title = "Flux-Cored Arc Welding (FCAW): Process and Use"

content = """
Flux-Cored Arc Welding (FCAW) uses a hollow tubular wire electrode filled with flux, combining the continuous wire feed and high productivity of GMAW with the slag-forming and self-shielding capabilities of SMAW. At Ridgecrest Metalworks, FCAW is used for heavy structural steel fabrication, thick-section welds, and applications where higher deposition rates than solid wire GMAW are required.

FCAW has two variants. FCAW-G (gas-shielded) uses both the flux core and an externally supplied shielding gas (typically 75/25 Ar/CO2 or 100% CO2). The combination of core flux and external gas produces excellent weld quality and low porosity; it is the preferred variant for shop work where gas supply is available. FCAW-S (self-shielded) generates all shielding from the flux core chemistry alone—no external gas is required. This makes FCAW-S suitable for outdoor welding in windy conditions where external gas shielding would be blown away, a distinct advantage over GMAW and FCAW-G.

FCAW produces higher deposition rates than solid wire GMAW because the flux core reduces the electrical resistance of the wire, allowing higher current for a given wire diameter. A .045-inch (1.2 mm) FCAW-G wire typically deposits 6–10 lb/hr vs. 4–7 lb/hr for the same diameter solid wire.

The flux core also produces a slag covering over the completed bead that must be removed between passes and from the final weld surface. Slag removal with a chipping hammer and wire brush is a required step—slag inclusions trapped between passes cause weld defects. Gas-shielded FCAW produces less slag than self-shielded, which generates significantly more slag.

FCAW is well-suited to flat and horizontal positions; out-of-position (vertical, overhead) welding requires specific low-hydrogen out-of-position FCAW wires and proper parameter control. Running parameters too hot out of position causes the weld pool to sag and run.

Common FCAW wires for mild steel include E71T-1 (FCAW-G, all-position) and E71T-8 (FCAW-S, all-position, self-shielded). Stainless FCAW wires such as E308LT and E316LT are used for austenitic stainless steel. Electrode storage and handling requirements apply similarly to SMAW low-hydrogen electrodes.
"""

version = "0.0.1"
