The number 8 designates the minimum tensile
Tensile Strength
Designator
Single Pass
Electrodes
For A5.36 Multiple Pass Electrodes

U.S. Customary Units

International System of Units (SI)
U.S.
Customary
Units
International
System of
Units (SI)
Min. Tensile
Strength
ksi (MPa)
Tensile
Strength
(ksi)
Min. Yield
Strengtha
(ksi)
Minimum
Percent
Elongationb
Tensile
Strength
(MPa)
Min. Yield
Strengtha
(MPa)
Minimum
Percent
Elongationb
6
7
8
9
10
11
12
13
43
49
55
62
69
76
83
90
60 (430)
70 (490)
80 (550)
90 (620)
100 (690)
110 (760)
120 (830)
130 (900)
60-80
70-95
80-100
90-110
100-120
110-130
120-140
130-150
48
58
68
78
88
98
108
118
22
22
19
17
16
15
14
14
430-550
490-660
550-690
620-760
690-830
760-900
830-970
900-1040
330
400
470
540
610
680
740
810
22
22
19
17
16
15
14
14
a) Yield strength at 0.2% offset.

b) In 2 in (50 mm]) gauge length when a 0.500 in. (12.5 mm) nominal diameter tensile specimen and nominal gauge length to diameter ratio of 4:1 (as specified in the Tension Test
section of AWS B4.0) is used. In 1 in. (25 mm) gauge length when a 0.250 in (6.5 mm) nominal tensile specimen is used as permitted for 0.045 in. (1.2 mm) and smaller sizes of
the E7XT11-AZ-CS3 (E49XT11-AZ-CS3).
c) Elongation requirement may be reduced by one percentage point if the tensile strength of the weld metal is in the upper 25% of the tensile strength range.
Illustration 4-7 Tension Test Requirements for Carbon and Low Alloy Steel Flux Cored Electrodes
(Source: AWS A5.36)
AWS A5.36
Shielding Gas
Designatora
C1
M12
M13
M14
M20
M21
M22
M23
M24
M25
M26
M27
M31
M32
M33
M34
M35
Z
AWS A5.36/5.36M Composition Ranges for Indicated

Main/Sub Groupb
Oxidizing Componentsc
% CO2
100
0.5 CO2 5
0.5 CO2 5
5 < CO2 15
15 < CO2 25
.05 CO2 5
5 < CO2 15
5 < CO2 15
15 < CO2 25
15 < CO2 25
25 < CO2 50
25 < CO2 50
5 < CO2 25
25 < CO2 25
% O2
0.5 O2 3
0.5 O2 3
3 < O2 10
3 < O2 10
0.5 O2 3
3 < O2 10
0.5 O2 3
3 < O2 10
10 < O2 15
2 < O2 10
10 < O2 15
10 < O2 15
Nominal Composition of Shielding Gases to be Used for Classification of Gas Shielded Electrodes to AWS A5.36/5.36M
ISO 14175
Designation
C1
M12-ArC-3
M13-ArO-2
M14-ArCO-3/2
M20-ArC-10
M21-ArC-20
M22-ArO-7
M23-ArO-7/3
M24-ArCO-10/2
M25-ArCO-10/7
M26-ArCO-20/2
M27-ArCO-20/7
M31-ArC-38
M32-ArO-12.5
M33-ArCO-38/6
M34-ArCO-15/12.5
M35-ArCO-38/12.5
Oxidizing Componentsc,e
% CO2
100
3
3
10
20
3
10
10
20
20
38
38
15
38
% O2
2
2
7
7
2
7
2
7
12.5
6
12.5
12.5
The designator Z indicates that the shielding gas used for electrode classification is not one of the shielding gases
specified in this table but is a different composition as agreed upon between the supplier and purchaser.
a) The Shielding Gas Designators are identical to the Main group/Sub-group designators used in AWS A5.32M/A5.32:2011 (ISO 14175:2008 MOD), Welding Consumables
Gases and Gas Mixtures for Fusion Welding and Allied Processes, for these same shielding gases.
b) Under AWS A5.32M/A5.32:2011, the inert gas used for the balance of the gas mixture may be either argon, helium, or some mixture thereof.
c) The mixture tolerances are:
For a component gas with a nominal concentration of >5%, 10% of nominal.
For a component gas with a nominal concentration of 1-5%, 0.5% absolute.
For a component gas with a nominal concentration of <1%, not specified in this standard.
d) AWS A5.32M/A5.32:2011 shielding gas designators begin with AWS A5.32 (ISO 14175). That part of the designation has been omitted from the Shielding Gas Designator
brevity.
e) The inert gas to be used for the balance of the gas mixtures specified for the classification of gas-shielded flux cored electrodes shall be argon.
Illustration 4-8 Composition Requirements for Shielding Gases

(Source: AWS A5.36)
18
5) The M21 designates the shielding gas. The absence

of a designator in this position would indicate a selfshielding electrode. See Illustration 4-8.
6) The P indicates the tested weld was Postweld
Treated. A letter A in this position would indicate as
welded, and a letter G would indicate as agreed between supplier and purchaser. Illustration 4-9 shows
the heat treatment test specifications.
7) The number 6 indicates impact test requirements as

shown in Illustration 4-10.
8) The Ni2 indicates the chemical composition of the
weld metal as shown in Illustration 4-12.
Optional supplementary designators pertaining to diffusible hydrogen and temperature variables can also be
added at the end of the electrode classification.
Preheat and Interpass

Temperaturea
AWS Weld Metal

Designation
For A5.36
U.S. Customary
Units
Postweld Heat Treatment

(PWHT) Temperaturea,b,c
For A5.36
International System
of Units (SI)
60 F preheat min.
15 C preheat min.
300 F 25 F Interpass 150 C 15 C Interpass
CS1, CS2, CS3
For A5.36
U.S. Customary
Units
For A5.36
International System
of Units (SI)
1150 F 25 F
620 C 15 C
300 F 25 F
150 C 15 C
1150 F 25 F
620 C 15 C
B1, B1L, B2, B2L, B2H, B3, B3L, B3H
350 F 25 F
275 C 15 C
1275 F 25 F
690 C 15 C
B6, B6L, B8, B8L
400 F 100 F
200 C 50 C
1375 F 25 F
745 C 15 C
B91, B92
500 F 100 F
260 C 50 C
1400 F 25 F
760 C 15 C
A1, Ni1, Ni2, Ni3, D2
D1, D3, K1, K2, K3, K4, K5, K6, K7,

K8, K9, K10, K11, W2
300 F 25 F
150 C 15 C
As agreed upon between supplier

and purchaser.
EXXTX-XGX-X, EXXTG-XGX-X, EXXTX-XGX-G

and purchaser.
and purchaser.
a) These temperatures are specified for testing under this specification and are not to be considered as recommendations for preheat and postweld heat treatment (PWHT) in
production welding. The requirements for production welding must be determined by the user.
b) Postweld heal treatment is required only for those classifications with the P designator for condition of heat treatment.
c) The PWHT schedule is as described in 9.2.1.2 of AWS A5.20/A5.20M.
d) PWHT temperature in excess of 1150 F (620 C) will decrease Charpy V-Notch impact strength.
e) Held at temperature for 2 hours -0 +15 minutes.
Illustration 4-9 Preheat, Interpass, and PWHT Temperatures

(Source: AWS A5.36)

U.S. Customary Units
Impact
Designatora,b
Maximum Test
Temperaturec,d (F)
+68

International System of Units (SI)
Minimum Average
Energy Level
Impact
Designatora,b
Maximum Test
Temperaturec,d (C)
+20
-20
-20
-40
-30
-50
-60
20 ftlbf
-40
-50
-80
-60
10
-100
-70
15
-150
10
-100
Z
G
No Impact Requirements.
Minimum Average
Energy Level
27 J
No Impact Requirements.
As agreed between supplier and purchaser.
a) Based on the results of the impact tests of the weld metal, the manufacturer shall insert in the classification the appropriate designator from this table.
b) When classifying an electrode to A5.36 using U.S. Customary Units, the Impact Designator indicates the maximum impact lest temperature in degrees Fahrenheit. When
classifying to A5.36M using the International System of Units (Sl), the Impact Designator indicates the maximum impact test temperature in degrees Celsius. With the exception
of the Impact Designator 4, a given Impact Designator will indicate different temperatures depending upon whether classification is according to A5.36 in U.S. Customary Units
or according to A5.36M in the International System of Units (SI). For example, a 2 Impact Designator when classifying to A5.36 indicates a lest temperature of -20 F. When
classifying to A5.36M, the 2 Impact Designator indicates a test temperature of -20 C, which is -4 F.
c) Weld metal from an electrode that meets the impact requirements at a given temperature also meets the requirements at all higher temperatures in this table. For example, weld
metal meeting the A5.36 requirements for designator 5 also meets the requirements for designators 4, 2, 0, and Y. (Weld metal meeting the A5.36M requirements for designator
5 also meets the requirements for designators 4, 3, 2, 0, and Y.)
d) Filler metal classification testing to demonstrate conformance to a specified minimum acceptable level for impact testing, i.e., minimum energy at specific temperature, can be
met by testing and meeting the minimum energy requirement at any lower temperature. In these cases, the actual temperature used for testing shall be listed on the
certification documentation when issued.
Illustration 4-10 Impact Test Requirements for Carbon and Low Alloy Steel Flux Cored Electrodes (Source: AWS A5.36)
19
Usability
Designatora
Process
General Description of Electrode Typeb,c
Position
of Weldinga, b
Polarityf
T1
FCAW-G
Flux cored electrodes of this type are gas-shielded and have a rutile base
slag. They are characterized by a spray transfer, low spatter loss, and a
moderate volume of slag which completely covers the weld.
H, F, VU, OH
DCEP
FCAW-G
Flux cored electrodes of this type are similar to the T1 type of electrode
but with higher manganese or silicon, or both. They are designed primarily
for single pass welding in the flat and horizontal positions. The higher levels
of deoxidizers in this electrode type allow single pass welding of heavily
oxidized or rimmed steel.
H, F, VU, OH
DCEP
FCAW-S
Flux cored electrodes of this type are self-shielded and are intended for
single pass welding and are characterized by a spray type transfer. The
titanium-based slag system is designed to make very high welding speeds
possible.
FCAW-S
Flux cored electrodes of this type are self-shielded and are characterized by
a globular type transfer. Its flouride-based basic slag system is designed to
make very high deposition rates possible and to make low sulfur welds for
improved resistance to hot cracking.
H, F
DCEP
FCAW-G
Flux cored electrodes of this type are gas-shielded and are characterized
by a globular transfer, slightly convex bead contour, and a thin slag that
may not completely cover the weld bead. They have a lime-flouride slag
system and develop improved impact properties and better cold cracking
resistance than typically exhibited by the T1 type electrodes.
H, F, VU, OH
DCEP or
DCEN
FCAW-S
a spray type transfer. Its oxide-based slag system is designed to produce
good low temperature impacts, good penetration into the root of the weld,
and excellent slag removal.
H, F
DCEP
FCAW-S
a small droplet to spray type transfer. The flouride-based slag system is designed to provide high deposition rates in the downhand positions with the
larger diameters and out of position capabilities with the smaller diameters.
H, F, VU, OH
DCEN
FCAW-S
Flux cored electrodes of this type are self-shielded and are characterized
by a small droplet to spray type transfer. The flouride-based slag system is
designed to provide improved out-of-position control. The weld metal pro- H, F, VD, VU, OH
duced typically exhibits very good low temperature notch toughness and
crack resistance.
T1S
T3S
T4
T5
T6
T7
T8
H, F
DCEP
DCEN
Continued on next page.
Illustration 4-11 Usability Characteristics for Carbon and Low Alloy Steel Flux Cored Electrodes
(Source: AWS A5.36)
20
Usability
Designatora
Process
General Description of Electrode Typeb,c
Position
of Weldinga, b
Polarityf
T9
FCAW-G
Flux cored electrodes of this type are similar in design and application to
the T1 types but with improved weld metal notch toughness capabilities.
H, F, VU, OH
DCEP
T10S
FCAW-S
a small droplet transfer. The flouride-based slag system is designed to make
single pass welds at high travel speeds on steel of any thickness.
H, F
DCEN
T11
FCAW-S
a smooth spray type transfer, limited slag coverage, and are generally not
recommended for the welding of materials over 3/4 in. (20 mm) thick.
H, F, VD, OH
DCEN
T12
FCAW-G
Flux cored electrodes of this type are similar in design and application to the
T1 types, however, they have been modified for improved impact toughness and to meet the lower manganese requirements of the A-No. 1 Analysis Group in the ASME Boiler and Pressure Vessel Code, Section IX.
H, F, VU, OH
DCEP
T14S
FCAW-S
a smooth spray type transfer. The slag system is designed for single pass
welds in all positions and at high travel speeds.
H, F, VD, OH
DCEN
T17
FCAW-S
This flux cored electrode type is a self-shielded electrode specifically deH, F, VD, VU, OH
signed for use with AC power sources with or without modified waveforms.
As agreed upon between supplier and purchaser.
Not Specified
ACh
Not Specified
a) An S is added to the end of the Usability Designator when the electrode being classified is recommended for single pass applications only.
b) For more information refer to AWS A5.36/A5.36M, A7, Description and Intended Use, in Annex A.
c) Properties of weld metal from electrodes that are used with external shielding gas will vary according to the shielding gas used. Electrodes classified with a specific shielding gas
should not be used with other shielding gases without first consulting the manufacturer of the electrode.
d) H = horizontal position, F = flat position, OH = overhead position, VU = vertical position with upward progression, VD - vertical position with downward progression.
e) Electrode sizes suitable for out-of-position welding, i.e., welding positions other that flat and horizontal, are usually those sizes that are smaller than the 3/32 in. (2.4 mm) size or
or the nearest size called for in Clause 9 for the groove weld. For that reason, electrodes meeting the requirements for the groove weld test may be classified as EX1TX-XXX-X
(where X represents the tensile strength, usability, shielding gas, if any, condition of heat treatment, impact test temperature, and weld metal composition designators) regardless
of their size.
f) The term DCEP refers to direct current electrode positive (dc, reverse polarity). The term DCEN refers to direct current electrode negative (dc, straight polarity).
g) Some EX1T5-XXX-X electrodes may be recommended for use on DCEN for improved out-of-position welding. Consult the manufacturer for the recommended polarity.
h) For this electrode type the welding current can be conventional sinusoidal alternating current, a modified AC waveform alternating between positive and negative, an alternating
DCEP waveform, or an alternating DCEN waveform.
Illustration 4-11 Usability Characteristics for Carbon and Low Alloy Steel Flux Cored Electrodes
(Source: AWS A5.36)
21
Weld Metal
UNS
Designation Numberb
Mn
Si
Weight Percentc
Ni
Cr
Mo
Al
Cu
Otherd
Carbon Steel Electrodes

CS1e
0.12
1.75
0.90
0.030
0.030
0.50f
0.20f
0.30f
0.08
0.35
CS2e,g
0.12
1.60
0.90
0.030
0.030
0.50f
0.20f
0.30f
0.08
0.35
CS3e
0.30
1.75
0.60
0.030
0.030
0.50f
0.20f
0.30f
0.08
1.8f,h
0.35
0.40 to
0.65
Molybdenum Steel Electrodes

A1
W1703X
0.12
1.25
0.030
0.030
0.30
Chromium-Molybdenum Steel Electrodes

B1
W5103X
0.05 to
0.12
1.25
0.80
0.030
0.030
0.40 to
0.65
0.40 to
0.65
B1L
W5113X
0.05
1.25
0.80
0.030
0.030
0.40 to
0.65
0.40 to
0.65
B2
W5203X
0.05 to
0.12
1.25
0.80
0.030
0.030
1.00 to
1.50
0.40 to
0.65
B2L
W5213X
0.05
1.25
0.80
0.030
0.030
1.00 to
1.50
0.40 to
0.65
B2H
W5223X
0.10 to
0.15
1.25
0.080
0.030
0.030
1.00 to
1.50
0.40 to
0.65
B3
W5303X
0.05 to
0.12
1.25
0.80
0.030
0.030
2.00 to
2.50
0.90 to
1.20
B3L
W5313X
0.05
1.25
0.80
0.030
0.030
2.00 to
2.50
0.90 to
1.20
B3H
W5323X
0.10 to
0.15
1.25
0.80
0.030
0.030
2.00 to
2.50
0.90 to
1.20
B6
W50231
0.05 to
0.12
1.25
1.00
0.030
0.025
0.40
4.0 to
6.0
0.45 to
0.65
0.50
B6L
W50230
0.05
1.25
1.00
0.030
0.025
0.40
4.0 to
6.0
0.45 to
0.65
0.50
B8
W50431
0.05 to
0.12
1.25
1.00
0.030
0.040
0.40
8.0 to
10.5
0.85 to
1.20
0.50
B8L
W50430
0.05
1.25
1.00
0.030
0.040
0.40
8.0 to
10.5
0.85 to
1.20
0.50
B91i
W50531
0.08 to
0.13
1.20j
0.50
0.015
0.020
0.80j
8.0 to
10.5
0.85 to
1.20
0.15 to
0.30
0.04
0.25
Nb: 0.02-0.10
N: 0.02-0.07
B92
0.08 to
0.15
1.20j
0.50
0.015
0.020
0.80j
8.0 to
10.0
.0.30 to
0.70
0.15 to
0.30
0.04
0.25
Nb: 0.02-0.08
W: 1.5-2.0
N: 0.02-0.08
Cok
Nickel Steel Electrodes

Ni1
W2103X
0.12
1.75
0.80
0.030
0.030
0.80 to
1.10
0.15
0.35
0.05
1.8h
Ni2
W2203X
0.12
1.50
0.80
0.030
0.030
1.75 to
2.75
1.8h
Ni3
W2303X
0.12
1.50
0.80
0.030
0.030
2.75 to
3.75
1.8h
Continued on next page.
Illustration 4-12 Chemical Composition Requirements for Carbon and Low Alloy Steel Flux Cored Electrodesa
(Source: AWS A5.36)
22
Weld Metal
UNS
Designation Numberb
Mn
Si
Weight Percentc
Ni
Cr
Mo
Al
Cu
Otherd
Manganese-Molybdenum Steel Electrodes

D1
W1913X
0.12
1.25 to
2.00
0.80
0.030
0.030
0.25 to
0.55
D2
W1923X
0.15
1.65 to
2.25
0.80
0.030
0.030
0.25 to
0.55
D3
W1933X
0.12
1.00 to
1.75
0.80
0.030
0.030
0.40 to
0.65
Other Low-Alloy Steel Electrodes

K1
W2113X
0.15
0.80 to
1.40
0.80
0.030
0.030
0.80 to
1.10
0.15
0.20 to
0.65
0.05
K2
W2123X
0.15
0.50 to
1.75
0.80
0.030
0.030
1.00 to
2.00
0.15
0.35
0.05
1.8h
K3
W2133X
0.15
0.75 to
2.25
0.80
0.030
0.030
1.25 to
2.60
0.15
0.20 to
0.65
0.05
K4
W2223X
0.15
1.25 to
2.25
0.80
0.030
0.030
1.75 to
2.60
0.20 to
0.60
0.20 to
0.65
0.05
K5
W2162X
0.10 to
0.25
0.60 to
1.60
0.80
0.030
0.030
0.75 to
2.00
0.20 to
0.60
0.15 to
0.55
0.05
K6
W2104X
0.15
0.50 to
1.50
0.80
0.030
0.030
0.40 to
1.00
0.20
0.15
0.05
1.8h
K7
W2105X
0.15
1.00 to
1.75
0.80
0.030
0.030
2.00 to
2.75
K8
W2143X
0.15
1.00 to
2.00
0.40
0.030
0.030
0.50 to
1.50
0.20
0.20
0.05
1.8h
K9
W2323X
0.07
0.50 to
1.50
0.60
0.015
0.015
1.30 to
3.75
0.20
0.50
0.05
0.06
K10
0.12
1.25 to
2.25
0.80
0.030
0.030
1.75 to
2.75
0.20
0.50
0.50
K11
0.15
1.00 to
2.00
0.80
0.030
0.030
0.40 to
1.00
0.20
0.50
0.05
1.8h
W2
W2013X
0.12
0.50 to
1.30
0.030
0.030
0.35 to
0.80
0.40 to
0.80
0.45 to
0.70
0.30 to
0.75
GSn

a) The weld metal shall be analyzed for the specific elements for which values are shown in this table.
b) Refer to ASTM DS-56/SAE HS-1086, Metals and Alloys in the Unified Numbering System. An X, when present in the last position, represents the usability designator for the
electrode type used to deposit the weld metal. An exception to this applies to the 11 electrode type where a 9 is used instead of an 11.
c) Single values arc maximums.
d) An analysis of the weld deposit for for boron is required and shall be reported if this element is intentionally added or if it is known to be present at levels in excess of 0.0010%.
e) The total of all the elements listed in this classification shall not exceed 5%.
f) The analysis of these elements shall be reported only if intentionally added.
g) Meets the lower Mn requirements of the A-No. 1 Analysis Group in the ASME Boiler and Pressure Vessel Code, Section DC, Welding and Brazing Qualifications, QW-422.
h) Applicable to self-shielded electrodes only. Electrodes intended for use with gas shielding normally do not have significant additions of aluminum.
i) The B91 designation is a new designation, replacving the B9 designation previously used for this alloy type.
j) Mn+Ni = 1.40% maximum. See AWS A5.36/A.536M, A7.17.2 in Annex A.
k) Analysis for Co is required to be reported if intentionally added, or if it is known to be present at levels greater than 0.20%.
m) The limit for gas-shielded electrodes is 0.18% maximum. The limit for self-shielded electrodes is 0.30% maximum.
n) The composition of weld metal is not particulalry meaningful since electrodes in this category are intended only for single pass welds. Dilution from the base metal in such weld is
usually quite high. See AWS A5.36/A.536M, A7.2 in Annex A.
Illustration 4-12 Chemical Composition Requirements for Carbon and Low Alloy Steel Flux Cored Electrodesa
(Source: AWS A5.36)
23
AWSd
Classification
UNS
Numberc
Weight Percentb,c
C
Cr
Ni
Mo
Nb + Ta
Mn
Si
Cu
Other
0.13
18.0 to
20.5
18.0 to
21.0
18.0 to
21.0
18.0 to
21.0
18.0 to
21.0
18.0 to
21.0
22.0 to
25.0
22.0 to
25.0
22.0 to
25.0
21.0 to
25.0
21.0 to
25.0
20.5 to
23.5
22.0 to
25.0
25.0 to
28.0
28.0 to
32.0
17.0 to
20.0
17.0 to
20.0
17.0 to
20.0
18.0 to
21.0
9.0 to
10.5
9.0 to
11.0
9.0 to
11.0
9.0 to
11.0
9.0 to
11.0
9.0 to
12.0
12.0 to
14.0
12.0 to
14.0
12.0 to
14.0
12.0 to
16.0
12.0 to
16.0
15.0 to
17.0
12.0 to
14.0
20.0 to
22.5
8.0 to
10.5
11.0 to
14.0
11.0 to
14.0
11.0 to
14.0
12.0 to
14.0
0.5 to
1.5
1.0
0.04
0.03
0.75
0.75
1.0
0.04
0.03
0.75
0.75
3.30 to
4.75
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
1.0 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.03
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
0.5 to
2.5
1.0
0.04
0.03
0.75
E307TX-X
W30731
E308TX-X
W30831
0.08
E308HTX-X
W30831
0.04 to
0.08
E308LTX-X
W30835
0.04
E308HMoTX-X
W30832
0.08
E308LMoTX-X
W30838
0.04
E309TX-X
W30931
0.10
E309HTX-X
W30931
0.04 to
0.10
E309LTX-X
W30935
0.04
E309LMoTX-X
W30939
0.12
E309LNiMoTX-X W30938
0.04
E309NiMoTX-X
W30936
0.04
E309LNbTX-X
W30932
0.04
E310TX-X
W31031
0.20
E312TX-X
W31331
0.15
E316TX-X
W31631
0.08
E316HTX-X
W31631
0.04 to
0.08
E316LTX-X
W31635
0.04
E317LTX-X
W31735
0.04
0.75
2.0 to
3.0
2.0 to
3.0
0.75
0.50
0.75
2.0 to
3.0
2.0 to
3.0
2.5 to
3.5
0.75
0.70 to
1.00
0.75
0.75
2.0 to
3.0
2.0 to
3.0
2.0 to
3.0
3.0 to
4.0
8xC min
to 1.0
max
E347TX-X
W34731
0.08
18.0 to
21.0
19.0 to
11.0
0.75
E347HTX-X
W34731
0.04 to
0.08
18.0 to
21.0
9.0 to
11.0
0.75
8xC min
to 1.0
max
0.5 to
2.5
1.0
0.04
0.03
0.75
E409TX-X
W40931
0.10
18.0 to
21.0
0.60
0.75
0.80
1.0
0.04
0.03
0.75
E409NbTX-X
W40957
0.10
10.5 to
13.5
0.6
0.5
1.2
1.0
0.04
0.03
0.75
E410TX-X
W41031
0.12
0.60
0.75
1.2
1.0
0.04
0.03
0.75
E410NiMoTX-X
W41036
0.06
4.0 to
5.0
0.40 to
0.70
1.0
1.0
0.04
0.03
0.75
E430TX-X
W43031
0.10
0.60
0.75
1.2
1.0
0.04
0.03
0.75
E430NbTX-X
W43057
0.10
0.6
0.5
1.2
1.0
0.04
0.03
0.75
W39239
0.04
7.5 to
10.0
8.5 to
10.5
8.0 to
10.5
2.5 to
4.0
2.9 to
3.9
2.5 to
4.5
0.5 to
1.5
E2209TX-X
11.0 to
13.5
11.0 to
12.5
15.0 to
18.0
15.0 to
18.0
21.0 to
24.0
24.0 to
27.0
24.0 to
27.0
8xC min
to 1.0
max
Ti=10xC
min to 1.5
max
0.5 to
2.0
0.5 to
1.5
0.5 to
2.5
1.0
0.04
0.03
0.75
1.5 to
2.5
0.75
W = 10
E2553TX-X
W39533
0.04
E2594TX-X
W39594
0.04
0.75
0.04
0.03
1.0
0.04
0.03
0.08 to
0.20
0.10 to
0.25
0.20 to
0.30
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
Not Specified
EGTX-X g
E307T0-3
W30733
0.13
E308T0-3
W30833
0.08
19.5 to
22.0
19.5 to
22.0
9.0 to
10.5
9.0 to
11.0
0.5 to
1.5
0.75
3.30 to
4.75
0.5 to
2.5
Illustration 4-13 Chemical Composition Requirements for Stainless Steel Flux Cored Electrodes
(Source: AWS A5.22)
24
AWSd
Classification
UNS
Numberc
Weight Percentb,c
C
Cr
Ni
9.0 to
11.0
9.0 to
11.0
9.0 to
11.0
9.0 to
10.7
9.0 to
12.0
12.0 to
14.0
12.0 to
14.0
12.0 to
16.0
12.0 to
16.0
12.0 to
14.0
20.0 to
22.5
8.0 to
10.5
11.0 to
14.0
11.0 to
14.0
11.0 to
14.0
13.0 to
15.0
Mo
Nb + Ta
Mn
Si
Cu
Other
0.75
1.0
0.04
0.03
0.75
0.75
1.0
0.04
0.03
0.75
2.0 to
3.0
1.8 to
2.4
2.0 to
3.0
0.75
0.75
2.0 to
3.0
2.0 to
3.0
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
1.25 to
2.25
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
1.0 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
E309LNbT0-3
W30934
0.4
E310T0-3
W31031
0.20
E312T0-3
W31231
0.15
E316T0-3
W31633
0.08
E316LT0-3
W31637
0.04
E316LKT0-3 f
W31630
0.04
E317LT0-3
W31737
0.04
19.5 to
22.0
19.5 to
22.0
18.0 to
21.0
19.0 to
21.5
18.0 to
21.0
23.0 to
25.5
23.0 to
25.5
21.0 to
25.0
21.0 to
25.0
23.0 to
25.5
25.0 to
28.0
28.0 to
32.0
18.0 to
20.5
18.0 to
20.5
17.0 to
20.0
18.5 to
21.0
E347LT0-3
W34733
0.08
19.0 to
21.5
9.0 to
11.0
0.75
8XC min
to 1.0
max
E409LT0-3
W40931
0.10
10.5 to
12.5
0.60
0.75
0.80
1.0
0.04
0.03
0.75
E410LT0-3
W41031
0.12
11.0 to
13.5
11.0 to
12.5
15.0 to
18.0
21.0 to
24.0
24.0 to
27.0
24.0 to
27.0
Ti=10xC
min to 1.5
max
E308HT0-3
W30833
0.08
E308LT0-3
W30837
0.04
E308MoT0-3
W30839
0.08
E308HMoT0-3
W30830
0.07 to
0.12
E308LMoT0-3
W30838
0.4
E309T0-3
W30933
0.10
E309LT0-3
W30937
0.4
E309MoT0-3
W30939
0.12
E309LMoT0-3
W30938
0.4
E410NiMoT0-3
W41036
0.06
E430T0-3
W43031
0.10
E2209T0-3
W39239
0.04
E2553T0-3
W39533
0.04
E2594T0-3
W39594
0.04
0.75
0.70 to
1.00
0.75
0.75
2.0 to
3.0
2.0 to
3.0
2.0 to
3.0
3.0 to
4.0
0.04
0.03
0.75
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.03
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
1.0
0.04
0.03
0.75
0.5 to
2.5
1.0
0.04
0.03
0.75
0.60
0.75
1.0
1.0
0.04
0.03
0.75
4.0 to
5.0
0.40 to
0.70
1.0
1.0
0.04
0.03
0.75
0.60
0.75
1.0
1.0
0.04
0.03
7.5 to
10.0
8.5 to
10.5
8.0 to
10.5
2.5 to
4.0
2.9 to
3.9
2.5 to
4.5
0.5 to
2.0
0.5 to
1.5
0.5 to
2.5
1.0
0.04
0.03
0.75
0.04
0.03
1.0
0.04
0.03
1.5
W = 10
1.2
0.04
0.03
0.75
0.08 to
0.75
0.20
0.10 to
0.75
0.25
0.20 to 1.5 to 2.5
0.30
Not Specified
EGTX-3g
R316LT1-5
W31635
0.03
18.0 to
21.0
22.0 to
25.0
17.0 to
20.0
R347T1-5
W34731
0.08
18.0 to
21.0
R308LT1-5
W30835
0.03
R309LT1-5
W30935
0.03
RGT1-5g
1.0
0.25 to
0.80
9.0 to
11.0
12.0 to
14.0
11.0 to
14.0
9.0 to
11.0
0.75
0.75
0.75
2.0 to
3.0
8XC min
to 1.0
max
0.5 to
2.5
0.5 to
2.5
0.5 to
2.5
1.2
0.04
0.03
0.75
1.2
0.04
0.03
0.75
0.5 to
2.5
1.2
0.04
0.03
0.75
Not Specified
a) The weld metal shall be analyzed for the specific elements in this table. If the presence of other elements is indicated in the course of this work, the amount of those elements
shall be determined to ensure that their total (excluding iron) does not exceed 0.50%.
b) Single values shown are maximum.
c) For flux cored electrodes and rods intended for elevated temperature service (above approximately 750 F [400 C] and for post weld heat treatment above 900 F [500 C],
bismuth (Bi) should be restricted to 0.002 wt % (20 ppm) maximum. See AWS A7.24 for more information.
d) In this table, the X following the T refers to the position of welding (1 for all-position or 0 for flat or horizontal operation) and the X following the dash refers to the shielding
medium (-1 or -4) as shown in the AWS Classification column in Table 2.
e) SAE HS-1086 / ASTM DS-56, Metals & Metal Alloys in the Unified Numbering System.
f) This alloy is designed for cryogenic applications.
g) See AWS A2.2.7 and A2.2.8.
Illustration 4-13 Chemical Composition Requirements for Stainless Steel Flux Cored Electrodes
(Source: AWS A5.22)
25
AWSa
Classification
External
Shielding Gasb
Welding
Polarity
EXXXTX-1
CO2
DCEP
EXXXTX-3
None (self-shielded)
DCEP
EXXXTX-4
75-85% Ar / remainder CO2
DCEP
EXXXTX-G
Not Specified
Not Specified
most important criteria for selecting a filler metal to

