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Questions and Answers
What does FCAW stand for?
What does FCAW stand for?
Flux Core Arc Welding
In the AWS electrode classification E71T-1M, the digit after the dash designates what?
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?
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?
Is external shielding gas essential for FCAW-S?
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?
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?
In the FCAW electrode classification E71T-1, the letter T indicates what?
In the FCAW electrode classification E71T-1, the letter T indicates what?
What types of metals are recommended for the FCAW-G process?
What types of metals are recommended for the FCAW-G process?
Is the FCAW-G process recommended for use outdoors in windy conditions?
Is the FCAW-G process recommended for use outdoors in windy conditions?
What type of drive rolls are recommended for use with FCAW electrode wire?
What type of drive rolls are recommended for use with FCAW electrode wire?
In FCAW, what are the two basic types of shielding?
In FCAW, what are the two basic types of shielding?
FCAW-G indicates what type of shielding?
FCAW-G indicates what type of shielding?
The FCAW process has the capability of being used in what positions?
The FCAW process has the capability of being used in what positions?
In FCAW, what does the flux inside the tubular wire do?
In FCAW, what does the flux inside the tubular wire do?
How can a welder prevent undercut when employing a weaving technique with FCAW?
How can a welder prevent undercut when employing a weaving technique with FCAW?
Label the diagram
Label the diagram
Label the diagram
Label the diagram
What type of current is used in FCAW?
What type of current is used in FCAW?
What are two types of welding guns used for FCAW?
What are two types of welding guns used for FCAW?
If you were going to FCAW weld outdoors what kind of wire would you use?
If you were going to FCAW weld outdoors what kind of wire would you use?
What would be the main cause of undercut in a FCAW weld?
What would be the main cause of undercut in a FCAW weld?
Which of the following can cause poor penetration?
Which of the following can cause poor penetration?
What could cause a weld to be brittle?
What could cause a weld to be brittle?
What would be the tensile strength of the electrode E70T-1?
What would be the tensile strength of the electrode E70T-1?
What does the T stand for in E70T-1?
What does the T stand for in E70T-1?
Which process has a higher deposition rate FCAW or SMAW?
Which process has a higher deposition rate FCAW or SMAW?
What is deposition rate?
What is deposition rate?
Shielding gas could be used with E80T-S wire to produce quality welds.
Shielding gas could be used with E80T-S wire to produce quality welds.
The first pass of a multipass weld is called what?
The first pass of a multipass weld is called what?
What does the -G from the classification E80T-G indicate?
What does the -G from the classification E80T-G indicate?
The flux inside the electrode provides protection from the atmosphere to the molten weld pool?
The flux inside the electrode provides protection from the atmosphere to the molten weld pool?
A groove left in the face of a FCAW formed by excessive levels of dissolved gasses in the weld metal is known as a _______________________________?
A groove left in the face of a FCAW formed by excessive levels of dissolved gasses in the weld metal is known as a _______________________________?
What are three possible causes of a worm-track?
What are three possible causes of a worm-track?
What does CTWD stand for?
What does CTWD stand for?
Which type of shielding gas is most likely to produce worm tracks?
Which type of shielding gas is most likely to produce worm tracks?
What type of metal would you weld with E308T-1 wire?
What type of metal would you weld with E308T-1 wire?
What position(s) could be welded with E81T-G wire?
What position(s) could be welded with E81T-G wire?
100% CO2 should be used with E80T-S wire?
100% CO2 should be used with E80T-S wire?
Slag that becomes trapped in a weld is known as an ______________________________?
Slag that becomes trapped in a weld is known as an ______________________________?
Generally speaking, smaller diameter FCAW wire is more expensive than larger diameter wire?
Generally speaking, smaller diameter FCAW wire is more expensive than larger diameter wire?
What is the main disadvantage of FCAW welding?
What is the main disadvantage of FCAW welding?
Included groove angle can be reduced __________ degrees when using FCAW.
Included groove angle can be reduced __________ degrees when using FCAW.
FCAW is better than GMAW when welding dirty or rusty metal because the wire contains ____________________.
FCAW is better than GMAW when welding dirty or rusty metal because the wire contains ____________________.
What is the minimum inspection method that should be used if you are welding semitruck chassis using FCAW?
What is the minimum inspection method that should be used if you are welding semitruck chassis using FCAW?
How are FCAW and GMAW similar?
How are FCAW and GMAW similar?
Metal that can be twisted, bent and shaped without cracking is said to be ___________________?
Metal that can be twisted, bent and shaped without cracking is said to be ___________________?
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.
Studying That Suits You
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Description
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.
