What is Flux Core Welding? All You Need To Know

Flux Core Welding is a popular welding method that is similar to MIG welding but has some specific differences that sets it apart. This method creates its own shielding and tends to be quicker, making it the ideal choice for outdoor projects.

You'll often find it used in construction, pipe welding or anywhere weather may be a concern.

What is flux core welding good for?

Flux core arc welding can be used for a variety of projects but is the top welding method choice for outdoor environments. Because it can weld so easily through rusting, flux core welding has become a popular welding method for pipeline construction and heavy machinery repairs.

Ideal Job Types:

• Construction sites
• Industrial or heavy machinery projects
• Railroad Industry
• Outdoor welding
• Thicker metal or metal prone to rust

Due to its high welding speed and increased ability to deposit filler metal. It is also a great choice if larger quantities are needed.

When considering welding positions, FCAW will work with most welding positions but there are some factors to consider.

• Flat or horizontal positions- There really are no major concerns. Controlling the weld pool is a bit more challenging. You can expect additional clean-up work caused by the spatter of the molten metal in this case.
• Vertical or overhead positions- This position can be a bit more tricky. This doesn't mean that it can't be done, it just means it comes with its own set of challenges. There is a chance of more dripping but this can be solved by using the gas-shielded FCAW approach, giving you more control.

Overall, it is a powerful method with fewer weld defects, making it ideal for thicker metal in more extreme conditions. The end result doesn't usually require super clean welds.

What's the difference between flux core and MIG welding?

Metal Inert Gas Welding, also known as MIG welding is a process where a continuous wire gets fed through a welding gun and melds into a weld pool. This welding pool then cools which results in joining the two metals together. The actual size and shape of the weld pool play an important role in the end result of the project.

When welding with the MIG method an arc is going to form between the wire and the metal you are working with. The heat given off will melt the wire and form a nice weld pool.

In this case, larger is not always better. A large or inconsistent weld pool may lead to weaknesses in the bond. There is a need for balance when forming the weld pool since one too small or unstable can also leave weaknesses.

You are in control of the weld pool by adjusting settings like heat, speed and the pace of the wire feeder. Consistency in this process will result in the highest quality.

If you looking for a good MIG Gun, check these out here:https://arc-zone.com/welding/mig-gmaw/self-shielded-flux-core-guns/?srsltid=AfmBOorokazLOA1FS-VaEFofmYk9inWvXpvN4GS7wrnGdWhEOOzP-o3Y

In the final step you'll use shielding gas to protect your new weld area. Typically, you will use argon or a mix (Carbon Dioxide). When looking at stick welding, this is protection added by the flux coating and serves the same purpose.

When comparing Flux Core and MIG welding it is important to note the following:

Flux Core welding and MIG welding are both arc welding methods that use wire feed to combine metal. They do have differences, including the type of wire used, the process for protecting the metal, and skill level.

1. Type of wire used: The main difference between flux-cored arc welding and MIG welding is the type of welding wire used. Flux Core Welding uses a tubular wire that creates shielding gas which results in a flag layer, protecting the weld. MIG welding also uses a wire but a solid wire.
2. Thickness of Metal: MIG Welding and Flux Core Welding use different thicknesses of materials. When using the MIG welding process you are usually using thin to medium thickness materials. Welding thicker materials is not ideal for MIG welding. Now in situations where necessary, MIG welding can still be used on thicker materials, but the wire and settings will require adjusting. Flux Core Welding can easily go through thicker metals, which makes it the welding method of choice for outdoor and heavy-duty projects. When any kind of work needs to be done on industrial projects you are going to want to consider this welding method.
3. Difficulty: MIG welding tends to be the easier welding method for beginners to learn. This welding process tends to create less spatter and the end result is more stable welds. If you were to ask most seasoned welders what they first learned when diving in, they will likely tell you it was MIG Welding.
4. Environments: Different than Flux Core Welding, MIG welding is not going to be your top choice for outdoor environments and is going to require cleaner materials to be used. This makes it less ideal for those industrial and heavy machinery projects.
5. Finish and Appearance: If you find yourself looking for clean and "prettier" looking welds or working with a more fragile metal, MIG Arc welding is going to be the go-to choice.