be used on low carbon and many low alloy steels.
a) The letters XXX stand for the designation of the chemical composition
(see AWS A5.22, Table 1). The X after the T designates the position of operation.
A 0 indicates flat or horizontal operation; a 1 indicates all-position operation.
Refer to AWS A5.22, Figure A and Clause A2 for a complete description of this
classification system.
b) The requirements for the use of a specified external shielding gas shall not be
construed to restrict the use of any other media, for which the electrodes are found
suitable, for any application other than the classification tests.
c) See AWS A2.2.7 to A2.2.9 for additional information.
d) AWS A5.32/A5.32M class SG-C.
e) AWS A5.32/A5.32M class SG-AC-25 or SG-AC-20.
f) AWS A5.32/A5.32M class SG-A.
g) AWS A5.32/A5.32M class SG-A, SG-AO-1 or SG-AO-2.
Illustration 4-14 Required Shielding Gas and Polarity for

Stainless Steel Flux Cored Electrodes
(Source: AWS A5.22)
The classification system for stainless steel electrodes is

based on the chemical composition of the weld metal
and the type of shielding to be employed during welding.
An example of a stainless steel electrode classification is
E308T1-1 where:
1) The E indicates an electrode.
2) The digits between the E and the T indicate the
chemical composition of the weld as shown in illustration 4-13.
3) Welding Position Flux cored electrodes are designed to be used in specific positions. Wire diameter
is the major factor limiting the position in which an
electrode can be used. All position electrodes are
available only in the smaller sizes. Flat and horizontal
position only electrodes may have very similar compositions but are available in all sizes or the larger
sizes which cannot be easily used for vertical and
overhead welding. Electrodes should be selected to
match the welding position.
4) Welding Current Flux cored electrodes are designed to operate on either direct current electrode
negative or direct current electrode positive. Electrodes operating on DCEN generally give lighter
penetration and higher deposition rates. Electrodes
operating on DCEP generally provide deeper penetration.
5) Joint Design and Fit-up Electrodes should be
chosen according to their penetration characteristics. Gas-shielded flux cored wires produce deeper
penetration than self-shielding wires. This can have
an effect on the joint design used.
3) The T stands for a tubular (flux cored) wire classification.

4) The next digit indicates the welding position. A 0
indicates flat and horizontal positions only, and a 1
indicates all positions.
5) The suffix indicates the type of shielding to be used
as shown in illustration 4-14.
Electrode Selection
The selection of the proper electrode for an application is
based on the type of metal to be welded and the specific
chemical and mechanical properties required of the joint.
Identification of the base metal is required to select an
electrode. If the type of metal is not known, tests must be
made based on visual, magnetic, chisel, flame, fracture,
spark or chemistry tests.
The selection of the proper filler metal for a specific job
application is quite involved but may be based on the
following factors.
1) Base Metal Strength Properties This is done by
choosing an electrode wire to match the tensile or
yield strength of a metal. This is usually one of the
2) Base Metal Composition The chemical composition of the metal to be welded should be known.
Closely matching the filler and base metal compositions is important when corrosion resistance and
creep resistance are needed. The filler metals for
welding stainless steels and alloy steels are usually
chosen on the basis of matching chemical compositions.
6) Thickness and Shape of Base Metal Weldments

may include thick sections or complex shapes which
may require maximum ductility to avoid weld cracking. Electrodes that give the best ductility should be
used for these applications.
7) Service Conditions and/or Specifications For
weldments subject to severe conditions such as low
temperature, high temperature, or shock loading,
an electrode that matches the ductility and impact
strength of the steel should be selected.
8) Production Efficiency and Job Conditions Large
diameter electrodes should be used, if possible, to
give higher deposition rates.
Flux cored electrodes for carbon and low alloy steels are
each designed for specific applications based on the
composition of the flux core of the wire. Each suffix used
indicates a general grouping of electrodes that have similar flux components and usability characteristics.
A T-1 electrode is a single or multiple pass electrode.
It operates on DCEP and requires gas shielding. It pro-
26
duces a flat to slightly convex weld bead with a moderate slag coating. T-1 electrodes produce a fine globular
transfer and low spatter levels. Welds produced with T-1
electrodes have good mechanical properties.
A T-2 electrode operates on DCEP and also requires gas
shielding. These electrodes are similar to T-1 types, but
are designed to weld over rust and scale. They are for
single-pass welding only because of their high silicon
and manganese contents.
T-3 electrodes are self-shielding wires using DCEP for
single-pass welding operations. These electrodes produce a fine globular transfer and are designed for welding sheet metal at high welding speeds.
T-4 electrodes are self-shielding wires using DCEP for
single or multiple-pass operation. These electrodes produce a globular metal transfer and light penetration for
joints with poor fit-up. Desulfurizing elements are contained in the flux core to help prevent weld cracking.
T-5 electrodes can be used to weld higher carbon steels,
or for joining low alloy steels to carbon steels because of
cleaner welds and lower hydrogen levels.
T-6 electrodes are self-shielded electrodes for single or
multiple pass welding using DCEP. These electrodes are
characterized by a fine globular transfer and deep penetration. The slag coating has good deep-groove removal
characteristics and produces good low temperature impact properties.
T-7 electrodes are self-shielded electrodes that operate
on DCEN for single or multiple pass welding. The larger
sizes of this type of electrode are designed to produce
high deposition rates. The smaller sizes are used for allposition welding. The slag coating desulfurizes the weld
metal to a very low level which helps prevent cracking.
T-8 electrodes are self-shielding electrodes for single or
multiple pass welding that operate on DCEN. The slag
system is designed to allow all-position welding. The slag
also desulfurizes the weld metal and produces good low
temperature impact properties.
T-10 electrodes are self-shielded, single-pass electrodes
that operate on DCEN. These electrodes are used for
making welds in the flat and horizontal positions at high
travel speeds.
T-11 electrodes are self-shielded electrodes that operate

on DCEN for single and multiple pass welding. These
are general purpose electrodes for all position welding
at moderate travel speeds. They produce a fine globular
transfer.
T-G electrodes are for multiple pass welding which are
not covered by another classification.
T-GS electrodes are single pass electrodes which are not
covered by another classification. The operating conditions and characteristics are not defined for the T-G and
the T-GS electrodes.
Electrode selection will be discussed in more detail in
Chapter 7.
Conformances and Approvals
Flux cored arc welding electrodes must conform to specifications, or be approved by code-making organizations
for many FCAW applications. Some of the code-making
organizations that issue specifications or approvals are
the American Welding Society (AWS), the American Bureau of Shipping (ABS), and other state and federal highway and military organizations. The American Welding
Society provides specifications or flux cored wire electrodes. Electrodes must meet specific requirements in
order to conform to a particular electrode classification.
Many code-making organizations such as the American
Society of Mechanical Engineers (ASME) and the American Petroleum Institute (API) recognize and use the AWS
specifications.
Some of the code-making organizations such as the
American Bureau of Shipping (ABS) and the military,
must directly approve the electrodes before they can be
used for welding on a project that is covered by that
code. These organizations send inspectors to witness
the welding and testing, as well as to approve the classification of the flux cored electrodes. To conform to the
AWS specifications for carbon and low alloy steel filler
metals, the electrodes must produce a weld deposit that
meets the specific mechanical and chemical requirements. For the stainless steel filler metal, the electrodes
must produce a weld deposit with a specific chemical
composition. The requirements will vary depending on
the class of the electrodes.
27
CHAPTER 5
WELDING APPLICATIONS
Flux cored arc welding has gained popularity for a wide
variety of applications. Flux cored arc welding has replaced shielded metal arc welding for some applications.
One of the major advantages of the process is the high
deposition rates obtained when compared to manual arc
welding processes. Flux cored arc welding deposition
rates are also generally higher than those obtained from gas metal arc welding. Because
flux cored arc welding is a semiautomatic
process, higher productivity can be obtained
compared to shielded metal arc welding. This
process also lends itself easily to machine
and automatic welding. Because of the versatility of flux cored arc welding, it has obtained wide application in shop fabrication,
maintenance and field erection work.
Gas-shielded flux cored wires have replaced shielded

metal arc welding and gas metal arc welding for many
shop applications. Flux cored arc welding is widely employed for welding of the thicker structural members
where the higher deposition rates provide more advantage.
For field welding, the self-shielding flux cored wires are commonly used. These flux cored
wires are preferred over the gasshielded types because a supply
of shielding gas is not required,
which makes the equipment
more portable.
Another advantage of the selfshielding electrodes for field

Each of the two variations of flux cored arc
welding has its advantages, but the areas
construction is that they can be
of application of the two variations often
used in windier conditions. This
overlap. The method of welding used deis because the decomposition
pends on the joint design, fit-up, availability
of the flux core which provides
of electrodes, and mechanical property rethe shielding is less sensitive
quirements of the welded joints. The selfto wind than an external gas
shielding electrode wire variation can often
shielding supply.
be used for applications that can be done by
shielded metal arc welding. This is especially
Another application of selftrue when welding in locations where comshielding electrodes is for the
Illustration 5-5
pressed gas cylinders are difficult to handle.
welding of galvanized steel roof
Photo courtesy of Bernard
Gas-shielded flux cored wires are used for
decking. Single-pass electrodes
using DCEN are preferred for
many applications that compete with gas
most applications because of the lighter penetration
metal arc welding. There are many different applications
possible but the most common ones are discussed in
produced which reduces the chances of burning through
this chapter.
the decking.
Ships
INDUSTRIES
Structures
One of the most important applications of flux cored arc
welding is in the structural fabrication industry. A wide
variety of low carbon and low alloy steels in many different thicknesses are used in this industry. Welding is done
in the shop and the field and flux cored arc welding is
readily adaptable to both types of wires. The major advantages of this process in the structural industry are the
high deposition rates, high production rates, deep penetrating characteristics and the adaptability of the process
for field erection welding. Because a large percentage of
the welds made in structural work are fillets, flux cored
arc welding is widely used for making large single-pass
fillet welds. Many of these welds would require multiple
passes using gas metal arc welding and shielded metal
arc welding.
Flux cored arc welding is employed in the shipbuilding

industry because of the wide variety of low carbon and
low alloy steels and metal thicknesses being welded.
Because this process can be used in the vertical and
overhead positions, it is employed in places where submerged arc welding cannot be used. The process is also
useful for vertical welding on metal thicknesses too thin
for electroslag welding to be economical. Most flux cored
arc welding is done semiautomatically but some automatic welding applications are employed.
Industrial Piping
Flux cored arc welding is used to some extent in the
industrial piping industry. This process is employed for
welding pipe in both the shop and the field for use in
steam generating plants, refineries, distilleries and chemical processing plants. Flux cored arc welding competes
28

with submerged arc welding, shielded metal arc welding,

and gas metal arc welding.
This process may be used to deposit all passes or it may
be used to deposit the fill and cover passes over a root
pass welded by another process. Flat position roll welding, (1G position) is often used for both semiautomatic
and automatic welding applications. This allows higher
welding currents with larger diameter wires and requires
fewer weld passes. Roll welding is often employed, especially on large diameter piping. Copper backing strips
are sometimes used to allow higher current levels and insure full penetration to the root of the joint. When welding
fixed position pipe, smaller diameter electrodes are used.
These electrodes operate at lower current levels and require more passes. In these positions, the root pass is
often welded using gas metal arc welding and sometimes
gas tungsten arc welding. In the 5G or horizontal fixed
position, welding the root pass by flux cored arc welding
is done using a downhill technique. The remaining passes are then welded using an uphill technique.
Flux cored arc welding is used for welding both carbon
steel and alloy steel pipe. A major application of the process is for welding chromium-molybdenum steel pipe.
This is the major type of alloy steel used for pipe. Flux
cored electrodes are preferred over the solid wire when
matching chemical compositions. This is because porosity is hard to avoid. Also, with the solid wire electrodes the
operating characteristics of solid wires are not as good,
which makes them more difficult to use. Most of the electrodes used for flux cored arc welding of pipe are gasshielded because of the better penetration produced and
the generally better mechanical properties produced.
Railroads
Flux cored arc welding is used extensively in the railroad
industry. Other processes such as shielded metal arc
welding, gas metal arc welding and submerged arc welding are also widely employed, so the choice of the welding process is based on the weld size, joint accessibility,
joint length and welding position. The longest welds on
the heavier metal thicknesses in the flat position are generally welded using submerged arc welding. Flux cored
arc welding is usually used on the heavier metal thicknesses where submerged arc welding is not practical.
Examples would be for joints in other positions, shorter
joints and where accessibility is more limited. Flux cored
arc welding is preferred over shielded metal arc welding
and gas metal arc welding for many uses because of the
higher deposition rates obtained.
Many different components on the engines and the rail
cars are commonly welded.
Most manufacturers of railroad engines and cars primarily use the gas-shielded electrode wires. Self shielding
electrodes are sometimes used where lighter penetration is desirable. Flux cored wires that have good weld-
29
ing characteristics when welding over rust and scale are

also popular in this industry because the amount of joint
cleaning time is reduced.
Automotive Products
Flux cored arc welding has gained popularity for use in
the automobile and truck manufacturing industries. This
process is used because of the high production rates
that can be obtained. Both the self-shielding and the
gas-shielded electrode wires have been used. The gasshielded wires are generally used when deeper penetration is required. Flux cored arc welding is also popular
because it can be easily automated. Components such
as frames, truck wheels, trailers and axle housings are
common applications. Flux cored arc welding is more
popular for trucks because of the larger thicknesses of
metal generally employed.
The use of flux cored arc welding has increased over gas
metal arc welding for many frame welding applications
because joint fit-up is less important, better appearing
weld beads can be produced, and flux cored arc welding
has better welder appeal.
Many flux cored electrodes have been developed for
welding over some rust and scale which reduces the
metal preparation time.
Flux cored arc welding is often employed for the welding
of axle housings and attachments.

A special application of flux cored arc welding is for the

welding of catalytic converters. These are made of type
409 stainless steel which is welded with an equivalent
filler metal using gas shielding.
Heavy Equipment
The heavy equipment manufacturing industry includes
mining, agricultural and earth moving equipment, as well
as, other items such as fork lift trucks and armored vehicles. Flux cored arc welding is popular in these industries because of the high deposition rates obtained. Fillet
welds are often encountered in these industries. Large
single pass fillet welds can often be welded by flux cored
arc welding which eliminates interpass cleaning time and
increases productivity.
The mining equipment manufacturing industry is a major
user of flux cored arc welding for welding a wide variety
of low carbon and low alloy steels.
Maintenance and Repair

Photo courtesy of Hobart Brothers Company
The flux cored arc welding process is very useful for maintenance and surfacing operations. Maintenance operations range from repairing and modifying plant and build-
30
ing facilities to repairing pipe, production equipment and

castings. Surfacing and salvaging operations include the
repair of mismachined parts, foundry defects, accommodating engineering changes, rebuilding worn parts, especially shafting and rollers, and overlaying parts with special materials. Reclamation includes the disassembly and
rewelding of defective items manufactured in the factory
and in the field. It has been used for maintaining and repairing items too expensive to repair with oxyacetylene
welding and other arc welding processes. Self shielding
flux cored electrodes are popular for field repairs and
maintenance because the equipment is more portable.
A metal overlay can be used to extend the usable life of
new parts which lack some of the wear-resistant qualities required for certain applications. Overlays are used
mostly to replace metal which has been worn away by
abrasion, corrosion, and impacts. An overlay provides
toughness and resistance to corrosion, abrasion and
wear at the exact location on the part where it is needed
most. The primary reason for weld overlaying of parts is
to prepare them for certain applications and to extend
their service life. Flux cored arc welding is widely employed because of its characteristic high deposition rate
and good weld bead appearance.
FLUX CORED ARC SPOT WELDING

Flux cored arc spot welding is a variation of the process
where a fusion weld is made through one sheet into an
adjacent sheet of a lap joint while the welding gun is held
stationary. The equipment used for arc spot welding is
the same as for normal welding, except that a timer and a
special gun nozzle is required. Flux cored arc spot welding is used on low carbon and low alloy steels and is generally preferred for welding thicker sheet metal and thin
plate sections. This is because of the greater penetrating
capability of the process as compared to gas tungsten or
gas metal arc spot welding. The flux cored arc welding
process also provides a wider penetration spot weld at
the interface between the plates to be joined. This produces a larger diameter spot weld with greater strength.
Flux cored arc spot welding is identical to gas metal arc
spot welding except that a flux cored electrode wire is
used. Carbon dioxide shielding is generally used but
argon-CO2 mixtures are sometimes used to reduce the
amount of penetration. When welding thinner metals, a
backup bar is used under the sheet metal.
The advantages of flux cored arc spot welding over resistance spot welding are:
1) Access is only required from the top of the joint
2) Flux cored arc spot welding can be done in all positions more easily
3) The gun is light and portable and can be taken to the
weldment
4) Weld joint fit-up is not as critical
5) Faster production rates can be obtained, particularly
on thicker metal
The main disadvantage of flux cored arc spot welding is
the consistency of weld size and strength is not as good.
Either the gas-shielded or self-shielded flux cored electrodes may be used. The weld is made by depressing the
trigger which starts the shielding gas, if used, and, after a
preflow interval, starts the arc and the wire feed. The arc
melts through the top sheet of the lap joint and fuses into
the bottom sheet. When the preset weld time is finished,
the arc and wire feed are stopped, followed by the gas
flow, if used. Metals of the same or different thicknesses
can be made. If dissimilar thicknesses are being welded,
the thinner member should always be placed on top. The
length of the spot weld cycle affects the penetration and
the amount of reinforcement on the surface of the weld
bead. Flux cored arc spot welding generally produces
larger, stronger weld nuggets on the same metal thicknesses as compared to gas metal arc spot welding. The
rest of the welding variables affect the weld in the same
way as normal weld.
31
CHAPTER 6
COST OF FLUX CORED ARC WELDING
The cost of welding is an important factor to consider
when selecting a welding process for an application. Flux
cored arc welding has advantages over other processes
which make it the most economical welding method for
many different applications. Factors such as deposition
rates, welding speeds, joint preparation time, operator
factors, and welding material costs must be compared to
properly choose a welding process.
The initial investment for the equipment can vary considerably depending on the size and complexity of the
equipment used. The equipment used is often basically
the same as for gas metal arc welding. Because of the
higher current levels used in flux cored arc welding, larger
power sources may be needed. With the self-shielding
electrode wires, a gas shielding system is not needed,
which simplifies and reduces the overall cost of the
equipment. In some cases where gas metal arc welding
equipment is available, a change to flux cored arc welding
would require almost no new equipment. The equipment
for semiautomatic welding is much less expensive than
equipment for automatic welding.
An advantage of flux cored arc welding over the manual
welding processes is that a lower degree of welder skill is
needed. A welder skilled in gas metal arc welding would
have very little trouble learning the flux cored arc welding
process that generally has good welder appeal. This is
particularly true when compared to gas metal arc welding at the higher current levels. Another example is the
comparison to semiautomatic submerged arc welding
where it is more difficult to weld because the weld puddle
is not visible. Semiautomatic flux cored arc welding usually competes with shielded metal arc welding, gas metal
arc welding and submerged arc welding. Automatic flux
cored arc welding usually competes with automatic gas
metal arc welding and submerged arc welding. In flux
cored arc welding, the costs of materials will vary depending on the electrode and whether or not shielding
gas is required. The electric power cost will depend on
the machine and the welding parameters.
The cost of this process consists of four major items which
are the labor and overhead, electrodes, shielding gas and
electric power. The cost calculation methods used in this
chapter can be used to compare the cost of flux cored arc
welding to the other processes.
LABOR COST
The labor cost is usually the largest cost factor of a process. Labor and overhead costs are generally combined
in cost calculations, which is common practice in many
plants. The overhead normally includes items such as
taxes, services, facilities maintenance and depreciation

of the equipment. The hourly labor and overhead rates
will vary considerably, so the actual rates for each plant
should be used in the cost calculations.
There are several items that are used in labor cost calculations. One of the most important is the operator factor, which is the percentage of the total welding time that
the arc is in operation. Because this process is applied
semiautomatically and automatically, the operator factor can vary widely. Operator factors for semiautomatic
welding usually range from 25% to as high as 60%. When
compared to gas metal arc welding, operator factors are
usually slightly lower with flux cored arc welding because
more time is spent removing slag. Since flux cored arc
welding uses a continuously fed electrode wire, operator
factors are much higher than those obtained in shielded
metal arc welding, where much time is spent changing
electrodes. Operator factors for machine and automatic
welding can range up to as high as 80% or more, depending on the application. Another factor used in many
cost calculations is the deposition rate. This is the rate at
which the electrode wire is deposited in the weld joint.
The deposition rate and travel speed affect the labor and
overhead costs because the rate at which the electrode is
deposited and the speed of welding affect the productivity. The deposition rate and travel speeds used are determined by the size of the electrode, the welding current,
the base metal thickness and the position of welding.
The equation for determining the labor and overhead
cost is:
Labor + Overhead
Pounds of Weld
X
Cost/hr
Deposit/Weld
Labor Cost =
Deposition Rate X Operator Factor
Or...
Labor Cost =
Total Welding Time X Labor
Overhead
ELECTRODE COST
The cost of the electrode wire per weld is determined by
several factors. The first is the weight of the weld deposited, which is dependent on the size and shape of the weld
to be made. A second factor is the cost per pound of
electrode wire, which is dependent on the type and size
of the electrode wire. Some types of mild steel electrodes
are substantially less expensive than other types. Small
diameter flux cored electrodes cost more per pound than
larger diameter flux cored electrodes because of the additional wire drawing operations required. Electrode wire is
less expensive per pound when supplied in a reel or large
coil, as compared to a small coil. The total amount of wire
32
purchased also affects the cost. Large shipments of wire

will generally cost less per pound than small shipments.
In relation to covered electrodes and solid wire electrodes, flux cored electrodes tend to be more expensive.
This factor can usually be offset by the higher deposition
rates obtained from flux cored arc welding. A third factor
is the deposition efficiency of the electrode. The deposition efficiency is the actual percentage of the total weight
of the electrode wire purchased that is actually deposited
in the weld. The deposition efficiency of flux cored wire
is lower than that of solid wires because the flux core
provides shielding gas and a slag covering. Self-shielding
flux cored wires typically have a deposition efficiency of
about 75-80%, which is much higher than obtained from
covered electrodes. Gas-shielded electrode wires have
deposition efficiencies ranging from 80-90%. These are
higher than those obtained from self-shielding wires because less of the core becomes shielding gas and slag.
With both types of flux cored wires, some wire is lost to
spatter and vaporization. Spatter is generally higher with
self-shielding electrodes which also contributes to the
lower deposition efficiencies. The type of shielding gas
used will have an effect on the deposition efficiency. Carbon dioxide will produce higher spatter levels than argoncarbon dioxide and argon-oxygen mixtures.
The equations used for determining the cost of an electrode wire are:
Wire
Wire Weight
Electrode
Wire Cost
Arc
Cost = Time X Feed X Unit of Length X Per Pound
Rate
Or...
Electrode
Cost =
Weight of Deposit X Wire Cost Per Pound
SHIELDING GAS COST

