FCAW Flashcards
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Questions and Answers

What does FCAW stand for?

Flux Core Arc Welding

In the AWS electrode classification E71T-1M, the digit after the dash designates what?

Chemical composition

What do you call a flux cored electrode that protects the weld zone from contaminants with fluxing elements released from the core of wire?

Self-shielded

Is external shielding gas essential for FCAW-S?

<p>False</p> Signup and view all the answers

When examining the electrode classification for a spool of filler metal to determine if it is designed for flux cored welding, what should you look for?

<p>A 'T' in the electrode classification</p> Signup and view all the answers

In the FCAW electrode classification E71T-1, the letter T indicates what?

<p>Tubular electrode</p> Signup and view all the answers

What types of metals are recommended for the FCAW-G process?

<p>Ferrous and nickel based alloys</p> Signup and view all the answers

Is the FCAW-G process recommended for use outdoors in windy conditions?

<p>False</p> Signup and view all the answers

What type of drive rolls are recommended for use with FCAW electrode wire?

<p>Knurled</p> Signup and view all the answers

In FCAW, what are the two basic types of shielding?

<p>Self shielding, External shielding gas</p> Signup and view all the answers

FCAW-G indicates what type of shielding?

<p>Gas-shielded</p> Signup and view all the answers

The FCAW process has the capability of being used in what positions?

<p>All positions</p> Signup and view all the answers

In FCAW, what does the flux inside the tubular wire do?

<p>Provide shielding</p> Signup and view all the answers

How can a welder prevent undercut when employing a weaving technique with FCAW?

<p>Stopping momentarily at the end of each weaving motion</p> Signup and view all the answers

Label the diagram

<p>A. Solidified slag = Shielding gas B. Molten slag = Contact tube C. Contact tube = Tubular electrode D. Tubular electrode = Powdered flux E. Powdered flux = Arc and metal transfer AB. Shielding gas = Solidified weld metal AC. Arc and metal transfer = Weld pool</p> Signup and view all the answers

Label the diagram

<p>A. Gas nozzle = Slag B. Contact tube = Shielding gas C. Slag = Electrode D. Shielding gas = Metal powder E. Electrode = Depth of penetration AB. Metal powder = Cooled too quickly AE. Depth of penetration = Current too high</p> Signup and view all the answers

What type of current is used in FCAW?

<p>Constant Voltage</p> Signup and view all the answers

What are two types of welding guns used for FCAW?

<p>Air Cooled, Water Cooled</p> Signup and view all the answers

If you were going to FCAW weld outdoors what kind of wire would you use?

<p>Self shielding</p> Signup and view all the answers

What would be the main cause of undercut in a FCAW weld?

<p>Current too high</p> Signup and view all the answers

Which of the following can cause poor penetration?

<p>Current too low</p> Signup and view all the answers

What could cause a weld to be brittle?

<p>Cooled too quickly</p> Signup and view all the answers

What would be the tensile strength of the electrode E70T-1?

<p>70,000 psi</p> Signup and view all the answers

What does the T stand for in E70T-1?

<p>Tubular electrode</p> Signup and view all the answers

Which process has a higher deposition rate FCAW or SMAW?

<p>FCAW</p> Signup and view all the answers

What is deposition rate?

<p>Amount of weld produced over a given amount of time</p> Signup and view all the answers

Shielding gas could be used with E80T-S wire to produce quality welds.

<p>False</p> Signup and view all the answers

The first pass of a multipass weld is called what?

<p>Root pass</p> Signup and view all the answers

What does the -G from the classification E80T-G indicate?

<p>Shielding gas is required</p> Signup and view all the answers

The flux inside the electrode provides protection from the atmosphere to the molten weld pool?

<p>True</p> Signup and view all the answers

A groove left in the face of a FCAW formed by excessive levels of dissolved gasses in the weld metal is known as a _______________________________?

<p>Worm track</p> Signup and view all the answers

What are three possible causes of a worm-track?

<ol> <li>Excessive moisture, 2) CTWD is too short, 3) Excessive arc voltage</li> </ol> Signup and view all the answers

What does CTWD stand for?

<p>Contact To Work Distance</p> Signup and view all the answers

Which type of shielding gas is most likely to produce worm tracks?

