Welding joins pieces of metal together via a strong metallic bond, but this is only a simple overview, and there is much more to it than this. For instance, there are different types of welding best suited for your project.
Today, we’re going to be looking at two of the most commonly used types of welding: Flux Core and MIG welder operations. Read on to learn more about each type as we try to get to the bottom of the Flux Core/MIG welder debate.
Also known as Flux Core Arc Welding, or FCAW, this form of welding utilizes a tubular wire with a hollow core. This hollow space within the wire is filled with flux, giving FCAW the first part of its name. The second part — Arc — refers to the arc between the continuous wire electrode of the welding device and the piece of material that is being welded.
FCAW can be carried out with or without a shielding gas, and this represents the two primary types of flux core welding. Self-shielded welding utilizes a longer electrode, extending the distance between the end of the unmelted electrode and the contact tube. The flux buildup itself will also provide shielding from atmospheric contamination.
When used with shielding gas, the length of the electrode is shorter, and a protective shield of gas is used to prevent this contamination. Gas-shielded flux core welding may be used in controlled environments, while self-shielded FCAW is typically used in locations where wind might blow the shield gas away, such as during outdoor welds.
MIG stands for Metal Inert Gas. With this form of welding, a continuous solid wire electrode is fed through a welding gun, and an arc is created from this electrode to the material that is being welded. The arc will then melt both the metal material in the electrode and the material in the weld pool, forming a connection between the two.
This type of welding will also require a shielding gas to protect the weld, simply because atmospheric contamination may cause a failure in the join. This is a key difference between Flux Core Welding and MIG Welding, as FGAW offers both gas-shielded and self-shielded options.
While Flux Core Arc Welding can be implemented both with or without shielding gases, these substances are still important to both types of welding. Different shielding gases may be deployed in particular applications or when welding specific types of metal. Learn more about some of the most common types of shielding gases used in welding.
Take a look at a quick summary of the key benefits of FGAW welding.
There are some disadvantages to using the Flux Core Arc Welding method.
MIG welding also has its own specific advantages.
There are downsides to this type of welding too.
Whether you are using MIG welding or Flux Core weld techniques, you can get strong results provided your materials and technique are sound. So, the question of Flux Core vs MIG welder is not really about welding quality and is more about what you plan to weld and where you plan to do it.
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Metal thickness is an important consideration when choosing MIG welding or Flux Core weld. As discussed above, FCAW provides high levels of penetration, so creating strong bonds on thick pieces of metal is a common application for this form of welding. Thinner metal, however, is less suited to this sort of penetration, so MIG welding might be more suitable.
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Some metals may be more suited to MIG and Flux Core welding, respectively. For example, stainless steel and some types of nickel alloy may be better welded with Flux Core equipment.
When it comes to welding mild steel, MIG welding is a great choice. Much simpler than TIG welding, it focuses on the task itself without the necessity of additional steps. Furthermore, with many welding machines offering MIG welding as one of their multi-process options, you can enjoy easy and efficient welding without compromising quality or precision.
The Flux Core Arc Welding process is a little more complex, as the welding wire feed, welding implement, and filler material all need to be considered. That said, both MIG and Flux Core Arc Welding can achieve good results on a mild steel project.
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The location of the weld is an important part of the Flux Core/MIG welder debate. The shielding gas in an arc welder is not suitable for welding outdoors simply because the gas will be blown away by any wind or movement of air, leaving the weld pool exposed to atmospheric contaminants.
As such, a gas-shielded Flux Core welder will need to be used exclusively indoors, out of the wind. The self-shielded version of the Flux Core Arc Welder may be suitable for outdoor use. This can be a problem from MIG welding, as this form of welding does not feature a self-shielding option. It is difficult to effectively operate any sort of gas-shielded welder out of doors.