The cost of the shielding gas depends on the flow rate,
arc time, and type of shielding gas. This factor is not included in a cost calculation for a self-shielding electrode.
Carbon dioxide is the least expensive and most commonly used shielding gas. Using an argon-carbon dioxide or argon-oxygen gas mixture will increase the costs
of welding.
The equation for determining the shielding gas cost is:
Shielding Gas Cost =
.045"
2375
1/16"
1230
5/64"
996
3/32"
640
7/64"
469
1/8"
346
3/32"
225
Cost of
Gas per
Cubic Ft.
The equation for electric power cost is:

Electric
Power Cost =
Inches of Wire
Per Pound
3704
Gas
Flow
The cost of the electric power is a relatively minor

cost factor, but it can become important when large
amounts of welding are required on an application. The
electric power cost is determined by the welding current,
welding voltage, power source efficiency and the cost
per kilowatt-hour. The power consumption of the power
source when idling will not be calculated because it is a
very small percentage of the total power consumption of
the power source. The power source efficiency will be
assumed for the calculations in this chapter.
For the first equation, the wire weight per unit of length
is needed. This figure will vary depending on the type of
electrode wire used. Some flux cored electrodes contain
more core elements than others. This is true of the selfshielding wires when compared to gas-shielded wires. A
good approximation of the percent fill or amount of flux
in a tubular wire for cost calculations is about 16% by
weight. This gives the inches of wire per pound as shown
.035"
ELECTRIC POWER COST
Deposition Efficiency
Wire
Diameter
Arc
Time
Illustration 6-1 Inches of Wire Per Pound of Wire
33
Welding
Welding
Current X Voltage
Power Source Efficiency
Arc
X Time X
Power Cost
per kW-hr
1000
SMAW
Manual
GMAW
Semiautomatic
E7024
E70S-3
E70T-4
E70T-1
EM 12K
Electrode Diameter
1/4"
1/16"
3/32"
3/32"
3/32"
Welding Current (amps)
380
350
375
475
550
Welding Voltage (volts)
33
25
28
29
33
Travel Speed (IPM)
11
18
12
15
12
Gas Flow (ft3/hr)
45
35
Total Welding Time (hr)
.0995
.0654
.0587
.0556
.0605
Arc Time (hr/ft)
.0348
.0327
.0264
.0250
.0272
270
215
200
120
30.00
30.00
30.00
30.00
30.00
35
50
45
45
45
Weight of Deposit (lbs)
.425
.425
.425
.425
.425
Electrode Cost ($/lb)
1.00
1.60
3.00
.3.00
1.60
67
93
80
90
100*
12.2
13.0
16.1
17.0
15.6
Gas Cost ($/ft3)
.13
.13
Gas Used ($/ft3)
.33
.33
Flux Cost ($/lb)
.50
Flux Used (lbs)
.53
Electric Power Cost ($/kW-hr)
.06
.06
.06
.06
.06
Power Source Efficiency (%)
50
80
80
80
80
Labor Cost ($/ft)
2.99
1.96
1.76
1.66
1.82
Filler Wire Cost ($/Ft)
.634
.731
1.594
1.417
.680
Flux Cost ($/Ft)
.265
Shielding Gas Cost ($/Ft)
.114
.114
Electric Power Cost ($/Ft)
.052
.022
.021
.025
.037
Total Cost ($/Ft)
3.676
2.827
3.375
3.216
2.802
Wire Feed Speed (in/min)

Labor + Overhead Costs ($/hr)
Operator Factor (%)
Deposition Efficiency (%)

Deposition Rate (lbs/hr)
FCAW
Semiautomatic
SAW
Semiautomatic
Illustration 6-2 Cost Comparison of SMAW, GMAW, FCAW and SAW

on a 1/2" (12.7 mm) Fillet Weld in the Horizontal Position
34
Examples
Illustration 6-2 shows the figures used for a cost calculation comparison of shielded metal arc welding, gas metal
arc welding, flux cored arc welding using a self-shielding
wire, flux cored arc welding using a gas-shielded wire and
submerged arc welding. The examples given are fairly
typical but the exact data should be obtained from the
manufacturers data sheets and the actual welding conditions.
In equations where arc time is necessary, it can be determined from the following equation:
Length of Weld X Number Passes
Arc Time =
Travel Speed
Weight of Deposit
Or...
Deposition Rate
The total welding time can then be determined by the

equation:
Arc Time
Total Welding Time =
Operator Factor
The following is a sample cost per foot of weld calculation for making a 1/2 in. (12.7 mm) fillet weld in the horizontal
position using semiautomatic flux cored arc welding with a gas-shielded electrode. Figures for calculation are taken
from Illustration 6-1 and 6-2.
Labor Cost =
Labor + Overhead
Cost/hr
Pounds of Weld
Deposit/Weld
Deposition Rate X Operator Factor

Wire
Wire Weight
Electrode
Wire Cost
Arc
Cost = Time X Feed X Unit of Length X Per Pound
Rate
Or,
Weight of Deposit X Wire Cost Per Pound
Electrode
Cost =
Shielding Gas Cost =
Electric
Power Cost =
Arc
Time
Welding
Welding
Current X Voltage
Power Source Efficiency
Gas
Flow
Arc
X Time X
Cost of
Gas per
Cubic Ft.
30 $/hr X .425 lbs/ft
= $1.66
17 lbs/hr X 45 %
.0250 hr/ft X 12000 in/hr X
(200 IPM x 60 min)
1 lb
X 3.00 $/lb
640 in.
= $1.417
.425 lbs/ft X 3.00 $/lb
90 %
.025 hr/ft X 35 ft3/hr X .13 $/ft3
Power Cost
per kW-hr =
1000
475 amps X 29 volts

80 %
.025
X hr/ft X
.06 $/kW-hr
1000
= $.114
= $.025
TOTAL WELD COST PER FOOT = $3.216
35
CHAPTER 7
WELDING METALLURGY
PROPERTIES OF THE WELD
MECHANICAL PROPERTIES
The properties of a weld include the chemical composition, mechanical strength, ductility, toughness, and the
microstructure. These items will relate to the weldability
of the metal. The weldability of a metal is the quality obtained and the ease of welding for the intended service
conditions. The chemical, physical and mechanical properties of the weld are affected by the types of materials used. The mechanical properties and microstructure
are determined by the heat input as well as the chemical
composition and physical properties of the weld.
The mechanical properties that are the most important in

the weld are the tensile strength, yield strength, elongation, reduction of area, and the impact strength. The first
two are measures of the strength of the material, the next
two are measures of the ductility of the material, and the
last is a measure of the toughness of the material. These
properties are often important in flux cored arc welding of
steels designed to give maximum strength, ductility, and
toughness. Flux cored arc welding can produce good
properties in the weld and heat affected zone. The slag
coating in flux cored arc welding slows the cooling rate
of the weld metal which reduces the tendency to become
brittle.
CHEMICAL COMPOSITION
The chemical composition of the base and filler metal
have a great influence on the weldability of a metal. This
property has an influence of the preheating and postheating used, as well as the welding parameters. For the
welding of stainless steels, the chemical composition of
the weld is often the most important property. The chemical composition of the weld must match the composition
of the base metal when corrosion resistance, thermal and
electrical conductivity, and appearance are major considerations. The chemical composition can also affect
the high and low temperature strength, as well as the microstructure and mechanical properties of the weld.
Preheating reduces the cooling rate of the weld after
welding to prevent cracking. The amount of preheat
needed depends on the type of metal being welded,
the metal thickness, and the amount of joint restraint. In
steels, those with higher carbon contents need higher
preheat than those with lower carbon equivalents. Illustration 7-1 shows typical preheat values for different metals welded by flux cored arc welding.
Another major factor that determines the amount of preheat needed is the thickness of the base metal. Thicker
base metals usually need higher preheat temperatures
than thinner base metals. Thick metal draws the heat
away from the welding zone quicker because there is a
large mass of metal to absorb the heat. This would cause
a quicker cooling of the weld if the same preheat temperature was used, as on thinner base metals. The third
major factor for determining the amount of preheat needed is the amount of joint restraint. Joint restraint is the resistance of a joint configuration to moving or relieving the
stresses due to welding during the heating and cooling of
the weld zone. Where there is high resistance to moving
or high joint restraint, large amounts of internal stresses
build up. Higher preheat temperatures are needed as the
amount of joint restraint increases. Slower cooling rates
reduce the amount of internal stresses that are building
up as the weld cools.
Flux cored arc welding produces a higher heat input

which will also tend to produce a slower cooling rate. A
disadvantage of the higher heat input is that distortion
is more of a problem than with gas metal arc welding.
The mechanical properties of the weld will vary depending on whether a self-shielded or gas-shielded flux cored
wire is used. Some self-shielded electrodes contain high
amounts of deoxidizers, which may produce weld metal
with relatively low impact toughness. Most of the gasshielded flux cored wires produce welds that have better
impact toughness.
The yield strength, ultimate tensile strength, elongation,
and reduction of area are all measured from a 505 in.
(12.8 mm) diameter machined tensile bar. The metal is
tested by pulling it in a tensile testing machine. Illustration 7-2 shows a tensile bar before and after testing.
The yield strength of the metal is the stress at which the
material is pulled beyond the point where it will return
to its original length. The ultimate tensile strength is the
maximum stress or load that can be carried by the material without breaking. Two points are marked on the
tensile bar before testing. After testing, the distance between the two points is measured again by putting the
two pieces of the tensile bar back together and measuring the change in the distance between them in percent.
Reduction of area is another method of measuring ductility. The original area of the cross section of the testing
bar is .20 sq. in. (128 sq. mm). During the testing, the
diameter of the bar reduces as it elongates. When the
bar finally breaks, the diameter of the bar at the breaking
point is measured, which is then used to determine the
area. The percent reduction of this cross sectional area is
called the reduction of area.
Impact tests are used to measure the toughness of a
metal. The toughness of a metal is the ability to absorb
mechanical energy by deforming before breaking. The
36
Type of Metal
Preheat
Medium Carbon Steel
400-500 F (205-260 C)
Low Carbon Steel
High Carbon Steel
Low Alloy Nickel Steel

Low Alloy Nickel Chrome Steel
Room Temperature or up to 200 F (93 C)

500-600 F (260-315 C)
Less than 1/4 (6.4 mm) thick
Room Temperature
More than 1/4 (6.4 mm) thick
500 F (260 C)
Carbon less than .20%
200-300 F (93-150 C)
Carbon .20%-.35%
600-800 F (315-425 C)
Carbon above .35%
900-1100 F (480-595 C)
Low Alloy Manganese Steel

Low Alloy Chrome Steel
Low Alloy Molybdenum Steel
400-500 F (205-260 C)
Up to 750 F (400 C)
Carbon less than .15%
Room Temperature
Carbon more than .15%
400-650 F (205-345 C)
Low Alloy High Tensile Steel
150-300 F (66-150 C)
Ferritic Stainless Steels
300-350 F (150-260 C)
Cast Irons
700-900 F (370-480 C)
Nickel
200-300 F (93-150 C)
Austenitic Stainless Steel
Room Temperature
Martensitic Stainless Steels
400-600 F (205-315 C)
Copper
500-800 F (260-425 C)
Aluminum
Room Temperature or up to 300 F (150 C)
Illustration 7-1 Preheats for Various Metals
Charpy V-notch test is the most commonly used method

of determining impact toughness. Illustration 7-3 shows
a typical Charpy V-notch bar.
These bars are usually 10 mm square and have a vshaped notch ground or machined in them. The bars are
then put into a machine where they are struck by a hammer attached to a pendulum. The energy that it takes to
break these bars is known as the impact strength and is
measured in foot-pounds (Joules).
MICROSTRUCTURE
There are three basic microstructural areas within a weldment. These are the weld metal, heat affected zone, and
the base metal. The weld metal is the area that was mol-
ten during welding. This is bounded by the fusion line

which is the maximum limit of melting. The heat affected
zone is the area where the heat from welding had an effect on the microstructure of the base metal. The limit
of visible heat affect is the outer limit of this area. The
base metal zone is the area that was not affected by the
welding. Illustration 7-4 shows a cross section of a weld
showing the different areas. The extent of change of the
microstructure is dependent on four factors:
1) The maximum temperature that the weld metal
reached.
2) The time that the weld spent at that temperature.
3) The chemical composition of the base metal.
4) The cooling rate of the weld.
Illustration 7-2 Tensile Strength Testing Bar
Illustration 7-3 Charpy V-Notch Bar
37
The weld metal zone, which is the area that is melted,

generally has the coarsest grain structure of the three areas. Usually a fairly fine grain size is produced on cooling
in most metals. Large grain size is undesirable because
it gives the weld poor toughness and poor cracking resistance. The solidification of the weld metal starts at
the edge of the weld puddle next to the base metal. The
grains that form at the edge, called dendrites, grow toward the molten center of the weld. Illustration 7-5 shows
the solidification pattern of a weld.
These dendrites give the weld metal its characteristic columnar grain structure. The grains that form in the weld
zone are similar to the grains that form in castings. Deoxidizers and scavengers are often added to filler metal
to help refine the grain size in the weld. The greater the
heat input to the weld and the longer that it is held at
high temperature, the larger the grain size. A faster cooling rate will produce a smaller grain size than a slower
cooling rate. Preheating will give larger grain sizes, but is
often necessary to prevent the formation of a hard, brittle
microstructure.
Illustration 7-4 Cross-Section of a Weld showing the

Different Zones and Lines in the Weld Area
Liquid
1. Crystal Formation
The heat affected zone is an area of change in the microstructure of the base metal. The area that is closest
to the weld metal usually undergoes grain growth. Other
parts of the heat affected zone will go through grain refinement. Other areas may be annealed and considerably
softened. Because of the changes due to the heat input
and cooling rate, areas of the heat affected zone can become embrittled and become the source of cracking. A
large heat input during welding will cause a larger heat
affected zone. This is often not desirable, so the welding
parameters used can help influence the size of the heat
affected zone.
Liquid
Steels
Flux cored arc welding is widely used for welding steels.
In general, steel is classified according to the carbon
content, such as low carbon, mild, medium carbon, and
high carbon steels. In addition, steel is also classified according to the alloys used. For the purpose of discussion
in this chapter, the different steels will be grouped according to their welding characteristics.
When welding steel, the carbon and other alloy content
influences the hardness and hardenability of the weld
metal which, in turn, influences the amount of preheat
Solid Grains
(Dendrites)
2. Solidification
Grains
3. Complete Solidification
Illustration 7-5 The Solidification Pattern

of the Weld Area
WELDABLE METALS
Flux cored arc welding is commonly used to weld most
steels and stainless steels. Some nickel alloys are also
welded by this process. Most nonferrous metals are not
welded by this process because of the high heat input
and because suitable electrode wires have not been developed.
Initial
Crystals
needed. The two terms, hardness and hardenability, are

not the same. The maximum hardness of a steel is primarily a function of the amount of carbon in the steel.
Hardenability is a measure of how easily a martensitic
structure is formed when the steel is quenched. Martensite is the phase or metallurgical structure in steel where
the maximum hardness of the steel can be obtained.
Steels with low hardenability must have very high cooling
rates after welding to form martensite, where steels with
high hardenabiIity will form martensite even when they
are slow cooled. The hardenability will determine to what
extent a steel will harden during welding. The carbon
equivalent formula is one of the best methods of determining the weldability of steels. This value is determined
by the amounts of the alloying elements use. There are
several different formulas used. One of the most popular
is as follows:
Carbon = %C + %Cr + %Mn + %Mo + %Ni + %Cu
Equivalent
10
6
10
20
40
38
Steels with lower carbon equivalents generally are more

readily weldable and require fewer precautions such
as the use of preheat and postheat. Steels with higher
carbon equivalents are generally more difficult to weld.
When welding some of the steels, it is more important to
match the mechanical properties than the chemical composition of the filler metal to the base metal. Often, filler
metal with a lower carbon content than the base metal is
used because the weld metal absorbs carbon from the
base metal. This is done to minimize the tendency for
weld cracking.
Low Carbon and Mild Steel
Low carbon and mild steels are those that have low carbon contents and are the most readily weldable. This
group of steels is the most widely used in industrial fabrication. This group also includes the high strength structural steels.
Low carbon steels have a carbon content up to .14%.
Mild steel has a carbon content ranging from .15 to
.29%. For many applications, preheating is not required
except on thick sections, highly restrained joints, or
where codes require preheating. Other precautions such
as interpass temperature control and postheating are
sometimes used. With thicker sections and highly restrained joints, preheating, interpass temperature control
and postheating are usually required to prevent cracking.
When welding these steels, electrodes of the E70-T class
are employed with carbon dioxide. Self-shielding wires
are also widely used. The filler metal should be chosen
so that it matches the tensile strength of the base metal.
When welding rimmed steels which have silicon contents less than .05%, filler metal with sufficient amounts
of deoxidizers must be chosen to prevent porosity. This
precaution is not necessary for welding steels containing
more than .05% silicon.
The high strength structural steels are steels whose yield
strength falls between 45,000 psi (310 MPa) and 70,000
psi (485 MPa) and their carbon content is generally below .25%. These steels have relatively small amounts
of alloying elements. Some common examples of these
steels are the ASTM designations of A242, A441 A572,
A588, A553 and A537.
Some low carbon and mild steel electrodes are designed
for welding over some rust and mill scale. The flux core
helps to reduce the bad effects of rust and mill scale but
some reduction in weld quality may occur. These flux
cored arc welding electrodes are preferred for many applications because cleaning of the base metal is less important. For applications where the maximum mechanical properties are not as important as higher deposition
rates and travel speeds, high welding currents can be
used.
Low Alloy Steels

The low alloy steels discussed here will be those steels
that are low carbon and have alloy additions less than
5%. This includes the quenched and tempered steels,
heat treated low alloy steels, and the low nickel alloy
steels. Elements such as nickel, chromium, manganese,
and molybdenum are the main alloying elements used.
These steels have a higher hardenability than mild steels
and it is this factor that is the principal complication in
welding. Low alloy steels have good weldability but are
not as easily weldable as the mild steels. This higher
hardenability permits martensite to form at lower cooling rates. As the alloy content and the carbon content
increases, the hardenability also increases. In general,
the weldability of the steel decreases as the hardenability
increases. One of the best methods for determining the
weldability of a low alloy steel is the use of the carbon
equivalent formula. Steels that have carbon equivalents
below about .40% usually do not require the use of preheating and postheating in the welding procedure and
generally have the best weldability. Steels with carbon
equivalents higher than .40% require more precautions
for welding. Generally, the higher the carbon equivalent,
the more difficult the steel is to weld.
The selection of electrodes for the welding of steels is
usually based on the strength and mechanical properties desired of the weld, rather than matching chemical
compositions. Low alloy steels are often welded using
the gas-shielded EXXT-1 and EXXT-5 electrodes. These
wires produce good, low temperature toughness and are
preferred for most applications. EXXT-4 and EXXT-8 selfshielded wires often contain nickel for good strength, and
aluminum as a deoxidizer to help give good mechanical
properties. In other cases, such as for the welding of low
nickel steels, the electrode wires are chosen to match the
chemical composition of the base metal.
The quenched and tempered heat treated steels have
yield strengths ranging from 50,000 psi (345 MPa) to very
high yield strengths and have carbon contents ranging
up to .25%. Some common examples of these types of
steel are the ASTM designations A533 Grade B, A514,
A517, A543 and A553. The 25% carbon limit is used to
provide fairly good weldability. These steels provide high
tensile and yield strength along with good ductility, notch
toughness, corrosion resistance, fatigue strength and
weldability. The presence of hydrogen is always bad in
steel, but it is even more critical in these types of steels
compared to mild steels. Preheat is generally not used
on thinner sections, but it is used on thicker or highly
restrained sections. Postweld heat treatment is usually
not used because the flux cored arc welds made in these
have a good toughness. The steels are generally used in
the welded or stress relieved conditions.
39
The nickel alloy steels included in these low alloy steel

groups are those with less than 5% nickel contents. The
2-1/4% and 3-1/2% nickel steels are usually welded with
electrodes that have the same general chemical compositions as the base metal. Preheating is required with
highly restrained joints. Most self-shielding wires for low
alloy steels have been developed for welding the low
nickel steels.
Heat Treatable Steels
The heat treatable steels are the medium and high carbon
steels and medium carbon steels that have been alloyed.
This group includes quenched and tempered steels after welding, normalized or annealed steels, and medium
and high carbon steels. These steels are more difficult to
weld than other types of steels already mentioned in this
chapter. The most important factor for selecting the type
of electrode to be used is matching the chemical compositions of the base metal and the filler metal.
Medium carbon steels are those that have carbon contents ranging from .30% to .59% and high carbon steels
have carbon contents ranging from .60% to about 1.0%.
When medium and high carbon steels are welded, precautions should be included in the welding procedure
because of the hardness that can occur in the weld joint.
As the carbon content increases up to .60%, the hardness of the fully hardened structure (or martensite) increases to a maximum value. When the carbon content is
above .60%, the hardness of the fully hardened structure
does not increase, so these steels can be welded using
about the same welding procedures as the medium carbon steels. Martensite, which is the phase that steel is in
at its fullest hardness, is harder and more brittle in high
carbon steel than it is in low carbon steel. A high carbon, martensitic structure can have a tendency to crack
in the weld metal and heat affected zone during cooling.
Welding procedures that lower the hardness of the heat
affected zone and the weld metal reduce the cracking
tendency. This can be done by using a procedure that
requires lower carbon content in the filler metal, and by
slowing the cooling rate. The procedure would include
preheat, interpass temperature control, and postheat.
The procedures used for welding medium carbon steels
can be simpler than the one just mentioned, but that depends on the specific applications.
Medium carbon steels can be welded with the E70T-E90T
classifications. High carbon steels should be welded with
the E80T-El20T using the electrode of the proper tensile
strength to match the tensile strength of the base metal.
Generally, very high carbon steels are not used in welded
production work. These steels are usually only welded in
repair work.
Mild steel electrodes may also be used, but the deposited
weld metal absorbs carbon from the base metal and thus
loses a considerable amount of ductility. Stainless steel
electrodes of the austenitic type are sometimes used, but

the fusion zone may still be hard and brittle. A preheat
and/or postheat will help reduce the brittle structure.
The quenched and tempered steels, after welding, have
carbon contents ranging from about .25% to .45%, which
distinguishes them from the steels that are quenched and
tempered before welding. These steels also have small
additions of alloying elements. Some common examples
of these steels are the AlSl designations 4130, 4140 and
4340. Because of the higher carbon contents, the steels
in this group can be heat treated to extremely high levels of strength and hardness. Some of these steels have
enough alloy content to give them high hardenability. Because of this combination of carbon and alloy content,
the steels must be preheated before welding. The weldability of these steels is also influenced by the purity of
the steels. High amounts of sulfur and phosphorous in
the steel increase the sensitivity to cracking and reduce
the ductility. Flux cored arc welding is often used for
welding these steels. Filler metal of the same chemical
composition as the base metal is required to obtain the
maximum strength. The composition of the weld metal is
usually similar to that of the base metal.
Chromium-Molybdenum Steels
The low chromium-molybdenum steels in this section
are those with alloy contents of about 6% or less. These
steels are in the low carbon range, generally up to .15%,
and are readily weldable. The chromium and molybdenum alloying elements provide these steels with good
oxidation resistance and high temperature strength. The
chromium is mainly responsible for the high oxidation resistance and the molybdenum is mainly responsible for
the high temperature strength.
The higher chrome-moly steels contain about 6-10%
chromium and .5-1% molybdenum. These steels are limited to a maximum carbon content of about .10% to limit
the hardness, because these steels are very sensitive to
air hardening. For the welding of these steels, preheating,
interpass temperature control, slow cooling, and postweld heat treatment are required to make a weld with
good mechanical properties. These steels generally do
not require preheating except when welding thick sections or highly restrained joints. Postheating is usually not
required on chromium molybdenum steels that contain
less than 2-1/4% Cr and 1% Mo.
Flux cored arc welding is one of the most common methods of welding the chromium-molybdenum steels. The
steels with less than 6% chromium are welded with a
carbon dioxide or argon-carbon dioxide mixture. For the
steels with 6% chromium or more, argon with small additions of carbon dioxide is often used. The filler metal is
chosen to match the chemical composition of the base
metal as closely as possible to give good corrosion resistance.
40
Free Machining Steels

Free machining steels are steels that have additions of
sulfur, phosphorous, selenium, or lead in them to make
these steels easier to machine. Except for the high sulfur,
lead, selenium, or phosphorous, these steels have chemical compositions similar to mild, low alloy, and stainless steels. The addition of these elements makes these
steels difficult to weld. The reason for this is that the elements, lead, phosphorous, selenium and sulfur, have
melting points that are much lower than the melting point
of the steel. As the weld solidifies, these elements retain
liquid much longer than the steel so that they coat the
grain boundaries, which cause hot cracking in the weld.
Hot cracking is cracking that occurs before the weld has
had a chance to cool. Because of this hot cracking problem, free machining steels cannot be welded easily. High
manganese filler metal and low base metal dilution will
help give the best results possible.
Stainless Steels
Most types of stainless steels can be welded by this process. The types that are very difficult to weld are types
such as 303, 416, 416 Se, 430 F, and 430 FSe, which
have high sulfur and selenium contents and Type 440,
which has a high carbon content. The major alloying element which distinguishes stainless steels from the other
types of steel is the chromium. Steels that have chromium contents greater than 11% are considered stainless steels. The high chromium content gives these very
good corrosion and oxidation resistance. The three major
groups of stainless steels that are welded are the austenitic, martensitic and ferritic types.
The austenitic types of stainless steels are generally the
easiest to weld. In addition to the high chromium content
of about 16-26%, these types have high nickel contents
ranging from 6-22%. These steels are designated by the
AISI as the 300 series. The 200 series, which have high
manganese contents to replace some of the nickel, are
also austenitic. Nickel and manganese are strong austenite formers and maintain an austenitic structure at
all temperatures. This structure gives these steels good
toughness and ductility but also makes them non-hardenable. A major problem when welding these types of
steels is carbide precipitation or sensitization, which
only occurs in the austenitic structure. This occurs when
the temperature of the steel is between approximately
1000-1600 F (540-870 C) and can greatly reduce the
resistance to corrosion. There are several methods for
preventing this problem:
1) A fast cooling rate after welding through this temperature range. This is a major reason why preheating is usually not used and why these steels require
a relatively low maximum interpass temperature on
multiple pass welds.
2) The use of extra low carbon base and filler metal