<p>Ar/CO2 mix</p> Signup and view all the answers

What type of metal would you weld with E308T-1 wire?

<p>Stainless Steel</p> Signup and view all the answers

What position(s) could be welded with E81T-G wire?

<p>All</p> Signup and view all the answers

100% CO2 should be used with E80T-S wire?

<p>False</p> Signup and view all the answers

Slag that becomes trapped in a weld is known as an ______________________________?

<p>Inclusion</p> Signup and view all the answers

Generally speaking, smaller diameter FCAW wire is more expensive than larger diameter wire?

<p>True</p> Signup and view all the answers

What is the main disadvantage of FCAW welding?

<p>Can only be used on ferrous and nickel based alloys</p> Signup and view all the answers

Included groove angle can be reduced __________ degrees when using FCAW.

<p>35 degrees</p> Signup and view all the answers

FCAW is better than GMAW when welding dirty or rusty metal because the wire contains ____________________.

<p>Deoxidizers</p> Signup and view all the answers

What is the minimum inspection method that should be used if you are welding semitruck chassis using FCAW?

<p>Visual</p> Signup and view all the answers

How are FCAW and GMAW similar?

<p>They are both wire-fed processes.</p> Signup and view all the answers

Metal that can be twisted, bent and shaped without cracking is said to be ___________________?

<p>Ductile</p> Signup and view all the answers

Study Notes

Flux Core Arc Welding (FCAW)

  • FCAW stands for Flux Core Arc Welding, a process utilizing a tubular wire filled with flux to protect the weld pool.
  • Fluxing elements released from the wire core help to shield the weld zone from contaminants.

Electrode Classifications

  • The AWS electrode classification consists of alphanumeric designations indicating specific properties; for example, in E71T-1M, the digit after the dash signifies chemical composition.
  • The letter "T" in electrode classification indicates it is a tubular electrode designed for flux-cored welding.
  • In the classification E80T-G, "-G" indicates that shielding gas is required.

Shielding Types

  • Two basic types of shielding in FCAW are self-shielding and gas-shielded (FCAW-G).
  • Self-shielded electrodes do not require external shielding gas, making them suitable for outdoor use without gas.
  • Gas-shielded FCAW (indicated as FCAW-G) utilizes additional shielding gas to enhance weld protection.

Welding Position and Process Capability

  • FCAW is versatile as it supports all welding positions, allowing adaptability during various applications.
  • Metal deposition rates in FCAW exceed those of Shielded Metal Arc Welding (SMAW), making it more efficient for production.

Welding Techniques and Quality Control

  • The first pass in a multipass weld is called the root pass, foundational for subsequent layers.
  • Proper technique during weaving can prevent defects like undercut, often achieved by pausing at the end of each motion.
  • Ensuring the correct distance from the contact tube to work distance (CTWD) is critical for maintaining arc quality.

Welding Consumables and Considerations

  • E70T-1 electrodes have a tensile strength of 70,000 psi—important for ensuring strength in welded joints.
  • In FCAW, specific drive rolls such as knurled rolls are recommended for effective feeding of electrode wire.
  • The welding of dirty or rusty metal is more effective with FCAW due to the inclusion of deoxidizers in the wire.

Defects and Their Causes

  • Worm tracks, grooves from excessive dissolved gases, can be caused by factors like excessive moisture, incorrect CTWD, or high arc voltage.
  • Inclusion, the entrapment of slag in a weld, is a common defect that can weaken the joint.

Economic and Material Aspects

  • Smaller diameter FCAW wire tends to be more expensive than larger diameter wire, impacting material costs in projects.
  • FCAW is limited to ferrous and nickel-based alloys, potentially constraining material options.

Inspection and Safety

  • Visual inspection is deemed the minimum level of scrutiny required for critical applications, such as welding semitruck chassis.
  • Safety and quality measures are essential components of successful FCAW practices.

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Test your knowledge of Flux Core Arc Welding (FCAW) with these flashcards. This quiz covers essential terms and concepts related to FCAW, including chemical composition and self-shielded electrodes. Perfect for students and professionals looking to enhance their understanding of this welding technique.

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