Mar. 17, 2025
For structural applications, some contractors have made the switch from stick welding to self-shielded flux-cored welding to increase productivity and give themselves a competitive edge.
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Self-shielded flux-cored welding offers much greater travel speeds and deposition rates compared to stick welding, while also eliminating the frequent stopping and starting required to change out stick electrodes.
For contractors considering this conversion, there are some key factors to keep in mind to help choose the right self-shielded flux-cored welding gun for the job ' and to use and maintain it properly. Gun options such as heat shields, configurable necks and adjustable cable lengths can help improve weld quality, efficiency and operator comfort in self-shielded flux-cored applications.
Self-shielded flux-cored welding is becoming more common on jobsites for several reasons. In addition to the greater productivity and deposition rates of the process, it also doesn't require a shielding gas to protect the weld pool, eliminating the hassle and cost of buying and storing gas containers on the jobsite.
Not using shielding gas also eliminates the need to set up tents or wind shields to protect the weld from the elements and the need to use specialty nozzles to control gas flow as is common with a gas-shielded flux-cored process.
Some training may be required for welders who are used to the stick process. The different ergonomics of the self-shielded flux-cored gun compared to the stick electrode holder require approaching the weld from different angles and using different travel angles and pressure.
When stick welding, the operator typically begins with the electrode (and therefore his or her body) farther from the weld. As the rod shortens during welding, the welder gets physically closer to the weld, applying pressure to the stick electrode as it melts into the weld pool. In self-shielded flux-cored welding, the welder stays in the same spot, maintaining a consistent distance between the contact tip and the weld pool. The proper contact-tip-to-work distance depends on the application, but at least 1/2 inch is a good rule of thumb.
Self-shielded flux-cored welding can be prone to slag inclusions if proper technique isn't followed. Regularly inspect the contact tip to ensure it's free from spatter and debris buildup, which helps ensure smooth wire feeding. Properly clean the weld between passes.
Welding guns for self-shielded flux-cored applications are available in various configurations. Choosing the right gun can help contractors tailor it to their specific needs and applications. Consider these features:
Heat shield: One of the most common features on self-shielded flux-cored welding guns is a hand guard or heat shield, which is available in different sizes. In applications that require access to a corner joint, choosing a smaller guard increases maneuverability and provides more access. When welders need to run at a higher voltage and deposit more filler metal into the weld, using a larger guard helps deflect the higher heat.
Neck lengths and bends: Gun necks are available in varying lengths and bend angles. A slimmer neck provides a better view of the weld pool and improved access to tight areas, for example. A shorter neck typically provides more control compared to a longer neck. Lightweight, rotatable necks can also reduce operator fatigue and improve weld visibility.
Replaceable or fixed cable liner: Some self-shielded flux-cored gun models are available with either a replaceable cable liner or a fixed cable liner. A replaceable cable liner provides benefits in harsh and demanding environments, since self-shielded flux-cored welding can be hard on equipment and consumables. Replaceable power cable liners provide quick and easy cable maintenance and can extend product life since welders can change out components that experience high levels of wear. In addition, choosing a replaceable cable liner with internal trigger leads means there is no external trigger cord that can catch on surrounding objects. Conversely, fixed cable liners tend to be larger, which can be an issue when welding in corners or tight spaces.
Dual schedule switch: A self-shielded flux-cored gun with an optional dual schedule switch allows for wire speed adjustment while welding. In some guns, this switch is integrated into the handle to keep it protected from spatter. The ability to toggle between weld parameters easily ' without having to stop welding and change settings ' saves time and improves productivity.
There are ways to extend the life of the gun and consumables. The necessary frequency of gun and consumable maintenance depends on the application and the welding environment.
Conduct routine checks to ensure front-end consumables are in good shape and all connections are tight. This helps keep heat resistance low and ensures proper electrical conductivity so the gun and consumables last longer. Consider using a rotatable gun neck with a collet-style connection, which makes it easier to drop the neck in and tighten it. Consumables that use compression fittings also provide more efficient energy transfer and less overheating to help extend product life.