(.03% C max.). Examples are 304L and 316L.
3) The use of a stabilized base and filler metal alloy containing columbium, tantalum, or titanium. Examples
are 347 and 321.
4) The use of a solution heat treatment to resolve the
carbides after welding.
Martensitic stainless steels are not as easy to weld as
the austenitic stainless steels. These stainless steels
have approximately 11-18% chromium, which is the major alloying element, and are designated by the AlSl as
the 400 series. Some examples are 403, 410, 420, and
440. These types of stainless steels are heat treatable
because they generally contain higher carbon contents
and a martensitic structure. Stainless steels with higher
carbon contents are more susceptible to cracking and
some, such as Type 440, have carbon contents so high
that they are often considered unweldable. A stainless
steel with carbon content greater than .10% will often
need preheating. Preheating is usually done in the range
of from 400-600 F (205-315 C) to avoid cracking. For
steels containing carbon contents greater than .20%, a
postweld heat treatment such as annealing is often required to improve the toughness of the weld produced.
Ferritic stainless steels are also more difficult to weld than
austentic stainless steels because they produce welds
having lower toughness than the base metal. These stainless steels form a ferritic grain structure and are also designated by the AISI as the 400 series. Some examples are
Types 405, 430, 442, and 446. These types are generally
less corrosion resistant than austenitic stainless steel. To
avoid a brittle structure in the weld, preheating and postheating are often required. Typical preheat temperatures
range from 300-500 F (150-260 C). Annealing is often
used after heat treatment welding to increase the toughness of the weld.
The flux cored arc welding process can produce stainless steel weld deposits with a quality similar to those
produced by gas metal arc welding. Lower current levels
may be desirable for welding stainless steel compared to
welding mild steel because of the higher thermal expansion, lower thermal conductivity and lower melting point
of stainless steel. The lower thermal conductivity and
higher thermal expansion causes more distortion and
warpage for a given heat input. Carbon dioxide, argoncarbon dioxide, and argon-oxygen mixtures are used.
Carbon dioxide causes a loss of silicon and manganese
and an increase in carbon in the low carbon stainless
steels. The use of carbon dioxide or EXXT-1 electrodes
is restricted for welding many of the stainless steels, especially austenitic grades, because the corrosion resistance may be reduced, due to carbon added to the weld
by gas. When good corrosion resistance is required, argon-carbon dioxide or argon-oxygen mixtures are used.
The argon-oxygen mixtures containing 1 or 2% oxygen
are used to improve the arc stability and weld puddle
41
wetting, as well as to eliminate carbon pickup from the

shielding gas. When the self-shielding EXXXT-3 electrodes are used, there is greater pickup of nitrogen from
the atmosphere into the weld metal. Nitrogen is an austenite stabilizer and when excessive nitrogen is absorbed
by the weld, there is a greater chance for micro-cracking
to occur. The welding position and arc length have a large
influence on this problem. An excessive arc length will
usually cause excessive nitrogen pickup in the weld. For
this reason, procedures for out-of-position welding with
self-shielding wires should be carefully controlled to produce a sound weld deposit.
The filler metal used for welding stainless steel is generally chosen to match the chemical composition of the
base metal. In the 200 series austenitic stainless steels,
300 series austenitic filler metal is usually used, due to a

lack of availability of 200 series filler metal. This weld joint
will generally be weaker than the surrounding base metal.
300 series filler metal is used on 300 series base metal.
The Type 410 and 420 electrodes are the only martensitic
stainless steel types recognized by the AWS. This limitation is often the reason why austenitic stainless steel
filler metal is used for welding martensitic stainless steel.
Austenitic filler metal provides a weld with lower strength
but higher toughness and eliminates the need for preheating and postheating. For the welding of ferritic stainless steels, both ferritic and austenitic filler metal may
be used. Ferritic filler metal is used when higher strength
and annealing postheat are required. Austenitic filler metal is used when higher ductility is required. Illustration 7-6
shows filler metal selection for stainless steels.
Chemical Analyses of Stainless Steels (percent)
AISI
Number
Carbon
201
202
0.15 max.
0.15 max.
301
302
302B
303
303Se
304
304L
305
308
309
309S
310
310S
314
316
316L
317
321
347
348
0.15 max.
0.15 max.
0.15 max.
0.15 max.
0.15 max.
0.08 max.
0.03 max.
0.12 max.
0.08 max.
0.20 max.
0.08 max.
0.25 max.
0.08 max.
0.25 max.
0.08 max.
0.03 max.
0.08 max.
0.08 max.
0.08 max.
0.08 max.
403
410
414
416
416Se
420
431
440A
440B
440C
0.15 max.
0.15 max.
0.15 max.
0.15 max.
0.15 max.
Over 0.15
0.20 max.
0.60-0.85
0.75-0.95
0.95-1.2
405
430
430F
430Se
446
0.08 max.
0.12 max.
0.12 max.
0.12 max.
0.20 max.
501
502
Over 0.10
0.10 max.
Manganese
Silicon
Chromium
Chromium-Nickel-Magnesium-Austenitic-Nonhardenable
5.5-7.5
1.0
16.0-18.0
7.5-10.
1.0
17.0-19.0
Chromium-Austenitic-Nonhardenable
2.0
1.0
16.0-18.0
2.0
1.0
17.0-19.0
2.0
2.0-3.0
17.0-19.0
2.0
1.0
17.0-19.0
2.0
1.0
17.0-19.0
2.0
1.0
18.0-20.0
2.0
1.0
18.0-20.0
2.0
1.0
17.0-19.0
2.0
1.0
19.0-21.0
2.0
1.0
22.0-24.0
2.0
1.0
22.0-24.0
2.0
1.0
24.0-26.0
2.0
1.50
24.0-26.0
2.0
1.50
23.0-26.0
2.0
1.5-3.0
16.0-18.0
2.0
1.0
16.0-18.0
2.0
1.0
18.0-20.0
2.0
1.0
17.0-19.0
2.0
1.0
17.0-19.0
2.0
1.0
17.0-19.0
Chromium-Martensitic-Hardenable
1.0
.05
11.5-13.0
1.0
1.0
11.5-13.5
1.0
1.0
11.5-13.5
1.25
1.0
12.0-14.0
1.25
1.0
12.0-14.0
1.0
1.0
12.0-14.0
1.0
1.0
15.0-17.0
1.0
1.0
16.0-18.0
1.0
1.0
16.0-18.0
1.0
1.0
16.0-18.0
Chromium-Ferritic-Nonhardenable
1.0
1.0
11.5-14.5
1.0
1.0
14.0-18.0
1.25
1.0
14.0-18.0
1.25
1.0
14.0-18.0
1.50
1.0
23.0-27.0
Martensitic
1.0
1.0
4.0-6.0
1.0
1.0
4.0-6.0
Nickel
Other
Elements
3.5-5.5
4.0-6.0
N2 0.25 max.
N2 0.25 max.
6.0-8.0
8.0-10.0
8.0-10.0
8.0-10.0
8.0-10.0
8.0-10.0
8.0-10.0
10.0-13.0
10.0-12.0
12.0-15.0
12.0-15.0
19.0-22.0
19.0-22.0
19.0-22.0
10.0-14.0
10.0-14.0
11.0-15.0
9.0-12.0
9.0-13.0
9.0-13.0
S 0.15 min.
Se 0.15 min.
Mo 2.0-3.0
Mo 2.0-3.0
Mo 3.0-4.0
Ti 5xC min.
Cb + Ta 10xC min.
Ta 0.10 max.
1.25-2.5
1.25-2.5
S 0.15 min.
Se 0.15 min.
Mo 0.75 max.
Mo 0.75 max.
Mo 0.75 max.
Al 1.1-0.3
S 0.15 min
Se 0.15 min.
N 0.25 max.
Mo 0.40-0.65
Mo 0.40-0.65
Illustration 7-6 AISI Stainless Steel Classification System (Courtesy of the American Iron and Steel Institute)
42
CHAPTER 8
WELD AND JOINT DESIGN
2) Strength Required
3) Welding Position
4) Joint Accessibility
5) Metal Thickness
6) Type of Metal
The weld joint designs used in flux cored arc welding are
determined by the design of the weldment, metallurgical
considerations, and codes or specifications. Another factor to consider is the method of flux cored arc welding
to be used. A properly selected joint design should allow
the highest quality weld to be made at the lowest possible cost. A weld joint consists of a specific weld being
made in a specific joint. A joint is defined as the junction
of members that are to be, or have been, joined. Illustration 8-1 shows the five basic joint types.
The edge and joint preparation are important because

they affect both the quality and cost of welding. The cost
items to be considered are the amount of filler metal required, the method of joint preparation, the amount of
labor required and the quality level required. Joints that
are more difficult to weld will often have more repair work
necessary than those that are easier to weld. This can
lead to significant increases in cost, since repair welding sometimes requires more time and expense than the
original weld.
Each joint type may be joined by many different types of

welds, the most common of which are shown in Illustration 8-2.
The type of weld made is governed by the joint configuration. Each of the different types of welds has their own
specific advantages. The nomenclature used for the various parts of groove and fillet welds is given in Illustration
8-3.
All of the five basic joint types are applicable to flux cored
arc welding, although the butt and T-joints are the most
widely used. Lap joints have the advantage of not requiring much preparation other than squaring off the edges
and making sure the members are in close contact. Edge
joints
are widely used on thin metal. Corner
Lapjoints generalButt
Lap
ly use similarCorner
edge preparations
to those used on T-joints.
Corner
There are several factors that influence the joint design to

be used:
Butt
1) Process Method
B Butt
C Corner
Butt
Butt
E Edge
L Lap
Lap
Lap
Corner
Corner
Butt
Corner
TT
Lap
1
2
1
2
1
Edge
T-Joint
Edge
T-Joint
Illustration 8-1 There are only five basic joints. They can, however, be used in combinations.
13
12
3
3
4
13
8
12
14
14
12
Plug
T-Joint
Plug
Slot
Slot
Edge
T-Joint
T-Joint
2. Single-V-Groove
3. Single-Bevel-Groove
4. Double-V-Groove
5. Double-Bevel-Groove
Groove
Edge
Edge
1. Square-Groove
13
12
13
12
149
13
12
16
Gro
14
15
Plug
Plug
Slot
Slot
14 16
Plug
15
6. Single-U-Groove
13
12
Slot Groove
9. Double-J-Groove
Groove
Bead
Groove
Bead 10. Single Fillet
Arc Seam Arc Seam
12
2
5
13
14
13 7
12
10
15
12
16
13
14
6
4
14
16
10
3
15
8. Single-J-Groove
10
16
15
14
13
12
16
15
4
2
7. Double-U-Groove
13
15 12
14
11
14
Arc Seam
11. Double Fillet
Arc Seam
11
Bead
Bead
12. Single-FlareArc SeamV-Groove
10
12
16
11
15
12
15
5
7 4
14
16
Bead
13. Edge
Weld in a
Flanged Butt Joint
Edge
13
13
11
12
14. Bead
14
13
12
14
10
13
16
15. Plug
15. Arc-Spot
or Arc-Seam
15
Edge Fillet
16
15
Fillet
10
11
16
14
Illustration 8-2 Common Types of Welds (Many other variations of welds are possible)
15
14
Edge
Edge
6
10
15
6
Fillet
Fillet
15
16
10
16
43
7
15 11
16
16
10
10
Groove Weld
5
6
7
4 5
Fillet Weld
5
2
3
1 2 3
1 2 3
47
56
1. ACTUAL THROAT OF A FILLET WELD: The shortest

distance from the root of the fillet weld to its face.
2. LEG OF A FILLET WELD: The distance from the root
2. ROOT FACE (RF): Groove face adjacent to the root
of the joint to the toe of the fillet weld.
of the joint.
3. ROOT OF A WELD: The points at which the weld
3. GROOVE FACE: The surface of a member included
intersects the base metal and extends furthest into
in the groove.
the weld joint.
4. BEVEL ANGLE (A): the angle formed between the
4. TOE OF A WELD: The junction between the face of
prepared edge of a member and a plane perpendicuthe weld and the base metal.
lar to the surface of the member.
5. FACE OF WELD: The exposed surface of a weld on
5. GROOVE ANGLE (A): the total included angle of the
the side from which the welding was done.
groove between parts to be joined by a groove weld.
6. DEPTH OF FUSION: The distance that fusion ex6. SIZE OF WELD (S): the joint penetration (depth of
tends into the base metal or previous pass from the
bevel plus the root penetration when specified).
surface melted during welding.
7. SIZE OF WELD (S): Leg length of the fillet.
7. PLATE THICKNESS (T): Thickness of plate welded.
1. ROOT OPENING (RO): the separation between the
members to be joined at the root of the joint.
Illustration 8-3 Weld Nomenclature
Many of the joint designs used for flux cored arc welding are similar to those used in gas metal arc welding or
shielded metal arc welding. Flux cored arc welding has
some characteristics which may affect the joint design.
The joint should be designed so the welder has good access to the joint and is able to properly manipulate the
electrode. Joints must be located so that an adequate
distance between the joint and nozzle of the welding gun
is created. The proper distance will vary depending on
the type of flux cored electrode being used.
PROCESS METHOD
The joint design, as well as the welding procedure, will
vary depending on whether the welding is done using
gas-shielded or self-shielded electrodes. Both methods
of flux cored arc welding achieve deeper penetration
than shielded metal arc welding. This permits the use
of narrower grooves with smaller groove angles, larger
root faces and narrower root openings. Differences also
exist between the two flux cored arc welding methods
because of the deeper penetration that is produced by
the gas-shielded electrode wires. Illustration 8-4 shows a
comparison of a flat position, V-groove weld on a backing strip for each of the two methods.
The joint design for the self-shielding wire requires a larger root opening to allow better access to the root of the
joint. The joint design for the gas-shielded wire does not
need such a wide root opening because complete penetration is easier to obtain. This weld would be less expensive to make using the gas-shielded electrode because
less filler metal is required. This difference in joint design
usually only applies when a backing strip is employed.
For joints not requiring a backing strip, gas-shielded and
self-shielded wires use the same joint designs.
STRENGTH
The strength required of a weld joint is a major factor
governing weld joint design. Weld joints may be either
full or partial penetration, depending on the strength required of the joint. Full or complete penetrating welds are
those that have weld metal through the full cross section of the joint. Partial penetrating welds are those where
weld metal only extends partially through the joint thickness. Welds that are subject to cyclic, impact, or static
loading require complete penetration. This is even more
important for applications that require low temperature
service. Partial penetration welds may be adequate for
joints where loading is static only. This type of joint is
easier to prepare and requires less filler metal than full
penetration joints. Fillet welds of the same leg size made
by this process are stronger than those made by shielded
metal arc welding. This is because of the deeper penetration obtained from flux cored arc welding, as shown
44
30
30
3/16
3/8
Gas-Shielded Electrode
Self-Shielded Electrode
Illustration 8-4 Comparison between Gas-Shielded and Self-Shielded Wire Joint Designs for the Flat Position
in Illustration 8-5. For some applications, the size of the

weld can be reduced which decreases the amount of
filler metal required. This can reduce the total cost also.
The amount of penetration obtained will be affected by
the root opening and root face used. A root opening is
used to allow good access to the root of the joint and is
usually used in full penetrating weld joints. A root opening is usually not used in partial penetration weld joints
because access to the root is not necessary and parts
are easier to fit together without a root opening. The size
of the root face is also affected. A larger root face is used
for partial penetration welds than for complete penetration welds because less penetration is required. Because
of the deep penetrating characteristics of flux cored arc
welding process, larger root faces are used for this process compared to shielded metal arc welding and gas
metal arc welding using short circuiting metal transfer.
This is to prevent burning through the back of the joint
being welded, which can be a problem in flux cored arc
welding because of the high welding currents used. When
compared to shielded metal arc welding, smaller groove
SMAW
Effective
Throat
FCAW
Effective
Throat
Illustration 8-5 Comparison between the penetrating

Characteristics of SMAW and FCAW
angles are used because the flux cored wire is smaller

than a covered electrode and operates with a higher current density. Because of the smaller electrode, access to
the root of the joint is better.
POSITION
Flux cored arc welding may be used in all welding positions based on the size and type of electrode wire used.
A diagram of the welding position capabilities is shown
Welding positions are classified by a set of numbers and
letters. The four basic welding positions are designated
by the numbers 1 for flat, 2 for horizontal, 3 for vertical
and 4 for overhead. A G designation indicates a groove
weld and an F designation indicates a fillet weld. The 2G,
5G and 6G positions are used in pipe welding. The large
diameter wires which are over 1/16 in. (1.6 mm) in diameter are limited to the flat and horizontal positions only
because the weld puddle becomes too large to control.
The smaller diameter electrodes, which are 1/16 in. (1.6
mm) and less can generally be used easily in all positions.
The joint configuration will vary depending on the position of welding. One example of this is that wider groove
angles are needed for vertical position welding. This is
done to provide enough room to manipulate the electrode wire in the joint. Weaving of the electrode is usually
required in vertical position welding to prevent excessive
reinforcement or dropping the weld metal out of the puddle. Joint designs for overhead welding are generally the
same as for flat position welding. Joints that are welded
in the horizontal position often have an unsymmetrical
joint configuration. This usually consists of a groove angle that has a horizontal lower groove face as shown in
Illustration 8-7. The upper groove face is raised accordingly to provide a groove angle that is large enough to
provide good access. The horizontal lower groove face
is used as a shelf to support the molten weld metal. This
joint configuration is less expensive to prepare because
the bevel is only made in one plate.
45
Fillet Welds
FLAT POSITION
1F
HORIZONTAL POSITION
2F
VERTICAL POSITION
3F
OVERHEAD POSITION
4F
Axis of Weld
Horizontal
Axis of Weld
Horizontal
Axis of Weld
Vertical
Axis of Weld
Horizontal
Groove Welds
FLAT POSITION
1G
HORIZONTAL POSITION
2G
VERTICAL POSITION
3G
OVERHEAD POSITION
4G
Plates, Axis of Weld

Horizontal
Plates vertical, Axis

of Weld Horizontal
Plates vertical, Axis of

Weld Vertical
Plates Overhead, Axis

of Weld Horizontal
FLAT
1G
HORIZONTAL
2G
HORIZONTAL FIXED
5G
45 FIXED
6G
Bell Hole
Arkansas Bell Hole
45 5
Pipe shall be turned or

rolled while welding axis of
pipe horizontal
Axis of Pipe Vertical
Pipe shall not be turned or

rolled while welding axis of
pipe horizontal
Illustration 8-6 Welding Test Positions
46
Pipe stationary with axis

approximately 45
THICKNESS
The thickness of the base metal has a large influence on
the joint preparation required to produce the best quality weld joint. Flux cored arc welding is used to weld
thicknesses down to 18 gauge (1.2 mm). The process is
also suitable for welding thick metal. Because of this, a
wide variety of joint designs are used. The most common
groove preparations used on butt joints are the squareV, J, U-bevel, and combination-grooves. The square-J,
bevel, and combination-groove preparations are also
used on T-joints. The different preparations are employed
on different thicknesses to make it possible to get complete or adequate penetration.
Square-groove welds are used on the thinnest metal
thicknesses. The square-groove joint design is the easiest to prepare and requires the least filler metal. Thicknesses up to 3/8 in. (9.5 mm) thick can be welded with
full penetration from both sides. This is thicker than the
square-groove joints that can be welded with full penetration by shielded metal arc welding or gas tungsten arc
welding, because of the hotter arc and deeper penetration produced by this process. Root openings are used
to allow complete penetration through the joint. Many
square-groove welds are made in one pass. A backing
strip may be used so that the root can be opened enough
to provide better accessibility and insure adequate penetration.
V-grooves for butt joints and bevel-grooves for T-joints
are commonly used for thicker metal up to about 3/4 in.
(19.1 mm). These joints are more difficult to prepare and
require more filler metal than square groove welds. The
included angle for a V-groove is usually up to 75 with
smaller groove angles such as 45 or 60 being more
1/8
45
3/32
3/8
Illustration 8-7 V-Groove Joint in the Horizontal Position
commonly employed. The smaller groove angles become

even more economical as the thickness of the metal increases. The wider groove angles are used to provide
better accessibility to the root of the joint. Because of the
deeper penetrating characteristics of this process, single
V-groove or single-bevel-groove welds are often welded with little or no root opening. Larger root faces and
smaller groove angles are often used compared to those
employed for shielded metal arc welding and gas tungsten arc welding. This helps to minimize the amount of
distortion and reduce the amount of filler metal required.
For complete penetration welds, root faces usually are
close to 1/8 in. (3.2 mm).
U- and J-grooves are generally used on thicknesses
greater than 5/8 in. (14.3 mm). These joint preparations
are the most difficult and expensive to prepare but the
radius at the root of the joint allows better access to
the root of the joint. Another advantage is that smaller
groove angles may be used compared to those used in
V-grooves. On thicker metal, this reduces the amount of
filler metal required and on very thick metals, the savings
become very substantial.
ACCESSIBILITY
The accessibility of the weld joint is another important
factor in determining the weld joint design. Welds can
be made from one or both sides of the weld joint. Single-V, J, U, bevel, and combination grooves are used
when accessibility is from one side only and on thinner
metal. Double-V, J, U, bevel, and combination grooves
are used on thicker metal where the joint can be welded
from both sides. Double-groove welds have three major
advantages over single-groove welds where accessibility
is only from one side. The first is that distortion is more
easily controlled through alternate weld bead sequencing. Weld beads are alternated from one side to the other
to keep the distortion from building up in the one direction. The weld roots are nearer the center of the plate. A
second advantage is that less filler metal is required to
fill a double groove joint than a single-groove joint. This
tends to make double-groove welds more economical on
metal 1 in. (25 mm) thick or greater. The third advantage
is that complete penetration can be more easily insured.
The root of the first pass on the plate can be gouged
or chipped out before the root pass on the second side
is welded, to make sure there is complete fusion at the
root. The disadvantages of joints welded from both sides
are that more joint preparation is required and gouging or
chipping is usually required to remove the root of the first
pass. Savings in the amount of filler metal needed for a
double-groove weld may more than compensate for the
extra joint preparation costs. Both of these add to the
labor time required. Welding on both sides of a squaregroove weld joint provides fuller penetration in thicker
metal than metal welded from one side only. This would
also save joint preparation time.
47
Backing Strips
TYPE OF METAL
When backing strips are used, joints are accessible from

one side only. Backing strips allow better access to the
root of the joint and support the molten weld metal.
These strips are available in two forms, which are fusible or nonfusible. Fusible backing strips are made of the
metal being welded and remain part of the weldment after
welding. These may be cut or machined off. Non-fusible
backing strips are made of copper, carbon, flux or ceramic backing in tape or composite form. These forms of
backing do not become part of the weld. Backing strips
on square-groove joints make a full penetration weld from
one side easier. For this application, using a backing strip
is more expensive because of the cost of a backing strip
and the larger amount of filler metal required. This is not
always the case. On V-groove joints, the backing strip
allows wider root openings and removes the need for a
root face, which reduces the groove preparation costs.
The flux cored arc welding process is used to weld steels,

some stainless steels and some nickels. The influence of
the type of metal on the joint design is based primarily
on the physical properties of the metal to be welded and
whether or not the metal has an oxide coating. For example, stainless steels have a lower thermal conductivity
than carbon steels. This causes the heat from welding
to remain in the weld zone longer, which enables slightly
greater thicknesses of stainless steel to be welded using
a square groove joint design. Stainless steels also have
an oxide coating which tends to reduce the depth of fusion of the weld. Consequently, stainless steels normally
employ larger groove angles and root openings than carbon steels. This allows the welder to direct the arc on the
base metal surfaces to obtain complete fusion.
The weld joint designs shown in the rest of this chapter

are those typically used for flux cored arc welding. All of
60
the partial penetration weld joint designs covered may
be welded using either the self-shielded or gas-shielded electrode wires. The joint dimensions will vary for full
penetration welds using backing strips, depending on
which method of flux cored arc welding is being used.
The joint designs that should be used only by the gasshielded method are indicated on these
joints. All other
0-1/8
full penetration welds may be made by either of the two
methods.
30
3/8
WELD JOINT DESIGNS
Backing Strip
Ranges are given on many of the joint dimensions to account for varying fit-up and types of electrode wires. The
thickness ranges given are those typically recommended
for use with the joint designs. Minimum weld sizes are
commonly used for partial penetration welds. Recommended minimum weld sizes are given in Illustration 8-9.
60
0-1/8
Illustration 8-8 Single-V-Groove Joints with and without
Backing Strip in the Same Thickness of Metal
Another advantage is that because the root may be

opened up, the groove angle may be reduced, which will
reduce the amount of filler metal required in thicker metal.
These effects are shown in Illustration 8-8 where single Vgroove joints are shown with and without a backing strip.
As discussed earlier in this chapter, the use of a backing
strip will have an effect on the joint designs used for gasshielded and self-shielded electrodes. The deeper penetrating characteristics of the gas-shielded electrode allow
the joint designs to be adjusted to take advantage of this.
Base Metal Thickness

of Thicker Part Joined
Minimum
Weld Size
To 1/4" (6.5mm) inclusive
1/8" (3mm)
Over 1/4" to 1/2" (6.4-12.7m) inclusive
3/16" (5mm)
Over 1/2" to 3/4" (12.7-19.0mm) inclusive
1/4" (6mm)
Over 3/4" to 1-1/2" (19.0-38.1mm) inclusive
5/16 (8mm)
Over 1-1/2" to 2-1/4" (38.1-57.1mm) inclusive
3/8" (10mm)
Over 2-1/4" to 6" (57.1-152mm) inclusive
1/2" (13mm)
Over 6" (152mm) inclusive
5/8" (16mm)
48
Illustration 8-9 Minimum Weld Sizes for