Check out this video to compare the two methods more:

https://youtu.be/ir7gVoKAG8o?si=4Eg6TE3v4xLHC_H9

What is the disadvantage of flux core welding?

Although Flux core arc welding has its many advantages, it does come with its own set of disadvantages. To name a few:

1. Clean up: Tends to create more of a mess, also known as "spatter". Because of the increased droplets of metal, extra clean-up time will be needed.
2. Ventilation: Due to the extra smoke created during this process, you will want to ensure you are protecting yourself from the increased fumes. This can make working conditions uncomfortable and create an increased risk of health concerns. Using proper ventilation can help decrease these risks.
3. Cost: The cost of Flux Core Welding is known to be higher than other welding processes, especially if you will be using gas-shielded metal. The added need for gas in this method results in a bigger price tag.
4. Difficulty: Flux Core welding is typically a more mastered welding technique and not one that beginners will dive right into. Even a seasoned welder can struggle to create a clean weld with this method.

With proper planning, the advantages of this welding process far outweigh the disadvantages.

Is flux core as strong as stick welding?

Flux core welding can absolutely be as strong as stick welding. Stick Welding has forever been known for its durability but you can get this strength and durability with the right amount of control with Flux cored arc welding as well.

The type of wire used, along with the quality of the welds, will play a factor in its strength. This makes Flux Core welding a preferred method for the industrial space. We recommend using a Self Shield Flux Core gun (welding machine) like this one found here:https://arc-zone.com/130gl-self-shield-flux-core-gun/?srsltid=AfmBOooSUj5N_s7sSe8Xa3tTwyOr-sGtm54JXtL06HLj53wqXM41VCmJ

When using gas-shielded flux core, welding can produce welds comparable to stick welding. Gas-shielded flux-cored arc welding uses a special flux-cored wire paired with an external shielding gas to protect the weld. This method allows you to go deeper into the metal, resulting in a stronger weld.

In this process, the wire used creates a shielding gas when the temperature is brought up. This gas protects the weld area which leaves a cleaner and stronger weld. Again, the consistency of the welder is going to really play a factor in the strength of that weld arc.

Paying attention to the thickness of the metal you will be using will be important. Stick welding will have a slight advantage in getting through those very thick metals.

Flux Core Arc Welding is likely to be a better choice if you are faced with an outdoor project where climate plays a role.

When comparing the clean-up of both of these processes, they are going to be fairly similar. Both are going to have more slag, so this isn't one area I would be too concerned about.

In the end, both methods are going to give you durable and strong welds, so just make sure to compare the thickness of the metal you are working with and whether or not you will be indoors or outdoors when making your decision.

Frequently asked questions:

What should be considered when choosing a flux core wire?

There are many factors that play a role in deciding which wire to choose, but below are a few key things to consider.

Type of metal: It is important to consider the type of material and the thickness of that material when choosing the correct wire. There are different types of wires designed for mild steel, stainless or aluminum.

Thickness of metal: The kind of wire you use will also vary depending on the thickness of your metal. Wires are designed differently for materials that will need deeper penetration.

Cost and availability: When shopping for wire, you will quickly see that prices vary greatly. Like most things, high-performance wires will cost you more, but the end result will reflect that quality. You will also find that some wires are harder to get in certain areas and require more lead time to secure.

What materials are most commonly welded with flux core?

1. Mild Steel: This is the most popular material welded with flux core wire.
2. Stainless Steel: You can use stainless steel with this method, but you will want to pay close attention to the type of wire you choose.
3. Carbon Steel: When deeper penetration is needed for thicker metals like carbon steel, the FCAW is a preferred choice.

Other materials can certainly be used, but more caution needs to be taken.

Conclusion

Like with any project, you'll want to review the scope of the work before deciding which route to take.

MIG welding continues to be the preferred method for clean, indoor projects. It can be used on thin metal and, when done correctly, leaves a clean and professional-looking weld. If you are just getting started in your welding journey, you will most likely want to kick off with this method.

Flux Core Arc Welding is superior in outdoor environments that require thicker materials and less aesthetically pleasing results. It is known for its durability, speed and versatility. Don't forget to consider your welding equipment and welding gun options you have on hand and the investment you are willing to make.