Flux Cored Arc Welding (FCAW) is an arc welding technique that involves creating an arc between a continuous tubular filler metal electrode and the weld pool.

Flux-cored arc welding (FCAW or FCA) is a type of semi-automatic or automatic arc welding. A continuously-fed consumable tubular electrode carrying a flux and a constant-voltage or, less typically, a constant-current welding power source are required for FCAW.

The approach involves shielding gas generated by a flux enclosed within the tubular electrode (a trade name is inner-shield), with or without additional shielding from an outside supplied gas.

Sometimes an externally provided shielding gas is utilized, but more often than not, the flux itself is depended on to generate the necessary protection from the atmosphere, creating both gaseous and liquid slag to protect the weld.

Flux core welding is a versatile method of welding that also super popular and versatile. I wrote this guide describing in full detail the pros and cons of flux core welding. This guide should also help you decide whether flux core welding is right for you, how to get started, and what to expect when starting up. So what are the pros and cons of flux core welding?

Several pros to flux core welding include portability, ease of use, versatility, usability outdoors, and the ability to weld through rust.  The cons of flux core welding include the cost of the electrodes, the appearance of the weld bead, spatter, and slag inclusions to name a couple.

Is Flux Core Welding Any Good?
Flux Core Welding, often abbreviated as FCAW, involves the use of a welding wire that is similar in many ways to Metal Inert Gas (MIG) welding except for the fact it includes a flux-cored compound within the wire that has the capability to remove the need for shielding gas.

As for the question of whether this welding method is any good, the answer is yes, provided that the weld bead is being laid down in the recommended circumstances, usually on thicker metals as will be discussed later in this article.

The Flux-cored welder is the field worker’s best friend because they are easy to move from site to site. They are also easy and straight-forward to operate when compared to stick welding. These machines can plug into the standard 120V power system in your home. Since a shielding gas is not needed, you can also use this method to weld in just about any type of weather.

As will also be discussed in further detail later, this welder is also one of the best systems for welding galvanized steel. This is because MIG welding is known for being nearly impossible to weld galvanized steel with because of issues with porosity.

One of the few downsides to this technology is the effort it takes to clean up the slag that is a by-product of the welding process. Fortunately, there are ways to mitigate these complaints that will be discussed in further detail below.

Pros of Flux Core Welding
There are several advantages to using flux core welding over other welding types, such as MIG welding. Learning flux core welding will provide you with the opportunity to weld a variety of materials both indoors and outdoors.

Flux Core Welding Can Easily Be Done Outdoors

Shielding gas is of utmost importance in Metal Inert Gas (MIG) Welding in order to keep the molten weld pool from oxygen, nitrogen and hydrogen in the atmosphere. If the weld pool reacts with these elements, it will become subject to failure from porosity.

Other reasons why you need to use shielding gases when welding includes the need to:

• Prevent excessive splatter
• Keep the arc stable
• Control the weld penetration into the base metal

While the solid wires used in MIG welding require shielding gases, flux core wires do not require the use of shielding gases. The mechanics behind this capability will be discussed later in further detail later in this article.

The upshot of this is that flux core wires are popular amongst those who frequently have to repair metal equipment outdoors. Flux core welding is popular at construction sites, in shipyards and in the farm field.

TUBULAR WELDING WIRE FLUX CORED MIG WIRE

Cost & Energy Savings

Flux-cored wires will cost at least a little more than a solid wire of the same size. You can see this by comparing the prices of the same-sized wire online.

This is not always apparent because there are many more factors to consider than whether or not the wire requires a shielding gas. Wires of the same size may serve different uses depending upon their chemical composition. There are wires made of premium materials that will also cost more.

Still, it has been suggested that you can save quite a bit of money by making the switch to gasless flux core wires, if you haven’t done so already. You will begin to really notice the cost savings once you become fully operational.

Depending upon the application, flux core wires can lay down a weld bead at a faster travel speed and with increased deposition rates. 

A flux core electrode is capable of depositing up to 25 pounds of wire per hour. A MIG electrode, deposits 8 pounds of wire per hour when it is performing at maximum efficiency.

This affects your operating costs because you may have to consume more energy to deposit a pound of solid wire than you would with a flux core wire. Energy savings are perhaps most pronounced when you are welding in position and when you are welding outdoors.

Ability to Weld Rusty Materials

You will find that flux core welding electrodes are much less fussy than solid wire electrodes when it comes to being able to weld metals that have become rusted or otherwise dirtied.

Gas-shielded electrodes usually only perform adequately on base metals that are clean. The presence of extensive rusting and milling is a death-knell of sorts to weld quality. This is because gas-welding through such contaminants can contribute to excess porosity in the weld bead, enhancing the risk of this weld failing.

Self-shielding flux electrodes, on the other hand, can effectively weld through rust and still produce a quality weld bead. A rusty or scaled surface will not contaminate the weld because the flux contained within the wire is more forgiving of the base metal than a solid wire used in conjunction with a shielding gas would be.

Flux Core Welding Easy to Learn

Flux core welding holds a reputation for being easier to learn. 

flux core welding is easier to learn than Stick Welding and TIG Welding. The skill level required to master Flux Core Welding is equivalent to that of MIG Welding.

Flux Core Welding/MIG Welding Machines Are Versatile

You can use the same small welding machine to perform both MIG and flux core welding. The machine can run off 115V electricity that you can get from your home and this welding machine is diverse in the number of purposes that it can serve.

Flux core welding can be used to weld all of the most common metals:

• Carbon steel
• Stainless steel
• Aluminum

This makes the flux core welder ideal for home shops and farms. You also don’t have to worry about hauling around a box of electrodes, since the welding gun is fed by a continuous loop of welding wire. The spools vary in size, with the largest of spoils being large enough to fit in a barrel.

Portability

Once you drop the gas tanks, the MIG welding machines can be moved from one location to the next with ease. MIG welding machines will typically weigh just under 40 pounds if you are going with the welders marketed towards DIYers.