Partial Joint Penetration Groove Welds
Basic Welding Symbols and their

Location Significance
Type of Weld
Arrow
Side
Other
Side
Both
Sides
Fillet
No Arrow
Side or
Other Side
Significance
not used
Slot
not used
not used
Plug
not used
not used
Spot or Projection
not used
Stud
not used
not used
Seam
not used
Back or Backing
not used
Surfacing
not used
not used
Edge
not used
not used
not used
Flare-V
not used
Flare Bevel
not used
E
W
E
L
D
Scarf for
Brazed Joint
Arrow Side
of Joint
Other Side
of Joint
Arrow of
Welding
Symbol
T-Joint
Other Side
Member of Joint
Lap Joint
Arrow Side
of Joint
Arrow of
Welding
Symbol
Field
Weld
Consumable
Insert
S or D(S)
Backing
Spacer
Convex
Concave
Process abbreviations
Where process abbreviations are to be included in the
tail of the welding symbol, reference is made to table
1, Designation of Welding and Allied Processes by
Letters of AWS A2.4:2012
American Welding Society
550 N.W. LeJeune Road, Miami, Florida 33126
Illustration 8-10 Welding Symbols
49
Arrow Side
of Joint
Edge Joint
Location of Elements of a Welding Symbol
not used
Meltthru
Arrow of
Welding
Symbol
Other Side of Joint
Contour
Flush or
Flat
Arrow Side
of Joint
Other Side
of Joint
Supplementary Symbols
Weld
Around
Butt Joint
not used
Bevel
Arrow of
Welding
Symbol
not used
not used
not used
Arrow Side
of Joint
Corner Joint
not used
not used
Arrow of
Welding
Symbol
Other Side
of Joint
Square
Basic Joints Identification

of Arrow Side
and Other Side Joint
Illustration 8-10 Welding Symbols (continued)
50
Application of Arrow and Other Side Convention

(A) Arrow side V-groove weld symbol
Weld Cross Section
Symbol
(B) Other side V-groove weld symbol
Symbol
Weld Cross Section
(C) Both sides V-groove weld symbol
Weld Cross Section
Symbol
Illustration 8-11 Weld Joint Designs
51
Application of Break in Arrow of Welding Symbol

(A) Arrow side
Weld Cross Section
Symbol
(B) Other side
Weld Cross Section
Symbol
(C) Both sides
Weld Cross Section
Symbol
Illustration 8-11 Weld Joint Designs (continued)
52
Combinations of Weld Symbols

(A) Back or backing, single J-groove and fillet weld symbols
Weld Cross Section
Symbol
(B) Double-bevel-groove and fillet weld symbols
Symbol
Weld Cross Section
(C) Single-bevel-groove and double fillet weld symbols
Weld Cross Section
Symbol
(D) Double-square-groove and double fillet weld symbols
Weld Cross Section
Symbol
53
Specification of Location and Extent of Fillet Welds

(A) Combined intermittent and continuous welds (one side of joint)
Welds
Symbols
(B) Combined intermittent and continuous welds (both sides of joint)
Welds
Symbols
(C) Welds definitely located
Welds
Symbols
(D) Welds approximately located
Welds
Symbols
54
Specification of Extent of Welding

(A) Welds with abrupt changes in direction
Welds
Symbols
Welds
Symbols
Welds
Symbols
55

(B) Application of weld-all-around symbol
Symbol
Welds
Symbol
Welds
Welds
Symbol
56

(C) Weld in several planes
Welds
Symbol
(D) Weld around a shaft
Welds
Symbol
(E) Seal weld
Symbol
Welds
57
Applications of Typical Weld Symbols

(A) Square-groove weld
Weld Cross Section
Symbol
(B) Single-bevel-groove weld
Weld Cross Section
Symbol
(C) Single-V-groove weld
Weld Cross Section
Symbol
(D) Edge weld
Weld Cross Section
Symbol
(B) Corner-flange weld
Weld Cross Section
Symbol
Joint Detailed
58
Symbol
Joint Not Detailed
CHAPTER 9
WELDING PROCEDURE VARIABLES
Welding variables are those factors which affect the operation of the arc and the formation of the weld deposit. A
smooth running arc and a quality weld deposit will result
when all of the variables are in proper balance. It is essential that the effect of each variable on the different properties or characteristics of the weld be fully understood
to increase the probability of producing the required
weld properties. It should also be recognized that some
welding variables are more easily applied as controls of
a welding process. Based on their ability to be used as
controls, welding variables can be divided into three distinct groups or classes. These are the preselected or fixed
variables, primary adjustable variables, and secondary
adjustable variables.
The preselected or fixed variables are those which can
only be changed in large steps or intervals and are therefore unfavorable as controls. For the flux cored arc welding process, these variables are set according to the type
of material being welded, the thickness of the material,
welding position, deposition rate required, and mechanical properties required. These are variables that cannot
be changed once the welding starts.
The primary adjustable variables are used to control the
welding process after the preselected variables have
been established. They control the formation of the weld
bead itself by affecting such things as penetration, bead
width, bead height, arc stability, deposition rate, and weld
soundness. The primary welding variables are welding
voltage, welding current, and travel speed. Because they
can be easily measured and continually adjusted over
a wide range, they can effectively be used as controls.
Specific values can be assigned to the primary adjustable
variables and these values can be accurately reset time
after time.
The secondary adjustable variables can also be changed
continuously over a wide range of values. However, they
are sometimes difficult to measure accurately. Therefore,
it is not easy to employ them as controls since, for the
most part, they cannot be assigned exact values. This
is especially true in semiautomatic welding operations.
Although difficult to measure, these variables should be
controlled within the range for proper operation. Secondary adjustable variables are such things as electrode extension or stick-out, work and travel angles.
The different variables affect the characteristics of the
weld such as the penetration of the weld, bead height,
bead width, and the deposition rate. The definitions of
bead height, bead width, and penetration are shown in
Illustration 9-1.
Bead Width
Bead Height
Penetration
Illustration 9-1 Bead Height, Width and Penetration
The penetration of the weld is defined as the greatest

depth, below the surface of the base metal or previous
weld bead that the weld metal reaches. The bead height
is the height of the weld metal above the surface of the
base metal. The bead width is the width of the weld bead.
The deposition rate is the weight of metal that is deposited per unit of time.
The welding variables are discussed in this chapter with
particular attention to the penetration, bead shape, deposition rate, and how they each affect the other welding
variables. Illustration 9-2 is a chart showing the effects of
welding variables on the three major characteristics.
FIXED VARIABLES
Electrode Type
The type of electrode wire will have an effect on the welding characteristics of this process. The flux core of the
electrodes contains different components that affect
bead shape, penetration, deposition rate, and the operating characteristics. Because of this, a wide variety of
operating characteristics exist which are similar to those
found with the various covered electrodes used in shielded metal arc welding. Some self-shielded flux cored
electrodes have been developed to operate on DCEN.
These electrodes produce relatively light penetration and
are used for many sheet welding and weld surfacing operations. Self-shielded electrodes that operate on DCEP
produce deeper penetration. Gas-shielded electrode
wires operate on DCEP and provide the deepest penetration of the different types because of the gas shielding in
addition to the flux core.
Many electrodes are designed to produce a stable arc
and high deposition rates at the higher current levels. Illustrations 9-3 and 9-4 show some deposition rate comparisons between several types of flux cored electrodes.
59
WELDING VARIABLE / CHANGE REQUIRED

Arc
Voltage
Desired
Characteristic
Welding
Current
Travel
Speed
Nozzle
Angle
Tip-to-Work
Distance
Wire
Size
Gas
Type
Deeper penetration
1. Increase
3. Trailing
Max. 25
2. Decrease
5. Smallera)
4. CO2
Shallower Penetration
1. Decrease
3. Leading
2. Increase
5. Largera)
4. Ar+CO2c)
Bead
Height
and
Width
Larger Bead
1. Increase
2. Decrease
3. Increasea)
Smaller Bead
1. Decrease
2. Increase
3. Decreasea)
Higher, Narrower
1. Decrease
2. Trailing
3. Increase
Flatter, Wider
1. Increase
2. 90 or
Leading
3. Decrease
Faster Deposition Rate
1. Increase
2. Increasea)
Slower Deposition Rate
1. Decrease
2. Decreasea) 3. Largerb)
3. Smallerb)
Key: 1. first choice, 2. second choice, 3. third choice, 4. fourth choice, and 5. fifth choice.
a) When these variables are changed, the wire feed speed must be adjusted so that the welding current remains constant.
b) See deposition rate section of welding variables section.
c) This change is especially helpful on materials 20 gauge and smaller thickness.
Illustration 9-2 Recommended Welding Variable Adjustments for Flux Cored Arc Welding
35
35
14
3/32" (2.4)
25
20
8
.045" (1.1)
1/8" (3.2)
10
6
4
12
10
20
8
15
10
1/16" (1.6)
5
14
6
5/64" (2.0)
E70T-8 DCEN
3/32" (2.4)
E70T-8 DCEN
4
2
0

0 100 200 300 400 500 600 700
Welding Current (Amperes)
0

0 100 200 300 400 500 600 700
Illustration 9-3 Deposition Rate Versus Current

for Externally Shielded Tubular Electrode Wires
Illustration 9-4 Deposition Rate Versus Current

for Self-Shielded Tubular Electrode Wires
60
Deposition Rate (kg/hr)
10
15
.120" (3.0)
E70T-4
12
Deposition Rate (lb/hr)
25
30
Deposition Rate (lb/hr)
30
3/32" (2.4)
E70T-4
Electrode Size
Each electrode wire diameter of a given type has a usable
welding current range. Larger diameter electrode wires
use higher welding currents to produce higher deposition rates and deeper penetration. The rate at which the
electrode melts is based on the welding current density
and the components in the flux. If two electrode wires
of the same type, but different diameters, are operated
at the same current level, the smaller electrode will give
a higher deposition rate because the current density is
higher. Illustrations 9-3 and 9-4 also show the deposition rates produced by different electrode diameters. The
amount of penetration is also based on the current density. A smaller electrode will produce deeper penetration
than a larger electrode at the same current setting. The
weld bead will be wider when using the larger electrode
wire. The choice of the optimum electrode size to be
used is based on the thickness of the metal to be welded,
the amount of penetration required, the position of welding, the deposition rate desired, the bead profile desired,
and the cost of the electrode wires. A smaller diameter
electrode is more costly on a weight basis although, for
out-of-position welding, the smaller diameter electrodes
are the only ones that can be used. For each application,
there is an optimum electrode size that can be used to
produce minimum welding costs.
PRIMARY VARIABLES
Welding Current
The amount of welding current has the greatest effect on
the deposition rate, weld bead size and shape, and the
weld penetration. Welding current is proportional to the
wire feed speed for a given electrode type, shielding gas
type and pressure and amount of electrode extension. In
a constant voltage system, the welding current is controlled by the knob on the wire feeder control, which sets
the wire feed speed. The welding current increases with
the wire feed speed.
Insufficient welding current produces large globular

transfer and excessive spatter in addition to poor penetration and excessive piling up of the weld metal. With
self-shielding electrodes, insufficient current can cause
porosity and the pickup of two much nitrogen from the
atmosphere. The nitrogen causes a harder weld that
has poorer ductility. Illustrations 9-6, 9-7, and 9-8 show
the effects of welding current on the penetration, bead
height, and bead width.
Welding Voltage (Arc Length)
The welding voltage is determined by the distance between the tip of the electrode and the work. In a constant
voltage system, the welding voltage is adjusted by a voltage control knob on the front of the power source. The
power source maintains a given voltage which maintains
a certain arc length. In a constant current system, the
voltage is controlled by the voltage sensing wire feeder.
The voltage sensing wire feeder regulates the wire feed
speed to maintain the arc length that produces the preselected arc voltage. For a given welding current, there is
a certain voltage that will provide the smoothest welding
arc. The arc voltage required for an application is dependent on the electrode size, type of shielding gas, position
of welding, type of joint, and base metal thickness.
When the other welding variables are held constant and
the welding voltage is increased, the weld bead becomes
wider and flatter. The effect of varying the arc voltage on
a gas-shielded electrode is shown in Illustration 9-9.
The penetration will increase up to an optimum voltage
level and then begin to decrease as shown in Illustration
9-6. A higher voltage is often used to bridge a gap be-
As shown in Illustrations 9-3 and 9-4, the deposition rate

of the process increases as the welding current increases. The lower part of the curve is flatter than the upper
part because at higher current levels, the melting rate of
the electrode increases at a faster rate as the current increases. This can be attributed to resistance heating of
the electrode extension beyond the contact tube. When
all of the other variables are held constant, increasing
the welding current will increase the electrode deposition
rate, increase penetration, and increase the size of the
weld bead. Illustration 9-5 shows the effect of welding
current.
An excessive welding current level will create a large,
deep penetrating weld bead which causes excessive
convexity and can burn through the bottom of the joint.
61
Proper
Current
Current
Too Low
Current
Too High
Illustration 9-5 Effect of Welding Current

on Bead Appearance and Bead Formation
TRAVEL SPEED in/min
(91)
30
(76)
24
(61)
18
(46)
12
6
(30)
Penetration
(15)
(0)
34
32
ARC VOLTS
An arc voltage that is too low will cause a narrow convex weld bead with excessive spatter and reduced penetration. Illustrations 9-7 and 9-8 show the effects of the
welding voltage on bead height and bead width.
36
(cm/min)
cause of the decreased penetration obtained. An excessive voltage or arc length will result in excessive amounts
of spatter and irregularly shaped weld beads. When using self-shielded electrodes, an excessive arc length can
also cause nitrogen pickup, which causes porosity in low
carbon steel weld metal. With the self-shielded stainless
steel electrodes nitrogen absorption can cause cracking. With all types of electrodes, undercutting can also
be produced. A decrease in the arc length results in a
narrower weld bead with a greater convexity and deeper
penetration.
30
28
26
24
Travel Speed
The travel speed influences the weld penetration and
the shape of the weld deposit. In semiautomatic welding, this is controlled by the welder and will vary somewhat depending on the welder. In machine and automatic
welding, as shown in Illustration 9-6, the penetration is
at a maximum with a certain travel speed. Increasing or
decreasing the travel speed from this point will reduce
the amount of penetration. When the travel speed is decreased, the amount of filler metal deposited per unit of
length increases, which creates a large, shallow weld
puddle. Weld metal tends to get slightly ahead of the arc
which reduces the penetration and produces a wide weld
bead. Reducing the travel speed will increase the bead
height as is shown in Illustration 9-7. Travel speeds that
are too slow can result in overheating the weld metal because of the excessive heat input, which creates a very
large heat affected zone. It can also cause excessive piling up of the weld metal, which has a rough appearance
and may trap slag. As the travel speed is increased, the
heat input into the base metal is reduced, which decreases the melting of the base metal and limits penetration.
The bead height and the bead width are also reduced.
An excessive travel speed will result in an irregular, ropy
weld bead that may have undercutting along the edges.
The effect of varying the travel speed on a self-shielded
electrode is shown in Illustration 9-10.
WELDING CURRENT AMPS
22
370
330
290
250
210
170
130
INCREASING PENETRATION
Illustration 9-6 Effect of Travel Speed, Arc Volts, and

Welding Current on Penetration
The effects of the primary welding variables are summarized in Illustration 9-11 for gas-shielded flux cored electrodes and in Illustration 9-12 for self-shielded flux cored
electrodes.
Proper
Voltage
Voltage
Too Low
Voltage
Too High
Illustration 9-9 Effect of Welding Voltage

62
(71)
24
(61)
20
(51)
16
(41)
12
(30)
(20)
TRAVEL SPEED in/min
TRAVEL SPEED in/min
28
31
(79)
29
(74)
23
(58)
19
(48)
15
(38)
11
(28)
(18)
(cm/min)
(81)
(cm/min)
32
34
34
ARC VOLTS
36
31
28
25
32
30
28
22
26
19
24
ARC VOLTS
Bead Height
37
600
600
550
550
500
500
450
450
400
400
350
350
300
Bead Width
INCREASING BEAD HEIGHT
300

Welding Current on Bead Height
Proper
Speed
Too
Fast
INCREASING BEAD WIDTH

Welding Current on Bead Width
Too
Slow
Illustration 9-10 Effect of Travel Speed

63
GOOD
Proper Current
Voltage & Speed
BAD
Welding Current
Too Low
(High Voltage)
BAD
Welding Current
Too High
(Low Voltage)
BAD
Welding Speed
Too Fast
BAD
Welding Speed
Too Slow
BAD
Insufficient
Shielding Gas
Coverage
Cross-section Fillet
Cross-section Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
A smooth, regular,
well formed bead.
Excessive spatter
and porosity.
Excessive spatter
and porosity
Weld bead
excessively wide
and flat.
Bead too small,

with contour
irregular.
Excessive bead
width.
No undercutting,
overlapping or
pileup.
Weld bead
excessively convex
and narrow.
Difficult slag
removal.
Overlapping without
penetration at edges.
Bead very irregular

with poor
penetration.
Uniform in cross
section.
Undercutting along
edges weakens joint.
Not enough weld

metal in cross
section.
Excellent weld at
minimal material and
labor cost.
Irregular bead
contour.
Wasted filler metal

and productive time.
Poor mechanical
properties.
Undercut at toe
lines of fillet
Fillet with
unequal legs.
Wasted filler metal
Weld metal not

properly shielded.
Wasted electrode
Illustration 9-11 Examples of Good and Bad Welds Flux Cored with External Shielding Gas
64
GOOD
Proper Current
Voltage & Speed
BAD
Welding Current
Too Low
(High Voltage)
BAD
Welding Current
Too High
(Low Voltage)
BAD
Welding Speed
Too Fast
BAD
Welding Speed
Too Slow
BAD
Insufficient
Shielding Gas
Coverage
Face Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
Face Weld Bead
A smooth, regular,
well formed bead.
Excessive spatter
and porosity.
Excessive spatter
and porosity
Weld bead
excessively wide
and flat.
Bead too small,

with contour
irregular.
Excessive bead
width.
No undercutting,
overlapping or
piling up.
Weld bead
excessively convex
and narrow.
Difficult slag
removal.
Overlapping without
penetration at edges.
Bead very irregular

with poor
penetration.
Uniform in cross
section.
Undercutting along
edges weakens joint.
Not enough weld

metal in cross
section.
Excellent weld at
minimal material and
labor cost.
Irregular bead
contour.
Wasted filler metal

Poor mechanical
properties.
Undercut at toe
lines of fillet
Fillet with
unequal legs.
Wasted filler metal
Weld metal not

properly shielded.
Wasted electrode
Illustration 9-12 Examples of Good and Bad Welds Flux Cored without External Shielding Gas
65
Tip-To-Work
Distance
1-1/2
38.1
Tip-To-Work Distance (in)
Contact Tube
50.8
Actual Stickout
Average Arc Length

Work
Illustration 9-13 Electrode Extension
Tip-To-Work Distance (mm)
Gas Nozzle
25.4
1/2
12.7
400 500 600

Illustration 9-14 Effect of Electrode Extension
on the Welding Current
SECONDARY VARIABLES
Electrode Extension
The electrode extension is the distance between the tip
of the contact tube and the tip of the electrode as shown
The length of electrode that extends beyond the contact tube is resistance heated in proportion to its length.
The amount of resistance heating that occurs affects the
electrode deposition rate and the amount of penetration,
as well as weld quality and arc stability, by varying the
welding current. Increasing the electrode extension reduces the welding current as shown in Illustration 9-14.
In semiautomatic welding, the electrode extension can
be varied by the welder to compensate for joint variation without interrupting the welding operation. Electrode
extension provides a good control during welding to
change the amount of penetration obtained.
In flux cored arc welding, the electrode extension is a
variable that must be held in balance with the shielding
conditions and the related welding variables. As the electrode extension is increased, the amount of preheating of
the wire is increased. For gas-shielded flux cored electrodes, an electrode extension ranging from 3/4 to 1-1/2
in. (19-38 mm) is normally recommended.
Because the shielding comes from the core of selfshielded electrodes alone, a longer electrode extension
is generally recommended to take advantage of the extra
preheating effect which is needed to activate the shielding components in the electrode core. Welding guns for
self-shielded electrodes often have nozzles where the
contact tube is set inside far enough to ensure a minimum electrode extension. Electrode extensions ranging
from 3/4 to 3-1/2 in. (19-89 mm) are commonly used.
This will vary depending on the type of electrode wire
so the manufacturers data should be consulted for each
electrode. An electrode extension that is too long will
produce an unstable arc and cause excessive spatter. An
extension that is too short will cause an excessive arc
length at a particular voltage setting. With gas-shielded
electrodes, excessive spatter may result which can build
up in the nozzle and restrict the shielding gas flow. Poor
shielding gas coverage can result in porosity and surface
oxidation of the weld bead.
The amount of electrode extension also has an effect on
the deposition rate. Increasing the electrode extension
will increase the preheating effect on the electrode and,
therefore, increase the deposition rate. Illustration 9-15
shows this for a gas-shielded flux cored electrode.
66

4.5 4.95 5.40 5.85 6.30 6.75 7.20 7.65 8.10 8.55 9.0
50.8
1-3/4
44.5
1-1/2
38.1
1-1/4
31.8
25.4
3/4
19.1
1/2
12.7
1/4
6.4
0
10 11 12 13 14 15 16 17 18 19 20
Deposition Rate (lbs/hr)
Tip-To-Work Distance (mm)
Tip-To-Work Distance (in)
Illustration 9-15 Effect of Electrode Extension on Deposition Rate
Electrode Angle
The angle at which the welding electrode is held with
respect to the weld joint is called the electrode angle.
These angles have an effect on the shape of the weld
bead and the amount of penetration. The electrode angles are called the travel and work angles and are shown
The travel angle is the angle between the joint and electrode in the longitudinal plane. A push angle exists when
the electrode points in the direction of travel. A drag angle exists when the electrode points in the direction opposite of travel. The work angle is the angle between the
electrode and the plane perpendicular to travel.
The angle at which the electrode is held during welding
determines the direction in which the arc force acts on
the weld pool. The electrode angles are used to shape the
weld bead and to prevent the slag from running ahead of
the weld pool and becoming trapped in the weld. When
making flat position fillet and groove welds, gravity tends
to make the molten slag run ahead of the weld pool. To
compensate for this, a drag angle is used which forces
the slag back. The proper travel angle depends on the
method of flux cored arc welding being used, the thick-
ness of the base metal, and the position of welding. Using gas-shielded electrodes, maximum weld penetration
is obtained with a 10 drag angle. Drag angles ranging
from about 2 to 15 are normally recommended, but a
drag angle greater than 25 should not be used. Drag angles greater than this do not provide good control of penetration. As the drag angle is decreased, the bead height
decreases and the width increases. This effect continues
into the push angle up to a point where the bead will
start to narrow down again. Push angles are generally not
recommended because of the greater chances of slag
entrapment occurring. For self-shielded electrodes, the
drag angles used are similar to those used in shielded
metal arc welding. Flat and horizontal position welding is
done using drag angles ranging from 20 to 45. Larger
angles may be used for thin sections. As the thickness of
the metal increases, smaller angles are used to increase
the penetration. For vertical position, uphill welding, a
push angle of 5 to 10 is recommended.
When making fillet welds in the horizontal position, the
weld metal tends to flow in both the horizontal and vertical directions. To compensate for the vertical flow, a work
angle of 40 to 50 from the upper plate is used.
67
Illustration 9-16 Travel Angle and Work Angle
68
CHAPTER 10
WELDING PROCEDURE SCHEDULES
When changing or adjusting the variables for welding, the effect of the variables on each other must be
considered. One variable cannot usually be drastically
changed without adjusting or changing the other variables, in order to obtain a stable arc and good overall
welding conditions.
1100
1000
450
.045
(1.1 mm)
400
WIRE FEED SPEED (in/min)
900
800
700
350
1/16
(1.6 mm)
300
600
250
500
400
300
200
100
0
WIRE FEED SPEED (mm/s)
The welding procedure schedules in this chapter give

typical welding conditions which can be used to obtain
high quality welds under normal welding conditions. Flux
cored arc welding uses a wide variety of operating conditions for welding mainly steels, some stainless steels
and some nickels. The procedure schedules presented in
this chapter are in no way a complete guide to the procedures that can be used for flux cored arc welding and
are not the only conditions which may be used to obtain
a specific weld. Other conditions could be used because
of factors such as weld appearance, welder skill, method
of application, and the specific application which may
require variations from the schedules. For example, automatic flux cored arc welding normally requires higher
amperage settings and faster travel speeds than semiautomatic welding. The type of electrode wire has a significant effect on the conditions. This is because the type of
electrode wire indicates whether a shielding is required,
the recommended electrical polarity, the recommended
amount of electrode extension, and other factors. As
the particular requirements of the application become
known, the settings may be adjusted to obtain the optimum welding conditions. Qualifying tests or finals should
be made under the actual conditions before applying the
information in the tables to actual production welding.
200
3/32
(2.4 mm)
150
100
1/8
(3.2 mm)
50
100 200 300 400 500 600 700 800 900

WELDING CURRENT (amperes)
Illustration 10-1 Wire Feed Speed Versus Welding

Current for Externally Shielded Tubular Wires
speed, it is sometimes more convenient to directly establish the welding current without exactly knowing the
wire feed speed. Illustrations 10-1 and 10-2 show wire
feed speeds and their corresponding welding currents
for several sizes of tubular electrode wire. Many of the
charts include welding conditions for both groove and fillet welds given on the same chart. Generally, fillet welds
will use the higher current levels for the ranges given and
groove welds will use the lower end of the current range.
WIRE FEED SPEED (in/min)
WIRE FEED SPEED (mm/s)
The following schedules are based on welding plain carbon steels using various types of electrodes wires in appropriate positions. Generally, electrode wires over 1/16"
(1.6 mm) diameter are limited to the flat and horizontal
positions. The welding schedules in300
clude the semiautomatic and auto125
matic methods of application, using
1/8
self-shielded and CO2 shielded elec(3.2 mm)
250
trode wires. The tables use the base
100
metal thickness or fillet size, number
3/32
5/64
200
of weld passes, electrode diameter,
(2.4 mm)
(2.0 mm)
welding current, welding voltage, wire
75
feed speed, gas flow rate (if used) and
150
travel speed as variables. Each table
contains the type of shielding gas (if
50
100
used), type of joint and the position of
welding being used. All of the schedules are based on using direct current
50
electrode positive. Both the welding
150 200 250 300 350 400 450 500 550 600
WELDING CURRENT (amperes)
current and wire feed speed values
are given because, even through the
Illustration 10-2 Wire Feed Speed Versus Welding
welding current is set by the wire feed
Current for Self-Shielded Tubular Wires
69
1) For fillet welds only.