Be sure to keep the contact tip clear of spatter buildup and inspect the tip for signs of wear or keyholing, and also inspect the cable for any damage or nicks.
While the self-shielded flux-cored process is capable of welding material with dirt, oil or mill scale, remember that better surface preparation delivers better results in any welding application. Properly cleaning the base material will help produce better welds.
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Because flux-cored welding produces a slag and spatter, there is also a need to remove the slag between passes and for post-weld cleaning. Be aware that travel angles beyond 20 or 25 degrees can increase spatter and arc instability. With flux-cored welding, it's recommended to use a drag technique with a travel angle of 5 to 15 degrees.
As more contractors look for ways to increase productivity and efficiency on the jobsite, the use of self-shielded flux-cored welding grows. Choosing a welding wire designed to improve a weld's chemical composition or deposition rates can provide even more benefits.
The self-shielded flux-cored process can be a good alternative to stick welding in many outdoor applications that boosts productivity and reduces costs.
This is a question our experts keep getting from time to time. Now, we have got the complete detailed explanation and answer for everyone, who is interested!
There are two types of flux-cored wires ' gas shielded and self-shielded. Gas-shielded flux-cored wires require external shielding gas, and the slag is easy to remove. Consider using gas-shielded flux-cored wires when welding on thicker metals or in out-of-position applications.
As an example, for a commonly used solid wire ' AWS ER70S-6 ' the 'ER' indicates that the filler metal is an electrode or rod; the '70' signifies that it has a tensile strength of 70,000 pounds per square inch (psi), and the 'S' means that it is a solid wire.
Both the wires can be used for similar jobs due to their identical capabilities. The major difference between the two products is prominent when the user is operating on contaminated or rusted surfaces, in which case the ER70S6 provides better penetration and higher quality of welds.
The LINCOLN ELECTRIC NR-211 flux-core wire is a good quality reel that, when welding, cools quickly to keep heat out of your project. It also produces very minimally spatter. The slag has good coverage but is easily removed, making cleanup a breeze. Unfortunately, the range is very small.
Flux core wire is not solid, so contaminants such as moisture can enter the wire. So, if flux core wires are exposed to moisture for a long time, they will go bad. ... While flux core wire can go bad, it does not merely go bad for no reason or without any signs.
You can use gas with a regular flux core, but it is a total waste of gas. The flux in dual shield wire doesn't shield the weld, it causes better deposition rates and weld characteristics in the weld. Gas is needed with a dual shield to shield the weld, but not with flux cored.
A flux core wire that features a 035 electrode implies that it is thicker than one, which measures 035 by. 005 inches. ... The thicker the diameter of a wire, the deeper the penetration. While 035 flux core wires work well with 250 V machines, 030 flux-cored wires deliver great performance when used with 210 V machines.
Flux Cored Wire Gas-shielded
030-inch diameter is a good all-around choice for welding a wide range of metal thicknesses. For welding thicker material at higher total heat levels, use. 035-inch wire (or . 045-inch wire if it's within your welder's output range).
The first reason why you may prefer gas-shielded solid core wire for MIG welding is the most obvious: You don't have to clean up the flux when you're done welding. The shielding gas saves you a clean-up step and helps you immediately create a clean weld.
Solid wire provides deep penetration in the root and usually has little spatter. Flux-cored wire has a larger ball-type transfer and produces low spatter levels. In addition, flux-cored wire produces a rounder penetration profile with excellent sidewall fusion.
While solid MIG wire requires a shielding gas to protect the weld, typically a mix of Argon and CO2, there's also flux-cored MIG wire that shields the weld on its own without the help of gas.
Flux cored wire should not be stored for more than 5 years. The older wire should be redried before use. Storeroom temperature should be kept as even as possible, temperature variations should not exceed ± 5°C.
If you want to learn more, please visit our website Flux Cored Wire Gas-Shielded.
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