2) Shielding gas is carbon dioxide.
3) Flat position only.
4) Semiautomatic welding.
Thickness
of Base
Metal
in. (mm)
1/8 (3.2)
3/16 (4.8)
1/4 (6.4)
5/16 (7.9)
3/8 (9.5)
1/2 (12.7)
5/8 (15.9)
3/4 (19.1)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Gas Flow
Rate
Ft3/hr.
(l/min)
Travel
Speed
in./min.
(mm/s)
24-26
300
100 (42)
35-45 (17-21)
44 (19)
3/32 (2.4)
24-26
350
120 (51)
35-45 (17-21)
42 (18)
1/8 (3.2)
24-26
450
90 (38)
35-45 (17-21)
47 (20)
3/32 (2.4)
24-26
400
155 (66)
35-45 (17-21)
24 (10)
1/8 (3.2)
25-27
500
105 (44)
35-45 (17-21)
30 (13)
3/32 (2.4)
28-30
500
205 (87)
35-45 (17-21)
22 (9)
1/8 (3.2)
28-30
500
105 (44)
35-45 (17-21)
22 (9)
3/32 (2.4)
28-30
500
205 (87)
35-45 (17-21)
15 (6)
1/8 (3.2)
29-31
575
130 (55)
35-45 (17-21)
20 (8)
3/32 (2.4)
29-31
525
220 (93)
35-45 (17-21)
11 (5)
1/8 (3.2)
30-32
625
150 (63)
35-45 (17-21)
14 (6)
3/32 (2.4)
29-31
475
190 (80)
35-45 (17-21)
12 (5)
1/8 (3.2)
28-30
500
105 (44)
35-45 (17-21)
14 (6)
3/32 (2.4)
29-31
500
205 (87)
35-45 (17-21)
13 (5)
1/8 (3.2)
29-31
500
105 (44)
35-45 (17-21)
13 (5)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
3/32 (2.4)
Illustration 10-3 Flux Cored Arc Welding of Plain Carbon and Low Alloy Steels
Using External Shielding Gas
70

3) Horizontal position only.
Thickness
of Base
Metal
in. (mm)
1/8 (3.2)
3/16 (4.8)
1/4 (6.4)
5/16 (7.9)
3/8 (9.5)
1/2 (12.7)
5/8 (15.9)
3/4 (19.1)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Gas Flow
Rate
Ft3/hr.
(l/min)
Travel
Speed
in./min.
(mm/s)
24-26
300
120 (51)
35-45 (17-21)
60 (25)
3/32 (2.4)
24-26
400
155 (66)
35-45 (17-21)
36 (15)
1/8 (3.2)
24-26
425
75 (32)
35-45 (17-21)
38 (16)
3/32 (2.4)
24-26
400
155 (66)
35-45 (17-21)
24 (10)
1/8 (3.2)
25-27
450
90 (38)
35-45 (17-21)
26 (11)
3/32 (2.4)
25-27
440
175 (74)
35-45 (17-21)
20 (8)
1/8 (3.2)
26-28
460
93 (39)
35-45 (17-21)
20 (8)
3/32 (2.4)
26-28
475
190 (80)
35-45 (17-21)
15 (6)
1/8 (3.2)
28-30
500
105 (44)
35-45 (17-21)
16 (7)
3/32 (2.4)
24-26
400
155 (66)
35-45 (17-21)
18 (8)
1/8 (3.2)
25-27
450
90 (38)
35-45 (17-21)
20 (8)
3/32 (2.4)
26-28
450
180 (90)
35-45 (17-21)
14 (6)
1/8 (3.2)
27-29
450
90 (38)
35-45 (17-21)
14 (6)
3/32 (2.4)
28-30
400
155 (66)
35-45 (17-21)
20 (8)
1/8 (3.2)
28-30
470
96 (41)
35-45 (17-21)
22 (9)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
3/32 (2.4)
71
1) For square groove welds up to 3/8 inch (9.5 mm) (9.5 mm) base metal thickness.
3) Flat position.
Thickness
of Base
Metal
in. (mm)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Gas Flow
Rate
Ft3/hr.
(l/min)
Travel
Speed
in./min.
(mm/s)
24-26
325-350
120 (51)
35-45 (17-21)
56 (24)
3/32 (2.4)
24-26
350-375
130 (55)
35-45 (17-21)
48 (20)
3/32 (2.4)
25-27
375-400
137 (58)
35-45 (17-21)
41 (17)
3/8 (9.5)
1/8 (3.2)
26-28
450-500
107 (45)
35-45 (17-21)
24 (10)
1/2 (12.7)
1/8 (3.2)
28-30
475-525
120 (51)
35-45 (17-21)
14 (6)
5/8 (15.9)
1/8 (3.2)
30-32
575-600
155 (66)
35-45 (17-21)
14-16 (6)
3/4 (19.1)
1/8 (3.2)
30-32
575-600
155 (66)
35-45 (17-21)
15-20 (6-8)
7/8 (22.2)
1/8 (3.2)
30-32
575-600
155 (66)
35-45 (17-21)
13-18 (5-8)
1 (25.4)
1/8 (3.2)
31-32
575-600
155 (66)
35-45 (17-21)
12-20 (5-8)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
1/8 (3.2)
3/32 (2.4)
3/16 (4.8)
1/4 (6.4)
72
1) For square groove welds up to 3/8 inch (9.5 mm) base metal thickness.
4) Automatic welding.
Thickness
of Base
Metal
in. (mm)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Gas Flow
Rate
Ft3/hr.
(l/min)
Travel
Speed
in./min.
(mm/s)
16-18
225-250
65 (27)
35-45 (17-21)
55 (23)
3/32 (2.4)
17-19
275-300
90 (38)
35-45 (17-21)
36 (15)
3/32 (2.4)
26-28
350-375
240 (102)
35-45 (17-21)
22 (9)
1/8 (3.2)
27-29
375-400
125 (53)
35-45 (17-21)
14 (6)
3/32 (2.4)
27-29
400-425
270 (114)
35-45 (17-21)
17 (7)
1/8 (3.2)
29-31
500-525
185 (78)
35-45 (17-21)
14 (6)
3/32 (2.4)
27-29
425-450
290 (123)
35-45 (17-21)
14 (6)
1/8 (3.2)
29-31
525-550
190 (80)
35-45 (17-21)
13 (5)
3/32 (2.4)
27-29
400-425
270 (114)
35-45 (17-21)
14-20 (6-8)
1/8 (3.2)
29-31
475-500
170 (72)
35-45 (17-21)
13-18 (5-8)
3/32 (2.4)
27-29
400-425
270 (114)
35-45 (17-21)
14-20 (6-8)
1/8 (3.2)
29-31
475-500
170 (72)
35-45 (17-21)
13-18 (5-8)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
1/8 (3.2)
3/32 (2.4)
3/16 (4.8)
1/4 (6.4)
3/8 (9.5)
1/2 (12.7)
5/8 (15.9)
3/4 (19.1)
73

2) Horizontal position.
Thickness
of Base
Metal
in. (mm)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Travel
Speed
in./min.
(mm/s)
25
200-225
80 (34)
16 (7)
3/32 (2.4)
26
250-275
95 (40)
12 (5)
3/32 (2.4)
286
375-400
130 (55)
10 (4)
3/8 (9.5)
1/8 (3.2)
28
400-425
95 (40)
12-14 (5-6)
1/2 (12.7)
1/8 (3.2)
29
425-450
107 (45)
14 (6)
5/8 (15.9)
1/8 (3.2)
28-30
400-425
95 (40)
12-16 (5-7)
3/4 (19.1)
1/8 (3.2)
28-30
425-450
107 (45)
12-16 (5-7)
7/8 (22.2)
1/8 (3.2)
29-31
475-500
120 (51)
12-16 (5-7)
1 (25.4)
1/8 (3.2)
28-31
425-450
107 (45)
12-16 (5-7)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
1/8 (3.2)
3/32 (2.4)
3/16 (4.8)
1/4 (6.4)
Using Self-Shielded Electrode Wires
74
1) For square groove welds up to 3/8 inch (9.5 mm) base metal thickness.
Thickness
of Base
Metal
in. (mm)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Travel
Speed
in./min.
(mm/s)
19
200-225
60 (25)
12 (5)
3/32 (2.4)
20
250-275
80 (34)
9 (4)
1/8 (3.2)
28
375-400
110 (47)
14 (6)
3/8 (9.5)
1/8 (3.2)
28-30
400-425
135 (57)
13-16 (5-7)
1/2 (12.7)
1/8 (3.2)
27-29
425-450
150 (63)
14-16 (6-7)
5/8 (15.9)
1/8 (3.2)
29-31
400-425
130 (55)
13-18 (5-8)
3/4 (19.1)
1/8 (3.2)
28-30
425-450
150 (63)
13-16 (5-7)
7/8 (22.2)
1/8 (3.2)
29-31
475-500
170 (72)
13-18 (5-8)
1 (25.4)
1/8 (3.2)
28-31
425-450
150 (63)
13-16 (5-7)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
1/8 (3.2)
3/32 (2.4)
3/16 (4.8)
1/4 (6.4)
Using Self-Shielded Electrode Wires
75
1) For fillet and groove welds.

3) All positions
5) Reduce amperage 25-35% for vertical positions
6) For square-groove welds up to 1/4 inch (6.4 mm) base metal thickness.
Thickness
of Base
Metal
in. (mm)
Welding
Current
Wire Feed
Speed
in./min. (mm/s)
Gas Flow
Rate
Ft3/hr.
(l/min)
Travel
Speed
in./min.
(mm/s)
22-24
150
60 (25)
35-45 (17-21)
30 (13)
.045 (1.1)
22-24
200
80 (34)
35-45 (17-21)
24-30 (10-13)
.045 (1.1)
23-25
220
110 (47)
35-45 (17-21)
15-18 (6-8)
3/8 (9.5)
.045 (1.1)
24-25
220
135 (57)
35-45 (17-21)
8-10 (3-4)
1/2 (12.7)
.045 (1.1)
24-26
220
150 (63)
35-45 (17-21)
8-10 (3-4)
3/4 (19.1)
.045 (1.1)
24-26
220
150 (63)
35-45 (17-21)
8-10 (3-4)
Number
of Passes
Electrode
Diameter
in. (mm)
Welding
Voltage
1/8 (3.2)
.045 (1.1)
3/16 (4.8)
1/4 (6.4)
Using Small Diameter Externally Shielded Electrode Wires
76
CHAPTER 11
PREWELD PREPARATIONS
Preweld preparations are necessary to obtain a good
quality weld. Operations that may need to be done before the welding is started are items such as preparing
the weld joint, maintenance of welding gun and cable assembly, fixturing the weldment, setting the variables, and,
in some cases, preheating. The amount of preweld preparation depends upon the size of the weld and weldment,
the type of base metal, the ease of fit-up, the quality requirements, the governing code or specifications, and the
welder.
PREPARING THE WELD JOINT

There are different ways of preparing the edges of the joint
for welding. The methods that are the most often used
for edge preparation are oxygen fuel gas cutting, plasma
arc cutting, air carbon arc gouging, shearing, machining,
grinding, and chipping. When they can be used, the thermal cutting methods, oxy-fuel gas, plasma arc cutting,
and air carbon arc cutting, are generally faster than the
mechanical cutting methods, with the exception of shearing. Oxygen fuel gas cutting is used on carbon and low
alloy steels. Plasma arc cutting is used on carbon, low alloy and stainless steels and is best for applications where
high production rates are required. Air carbon arc cutting
is used for preparing joints in most steels including stainless steels. This process should not be used on stainless
steels for critical corrosion applications because of the
carbon deposited, unless the cut surfaces are cleaned by
grinding and brushing. The surfaces cut by these thermal
methods sometimes have to be ground lightly to remove
scale or contamination. Common types of prepared weld
joints are the square, V-, U-, J-, bevel-, and combinationgrooves. The more complex types of bevels require longer
joint preparation times, which makes the joint preparation
more expensive.
Since flux cored arc welding is used on all metal thicknesses, all of the different joint preparations are widely
employed. Joints for fillet, or square-groove welds are
prepared simply by squaring the edges of the members
to be welded if the as-received edge is not suitable.
Next to the square edge preparation, the V-groove and
single-bevel grooves are the types most easily prepared
by oxygen fuel cutting, plasma arc cutting, chipping or
machining. These methods leave a smooth surface if
properly done. The edges of U- and J-grooves can be
done by using special tips and techniques with oxy-fuel
cutting or by machining. Machining produces the most
uniform groove. Carbon arc cutting is used extensively
for preparing U-grooves in steels and for removing part
of root passes, so that the joint can be welded from both
sides. Chipping is sometimes done on the back side of
the weld, when full penetration is required and a thermal

cutting method is not being used.
Weld backings are commonly used in flux cored arc welding to provide support for the weld metal and to control
the heat input. Copper, steel, stainless steel, and backing
tape are the most common types of weld backing. Copper is a widely used method of weld backing because it
does not fuse to thin metals. It also provides a fast cooling rate because of the high heat conductivity of copper,
which makes this the best method of controlling the heat
input. Steel backing is used when welding steels. These
are fusible and remain part of the weldment unless they
are cut off. These are often removed by oxy-fuel, air carbon arc cutting, or grinding. Stainless steels are good
backing materials for welding of stainless steels. Backing tape is popular because it can be molded to any joint
configuration, such as the inside of a pipe.
CLEANING THE WORK METAL

The welds made by flux cored arc welding are susceptible
to contamination during the welding process. The surface
of the base metal should be free of grease, oil, paint, plating, dirt, oxides or any other foreign material. This is especially critical when welding stainless steel. Flux cored arc
welding is less sensitive to contaminants than gas metal
arc welding because of the scavengers and deoxidizers
present in the flux core. Some flux cored electrodes that
are made specially for welding over rust and scale are
available. This is done to make preweld cleaning less
expensive. Very dirty workpieces are usually cleaned by
using solvent cleaners followed by vapor degreasing.
Simple degreasing is often used for cleaning carbon and
low alloy steel that have oxide free surfaces. Acid pickling
is generally used for cleaning scale and rust and can be
removed mechanically by grinding and abrasive blasting.
The type of cleaning operation will vary, depending on the
type of metal. Carbon and low alloy steels may be cleaned
chemically in a hydrochloric acid solution. Nickel alloys
and stainless steels may be cleaned by pickling which removes iron, sand blast residue and other contaminants.
Welding should never be done near chlorinated solvents
because the arc can create phosgene gas which is toxic.
Chemical cleaning can be done by pickling.
Just before welding, there are several other tasks that
should be performed. One is to grind or file the edges of
the joint smooth so that there are no burrs present. Burrs
can cause physical pain as well as create a place to trap
contaminants in a weld joint. Grinding is often used on
plain carbon and low alloy steels to remove burrs and
rust or mill scale from the area in and around the joint.
The surfaces of the joint and surrounding area should
77
be wire brushed. Mild steel brushes are used for cleaning plain carbon and low alloy steel. Stainless steel wire
brushes are used for cleaning stainless steel. The joint
surfaces and surface of the previous weld bead should
also be cleaned off between passes of a multiple pass
weld. Stainless steel brushes should be used on these
metals to avoid contamination due to rust or carbon from
the mild steel wire brushes. Welding should be done
soon after cleaning, especially on metals that form surface oxides such as stainless steel. Wire brushing does
not completely remove the oxide but it reduces the thickness and makes them easier to weld. Gloves should be
worn while cleaning stainless steels to prevent oil or dirt,
from the fingers, from getting on the joint surfaces, which
can also cause contamination.
FlXTURlNG AND POSITIONING

Fixturing can affect the shape, size and uniformity of a
weld bead. Fixtures are devices that are used to hold the
parts to be welded in proper relation to each other. When
fixturing is not used, it usually indicates that the resulting weld distortion can be tolerated or be corrected by
straightening operations. The three major functions of
fixtures are:
1) Locate and maintain parts in their position relative to
the assembly.
2) Increase the welding efficiency of the weld.
3) Control distortion in the weldment.
When a welding fixture is employed, the components of
a weldment can be assembled and securely held in place
while the weldment is positioned and welded. The use of
those devices is dependent on the specific application.
These devices are more often used when large numbers
of the same part are produced. When a fixture is used,
the production time for the weldments can be greatly reduced. They are also good for applications where close
tolerances must be held.
Positioners are used to move the workpiece into a position so that welding can be done more conveniently,
which improves the appearance and the quality of the
weld bead. Positioning is sometimes needed simply to
make the weld joint more accessible. The main objective of positioning is to put the joint in the flat or other
more favorable position. Positioners are particularly important in flux cored arc welding because they allow the
use of larger diameter flux cored electrode wires when
the weld joint can be rotated into the flat or horizontal
fillet. The larger diameter electrodes produce higher deposition rates, are less expensive, and generally reduce
the overall welding costs. Flat position welding usually
increases the quality of the weld because it makes the
welding easier.
Illustration 11-1 Induction Heating

PREHEATING
Preheating is sometimes required, but this depends on
the type of metal being welded, the base metal thickness, and the amount of joint restraint. These factors
were discussed in Chapter 7. The specific amount of
preheat needed for a given application is often obtained
from the welding procedure.
The preheat temperature of the metal should be carefully controlled. There are several methods of performing
this: furnace heating, electric induction coils, and electric resistance heating blankets. On thin materials, hot air
blasts or radiant lamps may be used. With these methods, temperature indicators are attached to the parts
being preheated. Oxy-fuel torches are another method
of preheating. This method gives more localized heating
than the methods that were previously mentioned. When
using oxy-fuel torches, it is important to avoid localized
overheating and deposits of incomplete combustion
products from collecting on the surface of the parts to
be welded. There are several methods of measuring the
temperature of preheat such as temperature sensitive
crayons, pellets and hand-held temperature indicators.
The crayons and pellets melt at a specific predetermined
temperature. The hand-held temperature indicators can
give meter readings, digital readings, or recorder readings of the temperature, depending on the type used.
78
CHAPTER 12
WELDING DISCONTINUITIES AND DEFECTS
Flux cored arc welding, like the other arc welding processes can have welding procedure problems that result in weld discontinuities or defects. Discontinuities
that can occur when using flux cored arc welding are
slag inclusions, porosity, wormhole porosity, undercutting, incomplete fusion, excessive melt through, wagon
tracks, excessive weld spatter, arc strikes and craters.
These problems with the welding technique or procedure
weaken the weld and can cause cracking. A poor welding
technique and improper choice of welding parameters are
major causes of weld defects. Some defects are caused
by the use of improper base metal, filler metal, or shielding gas. The base metal and filler metal should also be
cleaned to avoid creation of a discontinuity. Other problems that can occur and reduce the quality of the weld are
arc blow, loss of shielding, defective electrical contact between the contact tube and the electrode, and wire feed
stoppages.
Wagon Tracks
Wagon tracks are linear slag inclusions
that run along the longitudinal axis of
the weld. These result from allowing the slag to run ahead of the weld
puddle and by slag left on the previous pass. This is especially common
when slag forms in undercuts on the
previous pass. This discontinuity occurs along the toe line of the previous
weld bead and can be corrected by
correcting the electrode travel angles,
increasing the travel speed, or by doing a better slag cleaning.
Illustration 12-2
Wagon Tracks
Porosity
Porosity is a gas pocket in the weld metal that may be
scattered in small clusters or along the entire length
of the weld. These voids left in the weld cause it to be
weakened. Porosity may be internal, on the surface of
the weld bead, or both. This discontinuity is caused by
one or more of the following:
DISCONTINUITIES CAUSED BY
WELDING TECHNIQUE
Slag Inclusions
Flux cored arc welding produces a
slag covering over the weld. Slag inclusions occur when slag particles become trapped inside the weld. These
slag inclusions produce a weaker
weld and can serve as crack initiation
points. These can be caused by:
Illustration 12-1
1) Slag left on the previous weld pass
Slag Inclusion
2) An erratic travel speed
3) Improper electrode angles that let
the slag get ahead of the arc
4) A weaving motion that is too wide
5) A travel speed that is too slow which lets the weld
puddle get ahead of the arc
6) Too low an amperage setting
1) Inadequate shielding gas flow rate for gas-shielded

electrodes
2) Wind drafts that deflect the shielding gas
3) Contaminated or wet shielding gas
4) Excessive welding current
5) Excessive welding voltage
6) Excessive electrode extension
7) An excessive travel speed which causes freezing of
the weld puddle before gases can escape
8) Rust, grease, oil, moisture or dirt on the surface of the
base metal or electrode
9) Impurities in the base metal, such as sulfur and phosphorous in steel
This discontinuity can be prevented by:

1) Cleaning the slag off of the previous weld bead, especially along the toes of the weld
2) Using a uniform travel speed
3) Increase the drag angle to prevent the slag from getting ahead of the arc
4) Using a tighter weaving motion
5) Increasing the travel speed so that the arc is at the
front of the weld puddle
6) Increase the amperage setting
79
Illustration 12-3 left to right: Linear Porosity,

Clustered Porosity, Uniformly Scattered Porosity
This problem can be prevented or corrected by:

1) Increasing the shielding gas flow rate
2) Setting up wind shields
3) Replacing the cylinder of shielding gas
4) Lowering the welding current (reducing the wire feed
speed)
5) Decreasing the voltage
6) Decreasing the electrode extension
7) Reducing the travel speed
8) Cleaning the surface of the base metal or electrode
9) Changing to a different base metal with a different
composition
5) Pausing at each side of the weld bead when a weaving technique is used
6) Correcting the electrode angles being used
Incomplete Fusion
Wormhole Porosity
Wormhole porosity is the name given
to elongated gas pockets and is usually caused by sulfur in the steel or moisture on the surface of the base metal
which becomes trapped in the weld
joint. Wormhole porosity can seriously
reduce the strength of the weld. The
best methods of preventing this are to
clean the surfaces of the joint and preheat to remove moisture. If sulfur in the
steel is the problem, a more weldable
grade of steel should be selected.
Illustration 12-6 Incomplete Fusion
Illustration 12-4
Wormhole
Porosity
Undercutting
Undercutting is a groove melted in the
base metal next to the toe or root of a
weld that is not filled by the weld metal.
This is particularly a problem with fillet
welds. Undercutting causes a weaker
joint at the toe of the weld, which may
result in cracking. It is caused by one
or more of the following:
2) Arc voltage too high
3) Excessive travel speed which does
Illustration 12-5
Undercutting
not allow enough filler metal to be
added
4) Erratic feeding of the electrode wire
5) Excessive weaving speed
6) Incorrect electrode angles, especially on vertical and
horizontal welds
This can be prevented by:
1) Reducing the weld current
2) Reducing the welding voltage
3) Using a travel speed slow enough so that the weld
metal can completely fill all of the melted out areas of
the base metal
4) Cleaning the nozzle, inside of the contact tube, or
removing the jammed electrode wire
Incomplete fusion occurs when the weld metal is not

completely fused to the base metal. This can occur between the weld metal and the base metal or between
passes in a multiple pass weld. This is less of a problem
with flux cored arc welding than with shielded metal arc
welding and short-circuiting transfer gas metal arc welding because of the deeper penetration obtained. More
care should be taken when using a weaving technique
because there is more chance of creating this discontinuity. Incomplete fusion between passes in a multiple pass
weld often results from welding over a previous weld
bead that has excessive convexity. If an excessively convex weld bead is created, the surface should be ground
off enough so that complete fusion can be made in the
next pass. Causes of incomplete fusion can be:
1) Excessive travel speed which causes an excessively
convex weld bead
2) Welding current too low
3) Poor joint preparation that has too large of a root face
or too small a root opening
4) Letting the weld metal get ahead of the arc or letting the weld layer get too thick, which keeps the arc
away from the base metal.
Incomplete fusion can be prevented by:
1) Reducing the travel speed
2) Increasing the welding current
3) Increasing the root opening and
decreasing the root face
4) Using proper electrode angles or
increasing the travel speed
Overlapping
Overlapping is the protrusion of the
weld metal over the edge or toe of the
weld bead. This defect can cause an
area of incomplete fusion which creates a notch and can lead to crack ini-
80
Illustration 12-7
Overlapping
tiation. If overlapping is allowed to occur, grinding off the

excess weld metal after welding can be done. Overlapping is produced by one or more of the following:
1) Too slow a travel speed which permits the weld
puddle to get ahead of the electrode
2) Arc welding current that is too low
3) An incorrect electrode angle that allows the force of
the arc to push the molten weld metal over unfused
sections of the base metal.
Overlapping can be prevented or corrected by:
1) Using a higher travel speed
2) Using a higher welding current
3) Using the correct electrode angles
produce higher spatter levels than the same electrode

used with argon-carbon dioxide or argon-oxygen mixtures. This is due to the coarser droplet size promoted
by the carbon dioxide shielding. Excessive weld spatter
may also result from operating the electrode wire outside
the operating ranges of amperage, voltage and electrode
extension for which the electrode was designed by the
manufacturer. Methods of reducing the amount of spatter would then be to reduce the welding current, welding voltage, or electrode extension. When gas-shielded
wires are being used, changing the shielding gas from
carbon dioxide to an argon-carbon dioxide mixture will
further reduce spatter levels. If spatter is caused, it can
be removed by grinding or chipping.
Arc Strikes
Melt-Through
Melt-through occurs when the arc melts through the bottom of the weld and creates holes. It is usually caused by
the heat input being too high. This can also be caused by
one or more of the following:
2) A travel speed that is too slow
3) A root opening that is too wide or a root face that is
too small
Many codes prohibit striking the

arc on the surface of the workpiece. Striking the arc on the base
metal outside the weld joint can
produce a hard spot on the surface of the base metal. These arc
strikes might create a small notch
on the surface of the metal which
can act as an initiating point for
cracks.
Craters
This can be prevented by:

1) Reducing the welding current
2) Increasing the travel speed
3) Reducing the width of the root opening, using a slight
weaving motion, or increasing the electrode extension.
Excessive Welding Spatter
Flux cored arc welding may produce a
small amount of spatter but excessive
weld spatter creates a poor weld appearance, wastes electrodes, causes
difficult slag removal and can lead to
incomplete fusion in multipass welds.
Excessive spatter can also block the
flow of shielding gas from the nozzle
which causes porosity. The amount
of spatter produced by flux cored arc
welding will vary depending on the type
of metal transfer, type of electrode and Illustration 12-8
Excessive
the type of shielding gas used. (ElecSpatter
trode wires that produce a large droplet
size globular metal transfer will produce
more spatter than those that produce a fine globular
transfer. Self-shielded electrodes tend to produce higher
spatter levels than gas-shielding types.) The shielding
gas provides slightly better arc stability. A gas-shielded
electrode that is used with carbon dioxide shielding will
Illustration 12-9
Arc Strikes
Weld craters are depressions on the weld surface at the

point where the arc was broken. These are caused by
the solidification of the metal after the arc has been broken. The weld crater often cracks and can serve as an
origin for linear cracking back into the weld metal or into
the base metal. These craters can usually be removed
by chipping or grinding and the depression can be filled
in with a small deposit of filler metal. There are two common methods of preventing craters. The first is to reverse
the travel of the electrode a little way back into the weld
bead from the end before breaking the arc. The other
method is to stop the travel long enough to fill the crater
before breaking the arc.
Distortion and Warpage
Distortion and warpage are caused by the nonuniform
expansion and contraction of weld and base metal during the heating and cooling process of welding. If warpage changes the required dimensions of the total weldment, the weldment may not be acceptable. Methods
to reduce distortion and
warpage are:
1) Deposit only the required amount of weld
metal.
2) Alternate sides or sequence welds.
81
Illustration 12-10
Distortion
3) Preset parts to compensate for distortion.

Inadequate Joint Penetration
Inadequate joint penetration is commonly located
at the root of the weld
and is caused by an insufficient heat input while
welding. Insufficient heat
input can be caused by
Illustration 12-11
too low amperage, too
much electrode stickout, Inadequate Joint Penetration
or too fast a travel speed.
Inadequate joint penetration can also be caused by improper joint design or incorrect preparation of the joint
edges. A tight root opening or a small groove angle restricts the weld metal causing lack of penetration at the
root. To prevent this problem, insure that enough heat
is being used on a properly designed joint and that the
welder or operator has the skill necessary to produce the
desired weld.
CRACKING
Weldment cracking can be caused by an improper welding procedure, welder technique, or materials. All types
of cracking can be classified as either hot or cold cracking. These cracks are transverse or longitudinal to the
weld. Transverse cracks are perpendicular to the axis of
the weld where longitudinal shrinkage stresses are acting
on excessively hard and brittle weld metal. Longitudinal
cracks are often caused by high joint restraint and high
cooling rates. Preheating will often help to reduce these
problems.
Hot cracking occurs at elevated temperatures and generally happens just after the weld metal starts to solidify.
This type of cracking is often caused by excessive sulfur,
phosphorous and lead contents in the steel base metal.
It can also be caused by an improper method of breaking
the arc or in a root pass when the cross sectional area
of the weld bead is small compared to the mass of the
base metal.
Hot cracking often occurs in deep penetrating welds and
it can continue through successive layers if it is not repaired. Hot cracking can be prevented or minimized by:
1) Preheating to reduce shrinkage stresses in the weld
2) Using clean or uncontaminated shielding gas, base
metals and filler metals
3) Increasing the cross sectional area of the weld bead
4) Changing the contour of the weld bead
5) Using base metal with very low contents of those elements that tend to cause hot cracking.
6) In steel, using filler metals that are high in manganese
Crater cracks are shallow hot

cracks that are caused by improperly breaking the arc. Several types
are shown in Illustration 12-12.
Crater cracks may be prevented
the same way that craters are, by
reversing the travel of the electrode back into the weld bead a
little way, gradually reducing the
welding current at the end of the
weld, or by stopping the travel before breaking the arc.
Cold cracking occurs after the
Illustration 12-12
weld metal solidification is comCrater Cracks
plete. Cold cracking may occur
several days after welding and is generally caused by hydrogen embrittlement, excessive joint restraint, and rapid
cooling. Preheating, the use of a dry, high purity shielding
gas, and a proper cleaning procedure can help reduce
this problem. Cold cracking is often less of a problem
with flux cored arc welding than gas metal arc welding
because of the higher heat input of flux cored arc welding, which provides more of a preheating effect. This
helps to slightly reduce the problems with cold cracking
due to excessive cooling rates.
Centerline cracks are cold cracks that
often occur in single pass concave fillet welds. A longitudinal crack is a centerline crack that runs down the center
of the weld as shown in Illustration 1213.
Cold cracking may be caused by one
or more of the following:
1) A weld bead that is too small for
the thickness of the base metal
2) Poor fit-up
Illustration 12-13
3) High joint restraint
Longitudinal
4) Extension of a crater crack
Crack
The best methods of preventing centerline cracks are:
1) Increasing the bead size
2) Decreasing the gap width
3) Preheating
4) Filling weld craters
Base metal and underbead cracks are cold cracks that
form in the heat affected zone of the base metal.
82
Underbead cracks occur underneath the weld

bead as shown in Illustration 12-14.
Base metal cracks are
those cracks that originate in the heat affected zone of the weld.
Illustration 12-14
This type of cracking is
Underbead Cracks
caused by excessive joint
restraint, entrapped hydrogen, and a brittle microstructure. A brittle microstructure is caused by rapid cooling or
excessive heat input. Underbead and base metal cracking can be reduced or eliminated by using preheat.
OTHER PROBLEMS
Arc Blow
The electric current that flows through the electrode,
workpiece, and work cable sets up magnetic fields in a
circular path perpendicular to the direction of the current.
When the magnetic fields around the arc are unbalanced,
it tends to bend away from the greatest concentration
of the magnetic field. This deflection of the arc is called
arc blow. Deflection is usually in the direction of travel or
opposite to it, but it sometimes occurs to the side. Arc
blow can result in an irregular weld bead and incomplete
fusion.
Top View of Magnetic Field
No
Arc Blow
1) Welding toward an existing weld or tack weld

2) Reducing the welding current and reducing the arc
voltage
3) Placing the work connection as far as possible from
the weld, at the end of the weld, or at the start of the
weld, and weld toward the heavy tack weld
4) Change position of fixture or demagnetize base metal
or fixture
Inadequate Shielding
Many discontinuities that occur in
flux cored arc welding are caused
by inadequate shielding of the arc.
Inadequate shielding can cause
oxidation of the weld puddle and
porosity in the weld bead. This will
usually appear as surface porosity.
This problem can easily be detected because the arc will change color, the weld bead will be discolored
and the arc will become unstable
and difficult to control. The most
common causes of this problem
when using gas-shielded flux cored
arc welding are:
Illustration 12-16
Inadequate
Shielding
1) Blockage of gas flow in the torch or hoses or freezing

of the regulator with carbon dioxide
2) A leak in the gas system
3) Weld spatter blocking the nozzle of the welding
4) A very high travel speed
5) Improper flow rate
6) Wind or drafts
7) Too much distance between nozzle and work
Direction of Travel
Forward
Arc Blow
It is often encountered when welding magnetized metal

or near a magnetized fixture. This problem also occurs
when welding complex structures and on massive structures with high currents and poor fit-up. Forward arc
blow is encountered when welding away from the ground
connection or at the beginning of a weld joint. Backward
arc blow occurs toward the grounding connection, into a
corner or toward the end of a weld joint. There are several methods that can be used to correct the arc blow
problem:
Backward
Arc Blow
The most common causes of this problem for self-shielded electrodes are:
Illustration 12-15 Arc Blow
Direct current is susceptible to arc blow, especially when

welding is being done in corners and near the end of
joints. Arc blow occurs with direct current because the
induced magnetic field is in one direction. Arc blow is
shown in Illustration 12-15.
1) Electrode extension that is too short and doesnt

allow proper activation of shielding gas core components.
2) A very high travel speed
3) Winds or drafts. Self-shielding electrodes can withstand higher winds and drafts than gas-shielded
electrodes and are popular for use in field conditions
where wind is a problem
83
In general, inadequate shielding is more of a problem

with gas-shielding electrodes.
There are several ways that this problem can be corrected or prevented. The torch and hoses should be checked
before welding to make sure that the shielding gas can
flow freely and is not leaking. The nozzle and contact tube
should be cleaned of spatter regularly. A very high travel
speed may leave the weld puddle or part of it exposed to
the atmosphere. This may be corrected, in some cases
by inclining the gun in the direction of travel, using a nozzle that directs shielding gas back over the heated area,
or by increasing the gas flow rate. The best method is to
slow the travel speed. Increasing the gas flow rate will
increase the expense of the welding. An improper flow
rate may occasionally be a problem. For example, when
using carbon dioxide shielding in the overhead position,
highest gas flow rates may have to be used to provide
adequate shielding. Carbon dioxide is heavier than air
and will tend to fall away from the weld area. An excessive gas flow rate can cause excessive turbulence in the
weld puddle. When winds or air drafts are present, there
are several corrective steps that may be taken. One is to
switch from a gas-shielded electrode to a self-shielded
electrode. Setting up screens around the operation is another method of solving this problem. Increasing the gas
flow rate is helpful when using gas-shielded electrodes,
or increasing the electrode extension when using selfshielded electrodes. An excessive distance between the
end of the nozzle and the molten weld puddle will also
create a problem in providing adequate shielding, which
can be corrected by shortening this distance.
Clogged or Dirty Contact Tube
The power delivered to the arc in flux
cored arc welding depends on a transfer of current from the tip of the contact
tube to the electrode by means of a
sliding contact tube. A clogged, dirty or
worn contact tube can cause changes
in the amount of power transferred to
the electrode, which can have an effect
on the arc characteristics. It can also
cause an irregular weld bead and pos- Illustration 12-16
sible incomplete fusion because of the A Worn Contact
power fluctuations. A clogged contact
Tube
tube can stop the feed of the electrode
wire, which stops the welding arc. A contact tube can
become dirty or clogged by spatter from the arc, by rust,
scale, drawing compounds left from the manufacture of
the wire on the surface of the electrode, or by metal chips
created by tight wire feed rolls. These problems can best
be prevented by making sure that the electrode wire is
clean and the wire feed rolls are tight enough to feed the
wire without creating chips. A wire wipe, made of cloth is
often attached to the wire feeder to clean the electrode
wire as it is fed.
Wire Feed Stoppages

Wire feed stoppages are
generally less of a problem with flux cored arc
welding than with gas
metal arc welding because of the larger diameter electrode wires used
Illustration 12-17 Wire
in flux cored arc welding.
Wrapped Around Feed Rolls
However, this can still
be a problem. Wire feed
stoppages cause the arc to be extinguished and can
create an irregular weld bead because of the stops and
starts. Wire stoppages can also cause a loss of welding time because many of the problems take a long time
to correct when wire becomes wrapped around the wire
feed rolls, wadded up in bird nests in the wire feeder, or
broken. Wire feed stoppages can be caused by:
1) A clogged contact tube
2) A clogged circuit in the welding gun assembly
3) Sharp bends or kinks in the wire feed conduit
4) Excessive pressure on the wire feed roll which can
cause breakage of the wire
5) Inadequate pressure on the wire feed rolls
6) Attempting to feed the wire over excessively long
distances
7) A spool of wire clamped too tightly to the wire reel
support
Wire feed stoppages, in many cases, must be corrected
by taking the gun assembly apart and cutting and removing the wire, or by cutting and removing the wire from the
wire feeder. These both result in time lost to locate the
problem and feed the new length of wire through the assembly to the gun. Wire stoppages can be prevented by:
1) Cleaning the contact tube
2) Cleaning the conduit, which is usually done with
compressed air
3) Straightening or replacing the wire feed conduit
4) Reducing the pressure on the wire feed rolls to
prevent breakage
5) Increasing the pressure on the wire feed rolls to
provide adequate driving force
6) Using a shorter distance from the wire feeder to
the gun or from the wire feeder to the electrode
wire source
7) Reducing clamping pressure on the wire spool
84
CHAPTER 13
POSTWELD PROCEDURES
There are several operations that may be required after
welding, such as cleaning, inspection of the welds, and
postheating. These are items which may or may not be
part of the procedure. The operations performed will depend on the governing code or specification, type of metal, and the quality of the weld deposit.
c)
CLEANING
b)
Flux cored arc welding produces a moderate slag covering that must be removed after welding. Slag removal is
also required between passes of a multipass weld to prevent slag inclusions and incomplete fusion.
Slag removal is generally done using a chipping hammer.
A certain amount of spatter is created in flux cored arc
welding, which can make slag removal slightly more difficult. If an excessive amount of spatter is created, slag
removal may become very difficult. After the slag has
been removed, wire brushing or buffing can be done to
remove the loose slag particles and to remove discoloration around the bead. Mild steel brushes can be used on
most steels but stainless steel brushes should be used
on stainless steel to prevent contamination. Spatter can
be removed by grinding or wire brushing. Flux cored arc
welding usually produces a smooth weld surface. If a different weld profile is needed, grinding can be used, although grinding of weld profiles should be avoided, due
to the expense.
INSPECTION AND TESTING
Inspection and testing of the weld is usually done after

cleaning to determine the quality of the weld joint. There
a)
d)
Illustration 13-2 Nondestructive Testing Methods

a) Radiographic, b) Penetrant, c) Magnetic Particle,
and d) Ultrasonic Testing
are many different methods of inspection and testing,

which will not be covered in detail in this book. The use of
these methods will often depend on the code or specification that covered the welding or by the product specifications. Testing of a weldment may be done nondestructively or destructively.
Nondestructive testing is used to locate defects in the
weld and base metal. There are many different nonde-
c)
d)
b)
e)
a)
Illustration 13-1 Destructive Testing Methods

a) Etched Cross-Section, b) Tensile Strength, c) Guided Bend, d) Fillet Weld Break, and e) Impact Testing
85
structive testing methods. The most widely used nondestructive testing methods are visual, magnetic particle,
liquid penetrant, ultrasonic, and radiographic. Visual,
magnetic particle, and liquid penetrant
inspection are used to locate surface
defects, while ultrasonic, magnetic particle, and radiographic inspection are
used to locate internal defects.
od that is used for stress relieving and does not involve

the reheating of the weldments is called vibratory stress
relief. This method vibrates the weldment during or after
welding to relieve the residual stresses
during or after solidification. Annealing is a process involving heating and
cooling that is usually applied to induce
softening. This process is widely used
on steels that become very hard and
Destructive testing is used to deterbrittle because of welding. There are
mine the mechanical properties of the
several different kinds and when used
weld, such as the strength, ductility, and
on ferrous metals it is called full annealtoughness. Destructive testing is also
ing. Full annealing is the heating up of a
accomplished by several methods, dematerial to cause recrystallization of the
pending on the mechanical properties
grain structure, which causes softenbeing tested. Some of the most coming. This softening process is done by
mon types of destructive testing are
heating a ferrous metal to a temperature
tensile bar tests, impact tests, and bend
above the transformation range and
Illustration 13-3 Annealing
tests.
slowly cooling to a temperature below
this range. This process is usually done in a furnace to
REPAIRING OF WELDS
provide a controlled cooling rate.
Repairing the weld is usually needed when defects are
Normalizing is a heat treatment that is applied only to
found during inspection. When a defect is found, it can be
ferrous metals. Normalizing occurs when the metal is
gouged, ground, chipped, or machined out, depending
heated to a temperature above the transformation range
on the type of material being welded. For steels, grinding
and is cooled in still air to a temperature below this range.
and air carbon arc gouging are commonly used. When
The main difference between normalizing and annealmaximum corrosion resistance is required, air carbon arc
ing is that a normalized weldment is cooled in still air
gouging is used on stainless steels only when grinding or
which produces a quicker cooling rate and an annealed
wire brushing of the groove face to remove carbon deweldment is slowly cooled in a furnace. A normalizing
posits is done. For stainless steels, chipping is a common
heat treatment will refine the metal grain size and give
method for removing defects. Air carbon arc gouging is
a tougher weld, while an annealing heat treatment will
preferred for many applications because it is usually the
result in a softer weld.
quickest method. Grinding is popular for removing surStress relieving is the uniform heating of a weldment to a
face defects and shallow lying defects. Once the defects
have been removed, the low areas created by the grindhigh enough temperature, below the critical range, to reing and gouging can be rewelded using flux cored arc
lieve most of the residual stresses due to welding. This is
followed by uniform cooling. This operation is performed
welding or some other welding process. The welds are
then reinspected to make sure that the defects have been
on many steels after welding to relieve the residual
properly repaired.
stresses due to welding. This also reduces warpage during machining that
POSTHEATING
may occur with a high residual stress
buildup. On parts and metals that are
Postheating is the heat treatment aplikely to crack due to the internal stress
plied to the weld or weldment after
created by welding, the parts should
welding. Postheating is often required
be put into stress relief immediately
after the weld has been completed, but
after welding, without being allowed to
this depends upon the type of metal
cool to room temperature. The terms
being welded, the specific applicanormalizing and annealing are misnotion, and the governing code or specimers for this heat treatment.
fications. Many of the low carbon and
Illustration 13-4 Stress Relieving
low alloy steels are rarely postheated.
Quenching and tempering is another
There are various types of postheating that are used to
postweld heat treatment that is commonly used. The
obtain specific properties. Some of the most commonly
metal is heated up and then quenched to form a hard
used postheats are annealing, stress relieving, normaland brittle metallurgical structure. The weldment is then
izing, and quenching and tempering. Stress relieving is
tempered by reheating to a particular temperature, dethe most widely used heat treatment after welding. Pospendent on the degree of ductility, strength, toughness,
theating is accomplished by most of the same methods
and hardness desired. Tempering reduces the hardness
that are used for preheating, such as furnaces, induction
of the part as it increases the strength, toughness and
coils, and electric resistance heating blankets. One methductility of the weld.
86
CHAPTER 14
WELDER TRAINING AND QUALIFICATION
WELDER TRAINING
Flux cored arc welding requires a certain degree of skill
to produce good quality welds. In semiautomatic welding, the welder has to manipulate the welding gun and
control the speed of travel. Less skill is required to operate this process when compared to the manual welding
processes because the machine controls the arc length
and feeds the electrode wire. Welders skilled in manual
welding processes and gas metal arc welding generally
have less difficulty learning flux cored arc welding. This
process uses similar equipment and welding techniques
to those used in gas metal arc welding. At higher current
levels, when using larger diameter wires, flux cored arc
welding has a smoother arc and is easier to handle than
larger diameter solid wires with a carbon dioxide shielding. Because of the deep penetrating characteristics of
the process, lack of fusion and incomplete penetration
are easier to avoid and compensate for, than gas metal
arc welding using short-circuiting transfer.
The exact content of a training program will vary depending on the specific application of the process. A training
program should have enough flexibility so that it can be
adapted to changing needs and applications. Because
of this, the emphasis may be placed on certain areas of
training based on the complexity of the parts to be welded, type of metal, and governing code or specification.
A welding course that covers all position welding would
require more training time than one that simply covers flat
position welding only. A welding course for pipe would
require more training time than one for welding plate.
The major purpose of the training program is to give the
welder the skill and knowledge to be able to do the best
job possible. A training program may be broken up into
several areas depending on the training requirements of
the student.
Basic Flux Cored Arc Welding
The basic flux cored arc welding training program is used
to teach the students the basic skills necessary to weld
plate. This course provides training on how to make quality fillet and groove welds. The course also gives the students the knowledge of how to set up the equipment,
clean the base metal, basic operating principles and the
difficulties that are commonly encountered. The training also covers the different welding techniques used
for gas-shielded and self-shielded electrodes. Also covered are the techniques for welding out-of-position using small diameter electrodes. The training obtained by
the student should give the skill to perform a job welding
plate. This course should also provide the background
skill and knowledge required to take an advanced course
for a specific application such as for welding pipe. The
following is an outline for a course approximately 35

hours long:
1) Flux Cored Arc Welding, Course Overview
2) Introduction to Flux Cored Arc Welding
3) Safety & Health of Welders
4) Equipment Set Up, Adjustment &Maintenance
5) Fillet Welds, T-Joints, Horizontal, Vertical &
Overhead Positions (Gas & Self-Shielded)
6) Electrode Classification &Selection
7) Single-V-Groove Weld, Butt Joint, Horizontal
(2G)Position (Gas &Self-Shielded)
8) Single-V-Groove Weld, 2G Destructive Test
9) Single-V-Groove Weld, Butt Joint, Vertical (3G)
Position, Up (Gas &Self-Shielded)
10) Single-V-Groove Weld, Butt Joint, Overhead
(4G)Position (Gas &Self-Shielded)
11) Single-V-Groove Weld, Butt Joint, Horizontal (2G)
Position (Gas &Self-Shielded)
12) Single-V-Groove Weld, Butt Joint, Vertical (3G)
Position, Up with Stringers (Gas &Self-Shielded)
13) Single-V-Groove Weld 3G Destructive Test
14) Single-V-Groove Weld, Butt Joint, Flat (1G) Position
(Self-Shielded)
15) Fillet Weld, Lap Joint, Flat (1F) Position
(Metal-Cored)
16) Single-V-Groove Weld, Butt Joint, Flat (1G)Position,
(Metal-Cored) & Destructive Test
17) Single-V-Groove Weld, Butt Joint, Horizontal (2G)
Position, Pipe
18) Single-V-Groove Weld, Butt Joint, Horizontal Fixed
Position (5G) Pipe
WELDER QUALIFICATION
Before the welder can begin work on any job covered by
a welding code or specification, the welder must become
qualified under the code that applies.
Many different codes are in use today, and it is very important that the specific codes are referred to when taking qualification tests. In general, the following types of
work are covered by codes: pressure vessels and piping,
87
highway and railway bridges, public buildings, tanks and

containers, cross country pipelines, ordnance material,
ships and boats, and nuclear power plants. Several of
the specifications include consideration of the flux cored
arc welding process. These are:
1) ASME Boiler and Pressure Vessel Code, Section IX,
Qualification Standard for Welding and Brazing
2) ANSI/AWWA D-100 Welded Steel Tanks for Water
Storage
3) AWS D1.1, Structural Welding Code
4) ANSI/AWS B2.1, Standard for Welding Procedure and
Performance Qualification
5) AWS D14.1, Specification for Welding Industrial and
Mill Cranes
6) AWS D14.3, Specification for Welding Earthmoving
and Construction Equipment
7) API 1104 Standard for Welding Pipelines and Related
Facilities,
8) G 115, Marine Engineering Regulations
These specifications do not provide qualifications of the
flux cored arc welding process for all applications and
service requirements. For applications where AWS or
other specifications are not available or do not apply and
general criteria for qualification is desired, AWS B2.1,
Standard for Welding Procedure and Performance Qualification, is often used. Qualification is obtained differently
under the various codes. Qualification under one code
will not necessarily qualify a welder to weld under a different code. In most cases, under the ASME BPVC Section IX, Qualification Standard for Welding and Brazing,
qualififcation for one employer will not allow the welder to
work for another employer. If the welder uses a different
process or the welding procedure is altered drastically,
requalification is required. In most cases, if the welder is
continually employed, welding requalification is not required, providing the work performed meets the quality
requirements.
Illustration 14-3 Typical Qualification Standards
Qualifications tests may be given by responsible manufacturers or contractors. On pressure vessel work, the
welding procedure must also be qualified and this must
be done before the welders are qualified. Under other
codes, this is not necessary. To become qualified, the
welder must make specified welds using the required
process, base metal, base metal thickness, electrode
type, position and joint design. For example, in the AWS
Structural Welding Code (D1.1), certain joint designs are
considered prequalified for flux cored arc welding. Test
specimens must be made according to standardized sizes and under the observation of a qualified person. For
most government specifications, a government inspector
must witness the making of weld specimens. Specimens
must be properly identified and prepared for testing. The
most common test is a guided bend test. In some cases,
radiographic examinations, fracture tests, or other tests
are employed. Satisfactory completion of test specimens, providing that they meet acceptability standards,
will qualify the welder for specific types of welding. The
welding that will be allowed again depends on the particular code. In general, the code indicates the range of
thicknesses which may be welded, the positions which
may be employed, and the alloys which may be welded.
Qualification of welders is a highly technical subject and
cannot be covered fully here. It is recommended that the
actual code be obtained and studied prior to taking any
tests.
88
CHAPTER 15
WELDING SAFETY
Safety is an important consideration when welding.
Material Safety Data Sheets (MSDSs)
OSHA requires that employers must have a comprehensive hazard communication program to inform employees
about hazardous substances that might be used in the
workplace. The purpose of the MSDSs is to explain the
hazards involved in handling/using products such as welding consumables and the precautionary measures which
must be put in place for safe welding. The employer must
maintain continuous training concerning such materials,
and safety in general. Provisions to safeguard employees
are included in Material Safety Data Sheets (MSDSs) as
prescribed by the Hazard Communications Standard of
the U.S. Department of Labor. Information must be provided for all substances taken into the workplace except
food, drugs, cosmetics or tobacco products used for
personal consumption. The use of these data sheets in
all manufacturing workplaces has been mandated since
1985. Employees must be trained on the information in
Material Safety Data Sheets and labels.
AWS/ANSI Z49.1
A set of safety rules which should be followed is presented in the American National Standard Institute Z49.1,
Safety in Welding and Cutting, published by the American Welding Society. There are a number of hazards associated with shielded metal arc welding. These do not
necessarily result in serious injuries. They can also be of
a minor nature which can cause discomforts that irritate
and reduce the efficiency of the welders. These hazards
are:
1) Electrical shock
2) Arc radiation
3) Air contamination
4) Compressed gases
5) Fire and explosion
or ground rod. Welding cables with frayed or cracked insulation and faulty or badly worn connections can cause
electrical short circuits and shocks. An improperly insulated welding cable is both an electrical shock hazard and
a fire hazard.
The welding area should be dry and free of any standing
water. When it is necessary to weld in a damp or wet area,
the welder should wear rubber boots and stand on a dry,
insulated platform.
ARC RADIATION
Flux cored arc welding produces an intense welding arc
which emits ultraviolet and infrared rays. Skin that is exposed to the arc for a short time can suffer serious ultraviolet and infrared burns which are essentially the same
as sunburn, but the burn caused by welding can take
place in a much shorter time and can be very painful. The
welder should always wear protective clothing suitable for
welding to be done. These clothes should be fairly heavy
and fire resistant. Leather is often used to make jackets,
capes, and bibs, or other similar arrangements to shield
the shoulders, arms, and chest from radiation and spatter.
Leather gloves should be worn, but the gloves are often
lighter than those used for shielded metal arc welding.
The eyes must be protected from the radiation emitted by
the welding arc. The welding arc should never be viewed
by the naked eye at a distance closer than 30 ft. (9 m). Arc
burn can result if the eyes are not protected. Arc burn of
the eye is similar to sunburn of the skin and is extremely
painful for about 24 to 48 hours. Usually arc burn does not
permanently injure the eyes, but it can cause intense pain.
There are several commercial solutions that are available
to soothe the skin and eyes during the period of suffering.
Infrared arc rays can cause fatigue of the retina of the eye.
The effects of infrared rays are not nearly as noticeable or
immediate as the effects of ultraviolet rays. Infrared rays
6) Weld cleaning and other hazards
ELECTRICAL SHOCK
There are several precautions that should be taken to
prevent an electrical shock. First, make sure that the arc
welding equipment is properly installed, grounded, and in
good working condition. The electrical equipment should
be maintained and installed in accordance with the National Electrical Code and any state and local codes that
apply. Equipment should be operated within NEMA Standards usual operating conditions for proper safety and
equipment life. The case or frame of the power supply
should be connected to an adequate electrical ground,
such as an approved building ground, cold water pipe,
89
Illustration 15-1 Welding Helmets

Photos courtesy of Miller Electric Manufacturing Co.
Welding Current
(Amperes)
Minimum
Protective Shade
Suggesteda Shade
No. (Comfort)
Under 60
60-160
10
11
160-250
10
12
250-550
10
14
Welding Bandana
protects head.
Safety Goggles
protects eyes.
Light Welding Jacket
protects the chest and arms.
a) As a rule of thumb, start with a shade that is not too dark to see the weld zone. Then go to
a lighter shade which gives sufficient view of the weld zone without going below the minimum.
In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible
light spectrum.
Industrial Grade
Auto-Darkening Helmet
protects eyes and face.
Illustration 15-2 Suggested Filter Glass Shades

for Flux-Cored Arc Welding
Welding Gloves
protects hands.
are probably more dangerous in that their effects can be

longer lasting and result in impaired vision.
The flux cored welding arc is a relatively high energy arc
which is much brighter than lower current welding arcs.
Even though more smoke is given off from the arc area,
it does not shield arc rays effectively. Protection for the
eyes and face is provided by a head shield that has a window set in it, with a filter lens in the window. Helmets with
large windows are popular for welding with this process.
Small and large window helmets are shown in Illustration
15-1. Head shields are generally made of fiberglass or a
pressed fiber material so that they will be lightweight. The
filter lens is made of a dark glass or plastic that is capable of absorbing infrared rays, ultraviolet rays and most
visible light coming from the arc. The lens shade used
varies for different welders, different metals, and different
current levels, but it should be dark enough so that the
arc can be viewed without discomfort and not so dark
that the welder cannot see the arc clearly. Illustration 15-2
shows the AWS suggested lens shades. The higher the
lens number, the darker the lens. A clear glass should be
put on the outside of the welding lens to protect it from
spatter, scratching, and breakage. Welding should never
be done with a broken filter lens or with cracks in the head
shield.
AIR CONTAMINATION
One of the main problems with flux cored arc welding is
that it gives off more smoke and fumes than processes
such as gas tungsten arc welding, gas metal arc welding,
and submerged arc welding. It even tends to produce
higher smoke and fume levels than shielded metal arc
welding. A hazard warning for fume is placed on the electrode wire box.
The welding area should be adequately ventilated because fumes and gases such as ozone, carbon monoxide and carbon dioxide are hazardous for the welder
to breathe. When welding is done in confined areas, an
Leather Apron
protects lap.
Denim Pants
Without Cuffs
protects legs and feet.
Leather Shoes
protects feet.
Illustration 15-3 A Well-Dressed FCAW Welder
external air supply is required. This is furnished by the

use of a respirator on a special helmet. A second person
should stand just outside the confined area to lend assistance to the welder if necessary. Another method is to
use an exhaust system to remove welding fumes. Special
fume extractor nozzles that are attached to the welding
gun are popular for use with flux cored arc welding to
reduce the smoke levels produced. These nozzles are
connected to a filter and an exhaust pump, which greatly
reduce the smoke level.
The shielding gas may displace the air that the welder
needs for breathing. Because of this, welding should not
be done in an enclosed area or hole, which can cause
suffocation without the use of a respirator. Welding
should never be done near degreasing and cleaning operations. The fumes from chlorinated solvents used for
cleaning form a very toxic gas, called phosgene, when
exposed to an arc. A mechanical exhaust system should
be used when welding metals with lead, cadmium, and
zinc coatings. AWS/ANSI Z49.1 should be consulted for
ventilation requirements.
90
COMPRESSED GASES
The shielding gas used for flux cored arc welding is
compressed and stored in cylinders. One advantage
of self-shielded flux cored wire is that compressed gas
cylinders are not required, so this is primarily a safety
consideration when gas-shielded electrodes are used.
Improper handling of compressed gas cylinders can create a safety hazard. When in use, gas cylinders should be
secured to a wall or other structural support. The valve
of the cylinder should be opened slowly and the welder
should stand away from the face of the regulator when
doing this. The welding arc should never be struck on a
compressed gas cylinder. When not in use, gas cylinders
should be stored with their caps on. Caps should also be
on when they are moved. If the valve would get knocked
off, the cylinder acts like a missile, because of the escaping gas, and can cause injury and damage. When compressed gas cylinders are empty, the valve should be
closed and they should be marked empty. This is done
by marking the letters, MT or EMPTY on the cylinder.
FIRES AND EXPLOSIONS

Fires and explosions are hazards that can exist in a welding area if the proper precautions are not taken. The flux
cored arc welding process can produce sparks and spatter which can start a fire or explosion in the welding area,
if not kept free of flammable, volatile, or explosive materials, Heavy, fire resistant clothing, usually leather, is worn
by the welder to protect him from burns. Fires can also
be started by an electrical short, or by overheated, worn
welding cables.
In case of a fire that is started by a flammable liquid or
an electrical short, a CO2 or dry chemical type of fire extinguisher should be used. Fire extinguishers should be
kept at critical areas around the shop and the welders
should make a mental note of where they are Iocated.
Other precautions relating to explosions are also important. A welder should not weld on containers that have
held combustibles unless it is absolutely certain that
there are no fumes or residue left. Welding should not be
done on sealed containers without providing vents and
taking special precautions. When the welding gun is set
down or not in use, it should never be allowed to touch a
compressed gas cylinder.
WELD CLEANING AND OTHER HAZARDS

Hazards are also encountered during the weld cleaning
process. Precautions must be taken to prevent the skin
and eyes from hot slag particles. Flux cored are welding produces a moderate slag covering which must be
removed. The welding helmet or safety glasses, gloves,
and heavy clothing protect the skin from slag chipping
and grinding of the weld metal. Safety glasses shall also
be worn underneath the welding helmet to protect the

eyes from particles that could get inside the welding helmet. Screens shall be set up if there are other people in
the area, to protect them from arc burn.
SUMMARY OF SAFETY PRECAUTIONS

1) Make sure your arc welding equipment is installed
properly and grounded and is in good working
condition. This will help prevent fatal electric shocks.
2) Always wear protective clothing suitable for the
welding to be done. This will help prevent injuries
and burns.
3) Always wear proper eye protection, when welding,
cutting, or grinding. Do not look at the arc without
proper eye protection. This will prevent eye injuries
and arc flash.
4) Avoid breathing the air in the fume plume directly
above the arc. This will prevent illness due to
overexposure to hazardous materials in the
fume plume.
5) Keep your work area clean and free of hazards. Make
sure that no flammable, volatile, or explosive materials
are in or near the work area. Good housekeeping will
help prevent accidents.
6) Handle all compressed gas cylinders with extreme
care. Keep caps on when not in use. Damaged
cylinders can rupture with explosive violence.
7) Make sure that compressed gas cylinders are
secured to the wall or to other structural supports.
The impact of a fall can cause cylinder rupture or
valve failure.
8) When compressed gas cylinders are empty close the
valve and mark the cylinder empty. This will prevent
contamination from entering the cylinder.
9) Do not weld in a confined space without special
precautions. Poor ventilation can lead to asphyxiation. Accumulation of flammable gases can explode.
Always practice confined space safety.
(See ANSI/AWS Z49.1, Section 7)
10) Do not weld on containers that have held combustibles without taking special precautions. The heat
of welding can ignite residual gases and cause an
explosion. The heat can cause the release of
hazardous fumes. Always assure a container is clean
and safe for welding.
11) Do not weld on sealed containers or compartments
without providing vents and taking special
precautions. The heat of welding can cause gases
to expand. The increased pressure can lead to
an explosion.
91
12) Use mechanical exhaust at the point of welding when

welding lead, cadmium, chromium, manganese,
brass, bronze, zinc, or galvanized steel, and when
welding in a confined space. These low allowablelimit materials can cause serious injury. Ventilation
will prevent overexposure.
13) When it is necessary to weld in a damp or wet area,
wear rubber boots and stand on a dry insulated platform. This will minimize the chance of electric shocks.
14) Do not use cables with frayed, cracked, or bare spots
in the insulation. This will prevent stray arcs between
the bare cable and the ground. It will prevent electric
shocks.
15) When the welding gun is not in use, do not hang it on
a compressed gas cylinder.
10) Arc Welding Equipment, E-60974 Series,

Canadian Standards Association.
11) Safety Standards for Arc Welding Equipment,
series 60974, Underwriters Laboratories,
Northbrook, IL.
12) National Electric Code, NFPA 70, National Fire
Protection Association, Quincy, MA.
13) Thoriated Tungsten Electrodes, Safety and
Health Fact Sheet No. 27, American Welding
Society, Miami, FL.
14) Lens Shade Selector, F2.2. American Welding
Society, Miami, FL.
15) Transparent Welding Curtains by Sliney, Moss,
Miller & Stephens, May 1982, Welding Journal,
Miami, FL.
REFERENCES FOR WELDING SAFETY
16) The Welding Environment, American Welding

Society Miami, FL.
The primary reference for this book is Modern Welding

Technology, by Howard B. Cary and Scott C. Helzer, published by Pearson Prentice Hall, Upper Saddle River, NJ.
Other references cited include:
18) Characterization of Arc Welding Fume, CAWF,

American Welding Society, Miami, FL.
1) Report on a Danish Investigation into the Health

and Working Environment of Arc Welders, Welding
in the World, Vol. 10, Nos. 3 and 4, 1972.
2) Occupational Safety and Health Standards Code
of Federal Regulations Title 29 - Part 1910, U.S.
Dept. of Labor. Available from the Superintendent of
Documents, U.S. Printing Office, Washington, DC.
3) Safety in Welding, Cutting, and Allied Processes,
ANSI Z49.1 American Welding Society, Miami, FL.
4) Effects of Welding on Health, EWH series,
5) Hazard Communication Standard, 29 CFR
1910.1200, U.S. Department of Labor,
Washington, DC.
6)
Threshold Limit Values for Chemical Substances
and Physical Agents and Biological Exposure
Indices, American Conference of Governmental
Industrial Hygienists, Cincinnati, OH.
7) Welding Workplace Safety, by Hallock Campbell.
Data Sheet No. 79A, Sept., 1986, Welding Journal.
8)
Safety Signs and Colors, standards series ANSI
Z535 America National Standards Institute,
New York, NY.
9)
Electric Arc Welding Power Sources, EW-1,
National Electrical Manufacturers Association,
Rosslyn, VA.
17) Fumes and Gases in the Welding Environment,

19) Method for Sampling Airborne Particles Generated

by Welding and Allied Processes, F1.1, American
Welding Society, Miami, FL.
20) Industrial Ventilation - A Manual of Recommended
Practice, American Conference of Governmental
Industrial Hygienists, Cincinnati, OH.
21) A Sampling Strategy Guide for Evaluating
Contaminants in the Welding Environment, F1.3,
22) Laboratory Method for Measuring Fume Generation Rates and Total Fume Emission of Welding and
Allied Processes, F1.2, American Welding Society,
Miami, FL.
23) Handling Acetylene Cylinders in Fire Situations,
Safety Bulletin No. SB-4, Compressed Gas
Association, York, NY.
24) Hot Work Permits (Flame or Sparks) Data Sheet
522, National Safety Council, Chicago, Illinois.
25) Standard for Fire Prevention During Welding,
Cutting and Other Hotwork, NFPA 51B, National
Fire Protection Association, Quincy, MA.
26) Safe Practices for the Preparation of Containers
and Piping for Welding and Cutting. F4.1, American
27) Safe Hot Tapping Practices in the Petroleum and
Petrochemical Industries, RP 2201, American
Petroleum Institute, Washington, DC.
92
28) Cylinders: Safe Storage, Handling, and Use, Safety and Health Fact Sheet No. 30. American Welding
Society, Miami, FL.
29) Arc Welding and Cutting Noise, AWN, American
30) Safety and Health Fact Sheets, SHF, American
48) Recommended Practices for Resistance Welding,

C1.1, American Welding Society, Miami, FL.
49) Recommended Practices for Air Carbon Arc
Gouging and Cutting, C5.3, American Welding
Society, Miami, FL.
50) Recommended Practices for Plasma Arc Cutting
and Gouging, C5.2, American Welding Society,
Miami, FL.
31) Using Transparent Welding Curtains by Dean R.

Wilson, Welding Journal, September 2005, American Welding Society, Miami, FL.
51) Recommended Practices for Electron Beam

Welding, C7.1, American Welding Society,
Miami, FL.
32) Methods for Sampling and Analyzing Gases from

Welding and Allied Processes, F1.5, American
52) Thermal Spray Manual, TSM, American Welding

Society, Miami, FL.
33) Guide for Estimating Welding Emissions for EPA

and Ventilation Permit Reporting, F1.6, American
53) Thermal Spraying Practice, Theory and

Application, TSS, American Welding Society,
Miami, FL.
34) Lens Shade Selector, F2.2, American Welding

Society, Miami, FL.
54) Recommended Practices for Laser Beam

Welding, Cutting, and Drilling, C7.2, American
35) Specification for Use and Performance of

Transparent Welding Curtains and Screens, F2.3,
Web Sites
36) Ventilation Guide for Weld Fume, F3.2, American

1) American Welding Society, http://www.aws.org
37) Lockout/Tagout, Safety and Health Fact Sheet No.

18, American Welding Society, Miami, FL.
2) Occupational Safety and Health Administration,

http://www.osha.gov
38) Underwater Cutting and Welding, NAVSEA

S0300-BB-MAN-010, U.S. Dept. of the Navy, Naval
Sea Systems Command, Washington, DC.
3) National Institute for Occupational Safety and Health,

http://www.cdc.gov/niosh
39) Occupational and Educational Personal Eye and

Face Protection Devices, ANSI Z87.1 American
National Standards Institute, New York, NY.
40) Chromium, Nickel, and Welding, International
Agency for Research on Cancer (IARC), Volume 49,
1990.
41) Specification for Underwater Welding, D3.6M,
42) Specification for Robotic Arc Welding Safety,
D16.1, American Welding Society, Miami, FL.
43) Risk Assessment Guide for Robotic Arc Welding.
D16.3, American Welding Society, Miami, FL.
44) Braze Safely BRS, American Welding Society,
Miami, FL.
4) National Fire Protection Association,

http://www.nfpa.org
5) U.S. Government Printing Office,
http://www.gpo.gov
6) American Conference of Governmental Industrial
Hygienists, http://www.acgih.org
7) Canadian Standards Association,
http://www.csa.ca
8) American National Standards Association,
http://www.ansi.org
9) Compressed Gas Association,
http://www.cganet.com
10) American Petroleum Institute, http://www.api.org
11) Underwriters Laboratories, http://www.ul.com
45) Brazing Handbook, BRH, American Welding

Society, Miami, FL.
12) National Electrical Manufacturers Association,

http://www. www.nema.org
46) Soldering Handbook, SHB, American Welding

Society, Miami, FL.
13) Global Engineering Documents,

http://www.global.ihs.com
47) Resistance Welding Manual, RWM, American

14) World Engineering Xchange, Ltd.,

http://pubs.aws.org
93
INDEX
Index Terms
Links
A
Accessibility
47
Accessories
13
Advantages of FCAW
62
Acid Pickling
77
Air Carbon Arc Gouging
77
Air Contamination
90
Alternating Current
Annealing
41-42
Arc Blow
83
Arc Length
47
86
86
2-5
42
61-62
66
87
Arc Radiation
89
Arc Strikes
81
Arc Systems
Argon-Carbon Dioxide Mixtures
15
Argon-Oxygen Mixtures
15
Austenitic Stainless Steel
37
Automotive Products
30
AWS/ANSI Z49.1
89
41-42
B
Backing Strips
48
Base Metal Cracks
83
Bead Height
59
61-63
Bead Width
59
61-65
Bevel Angle
44
C
Cables
12
Recommended Lengths
Cadmium
13
90
This page has been reformatted by Knovel to provide easier navigation.
92
67
Index Terms
Links
Carbon Dioxide
11-12
14-15
31
33
39-41
81
83-84
87
90
Carbon Equivalent
Carbon Steel
36
38-39
16-17
40
62
29
Carriages
13
Centerline Crack
82
Charpy V-Notch Test
37
Chemical Composition
36
Chipping
13
47
61
77
85-86
91
22
29
39
40-42
92-93
Chromium
Chromium-Molybdenum Steels
40
Cleaning
85
Cleaning the Work Metal
77
Clogged Contact Tube
84
Cold Cracking
20
Columbium
41
Complete Penetration
44-45
Compressed Gases
91
Conformances
27
Constant Current
3-9
Controls
47
61
Corrosion Resistance
Cost of Flux Cored Arc Welding
15
26
39-41
86
36
32
Comparison Table
34
Electric Power
33
Electrodes
32
Labor and Overhead
32
Shielding Gas
33
Cracking
82
Craters
81
Crater Cracks
82
Current Density
82
5
45
61
Index Terms
Links
D
Degreasing
77
Dendrites
38
Deoxidizers
20
90
36
38-39
15
33-35
1-2
13
20
26-35
39
59-61
66-67
78
77
Deposition Rate
Destructive Testing
85-86
Direct Current Electrode Negative
21
26
Direct Current Electrode Positive
21
26
Dirty Contact Tube
84
Discontinuities Caused By Welding Technique
79
Distortion
81
Drag Angle
67
Drive Rolls
9-11
Ductility
Duty Cycle
79
14-15
26
36
39-42
61
86
6-8
11-12
E
Effective Throat
48
Electric Power Cost
33
Electrical Shock
89
Electrode Angle
67
Electrode Cost
32
Electrode Extension
66
Electrode Lead
Electrode Size
61
Electrode Selection
26
Electrode Type
59
Electrodes
16
Classification
16
Selection
26
Conformances and Approvals
27
Elongation
69
17-18
12
36
Index Terms
Links
Equipment for Welding
Excessive Spatter
81
Explosions
91
F
Fires
91
Fixed Variables
59
Fixturing
78
Flux Cored Arc Spot Welding
31
Free Machining Steels
41
Fume Extractors
11
Fusion Line
37
G
Gas Shielding System
Generator Welding Machines
1-2
32
Grain Size
38
86
Grinding
77
81
85-86
47-48
82
38
40
14
36-38
40
62
82-82
91
Groove Angle
44-45
H
Hardenability
38-40
Hardness
14
86
Heat Affected Zone
Heat Treatable Steels
40
Heavy Equipment
30
Helium
Helmet
89-91
High Carbon Steel
37-38
Filler Metal Classification

Preheat Temperatures
Hot Cracking
18
40
16-23
37
20
41
82
Index Terms
Links
I
Impact Strength
19
26
36-37
Impact Tests
19
36
86
Inadequate Joint Penetration
82
Inadequate Shielding
83
Inclusions
14
79
85
Industries
28
Incomplete Fusion
80
Industrial Piping
28
Inspection and Testing
85
32
43
47
77
80
Joint Restraint
36
78
Joints, Common Types
43
Introduction to the Process
J
Joint Preparation
K
Kilowatt
33
L
Labor Cost
32
Lead (element)
41
Limitations of FCAW
Longitudinal Crack
82
Low Alloy Steels
39

Low Carbon Steel
16-23
37
39

16-23
37
M
Machine Welding Guns
11
Magnesium
42
82
82-83
Index Terms
Links
Maintenance and Repair

Martensite
30
38-40
Martensitic Stainless Steels
89
Material Safety Data Sheets
89
Mechanical Properties
36
Medium Carbon Steel
37
37
Melt-Through
81
Melting Point
41
Metal Transfer
Methods of Application
Microstructure
37
Mild Steel
39
16-23
Inches Per Pound of Wire
33
37
Minimum Effective Throat
40
46
Moisture
14-16
79-80
Molybdenum
22-23
29
37
22
37-41
77
14
42
39-40
Motion Devices
13
N
Nickel
Nitrogen
61-62
Nondestructive Testing
Normalizing
85-86
86
O
Operator Factor
32
Other Equipment
13
Other Problems
83
Overlapping
80
Oxidation
15
83
34-35
40-41
66
Index Terms
Links
P
Partial Penetration Weld
Phosgene
Phosphorous
444-45
48
77
90
40-41
79
Plasma Arc Cutting
77
Porosity
79
Position
45
Positioning
78
Postheating
86
Postweld Procedures
85
Power Source Duty Cycle
Power Sources
Preheating
78
Preparing the Weld Joint
77
Preselected Variables
59
Preweld Preparations
77
Primary Variables
61
Principles of Operation
Procedure Schedules
69
Procedure Variables
59
Process Method
44
Properties of the Weld
36
Protective Clothing
89
Push Angle
91
67-68
Q
Quenching and Tempering
86
R
Radiographic
85-86
Railroads
29
Reduction of Area
36
References for Welding Safety
92
Repairing of Welds
86
Reverse Polarity
Root Face
44
Root Opening
44
88
21
82
Index Terms
Links
S
Safety
89
Scavengers
16
Secondary Variables
66
Selenium
41
Shearing
77
Shielding Gases and Electrodes
14
Shielding Gas Cost
33
Shielding Gas Equipment
12
Shielding Gas Flow
38
77
12
15
66
79-80
Shielding Gases
14
Ships
28
Short Circuiting Metal Transfer
45
Slag
1-3
13
15-16
20-21
27-28
32-33
36
62
64-65
67
79
85
38
81-82
1-2
4-5
11
13
15-16
20
27
33
61-62
64-66
79
81
83-85
89-91
91
Slag Inclusions
79
Solidification
16
86
Spatter
Stainless Steels
41
Classification
42
24-27
Inches Per Pound of Wire
33
37
Steels
Straight Polarity
38
6
Strength
44
Stress Relieving
86
Structures
28
21
Index Terms
Links
Sulfur
20
40-41
79-80
14
17-18
21
36-37
39-40
85
Thermal Conductivity
41
48
Thermal Cutting
77
Thickness
47
Toe of Weld
44
82
Summary of Safety Precautions
91
T
Tensile Strength
Toughness
36-38
Transformer-Rectifier Welding Machines
Travel Angle
67-68
Travel Speed
62
Types of Current
Type of Weld Metal
48
Types of Power Sources
U
Ultimate Tensile Strength
36
Ultrasonic Testing
85
Undercutting
80
V
Ventilation
Volt-Ampere Curves
Voltage
90-91
4
3-9
33
61-65
69
W
Wagon Tracks
79
Warpage
81
Water Circulators
13
Weldable Metals
38
59
Index Terms
Links
Weld and Joint Design
43
Position
46
Strength
44
Thickness
47
Type of Metal
48
Weld Joint Designs
48
Weld Backing
77
Weld Cleaning and Other Hazards
91
Welds, Common Types
43
Welder Training and Qualification
87
Welder Training
87
Basic FCAW
87
Welder Qualification
88
Welding Applications
28
Welding Cables
12
Welding Current
61
Welding Discontinuities and Defects
79
Welding Lens
90
Welding Metallurgy
36
Welding Symbols
49
Welding Voltage (Arc Length)
61
Wire Feed Stoppages
84
Wire Feeders
Work Angle
68
Wormhole Porosity
86
50
Y
Yield Strength
14-15
17-18
36
39
90
92
Z
Zinc
26
APPENDIX
Sources for Standards
Organizations that originate or contribute to code preparation and updating

Association of American Railroads (AAH)
425 Third Street, SW
Washington, DC 20024
(202) 639-2100
http://www.aar.org
American Welding Society (AWS)

550 NW LeJeune Road
Miami, FL 33126
(800) 443-9353
http://www.aws.org
American Association of State Highway and Transportation Officials (AASHTO)

444 N Capitol Street NW, Suite 249
(202) 624-5800
http://www.transportation.org
Compressed Gas Association (CGA)

14501 George Carter Way, Suite 103
Chantilly, VA 20151
(703) 788-2700
http://www.cganet.com
American Bureau of Shipping and Affiliated Companies

(ABS)
16855 Northchase Drive
Houston TX 77060 USA
(281) 877-5800
http://www.eagle.org
American Institute of Steel Construction (AISC)
One East Wacker Drive, Suite 700
Chicago, IL 60601-1802
(312) 670-2400
http://www.aisc.org
American National Standards Institute (ANSI)
1899 L Street, NW
11th Floor
(202) 293-8020
http://www.ansi.org
Global Engineering Documents

15 Inverness Way East
Englewood, CO 80112
(800) 854-7179
http://global.ihs.com
Hobart Institute of Welding Technology (HIWT)
400 Trade Square East
Troy, OH 45373
(800) 332-9448 or (937) 332-5433
http://www.welding.org
MIL-STDS & NAVSHIP Specifications & Standards Document Automation and Production Service
700 Robbins Avenue
Bldg 4/D
Philadelphia, PA 19111
(215) 697-6257
https://assist.daps.dla.mil
American Petroleum Institute (API)

1220 L Street, NW
Washington, DC 20005-4070
(202) 682-8000
http://www.api.org
National Board of Boiler & Pressure Vessel Inspectors

(NBBPVI)
1055 Crupper Avenue
Columbus, OH 43229-1183
(614) 888-8320
http://www.nationalboard.org
American Society of Mechanical Engineers (ASME)

P.O. Box 2300, 22 Law Drive
Fairfield, NJ 07007-2300
(800) 843-2763 (U.S/Canada)
http://www.asme.org
National Certified Pipe Welding Bureau (NCPWB)

1385 Piccard Drive
Rockville, MD 20850
(301) 869-5800
http://www.mcaa.org
American Society for Nondestructive Testing (ASNT)

P.O. Box 28518 , 1711 Arlingate Lane
Columbus, OH 43228-0518
(800) 222-2768 or (614) 274-6003
http://www.asnt.org
National Electrical Manufacturers Association (NEMA)

1300 North 17th Street, Suite 1752
Rosslyn, VA 22209
(703) 841-3200
http://www.nema.org
American Society for Testing Materials (ASTM)

P.O. Box C700, 100 Barr Harbor Drive
West Conshohocken, PA 19428-2959
(610) 832-9500
http://www.astm.org
National Fire Protection Association (NFPA)

1 Batterymarch Park
Quincy, MA, 02169-7471
(617) 770-3000
http://www.nfpa.org
104

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EW-492

Flux Cored Arc Welding

1. Introduction to the Process . . . . . . . . . . . . . . . . . . . . . . . . . 1

Appendix: Sources for Standards . . . . . . . . . . . . . . . . . . . . .104

2012, 2002, 1994 Hobart Institute of Welding Technology

Flux cored arc welding is similar to gas metal

Illustration 1-1 Flux Cored Arc Welding

the disintegration of electrode coatings. Results of this

A major development in flux cored arc welding in the

ADVANTAGES AND LIMITATIONS

atmosphere. Most self-shielding wires also operate using

LOAD CURRENT (D.C. AMPERES)

Illustration 2-1 Constant Voltage Volt-Ampere Curve

LOAD CURRENT (D.C. AMPERES)

Illustration 2-2 Different Slope Obtained

wire and the work. This is not as important in flux cored

Open circuit voltage

WELD CURRENT (AMPERES)

Illustration 2-3 Constant Current

With the constant current arc system, the welder would

of transfer. These are spray transfer, globular transfer,

Illustration 2-5 Metal Transfer in Flux Cored Arc Welding

Wire Feed Control

In general, these lower duty cycle machines are the

Feeder Contactor Control

Illustration 3-1 Equipment for Flux Cored Arc Welding

Illustration 3-2 Particle Flow for DCEP and DCEN

Illustration 3-3 Gas Powered Welder/Generator

transformer circuit. A rectifier is an electrical device which

welding. A 650 amp solid state controlled power source

Illustration 3-4 Three phase Power Source

welding, a separate control box is often used to control

4-Roll Gear Box

2-Roll Gear Box

Illustration 3-7 Wire Feeder Assembly

Photo courtesy of Miller Electric Manufacturing Co.

Illustration 3-6 Variable Speed

Photo courtesy of Miller Electric Manufacturing Co.

flattened. V-knurled drive rolls are most commonly used

Wire Feed Speed

Illustration 3-9 Wire Feed Speeds obtained

Illustration 3-10 600 Ampere Air-Cooled Gun

Illustration 3-11 Gun for Self-Shielded

and duty cycles required. The welding gun is mounted

Machine Welding Guns

FCAW gun with

Illustration 3-12 An Insulated Extension Guide

Illustration 3-13 Automatic Welding Guns

Illustration 3-14 Fume Extractor Nozzle

reduces air pollution and gives better visibility. Welding

Illustration 3-15 Flowmeter and Regulator

SHIELDING GAS EQUIPMENT

The shielding gas equipment used for gas-shielded flux

The welding cables and connectors are used to connect

The shielding gases are supplied in liquid form when they

Length of Cable in Feet Cable Size A.W.G.

Motor driven carriages that run on tracks or directly on the

Motion devices are used for machine and automatic

Hydrogen may come from water in the atmosphere or