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Me welding FCAW (Flux Core Arc Welding)...  Ok so I am not completely terrible.. but I have a ways to go yet.. most of my issues thus far is learning spacing and angling (sp?).  They are different from GMAW... I thought I would post a few of my first practice plate...  Any insight would be appreciated... but like I said already, I know I need to angle up a tad bit.Side note, instructor does not want me to weave at all... ( although I can make the bead look a lot better if they would let me but for now, no weave )(this is in the 2G position... right to left)And for those of you wondering why I start low on the bead is because I do not have an auto-darkening helmet.. and I start low to make sure I fill in decently...  (probably a bad habit, but I can't see till I strike an arc.. )Once again, I need input... my instructor from last semester got a better job offer so he left.. and the guy that filled in for him, hates FCAW.... so he is not a whole lot of help... don't get me wrong he knows how... just doesn't have the patience for me at this moment... LOL...
Reply:I think there is 6 or 7 beads total in this piece (all stringers)...  obviously you can only see a few of them... just noting...
Reply:Looks good.  Listen to your instructor. You need to be able to run stringers and weave.  You are getting it.  Beads are pretty smooth and steady, looks like the heat is right.Can you touch the wire to the work, helmet down and pull the trigger?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Thanks David,I can do that, but for some reason,it seems I have a purosity ball when I do that... I have noticed that I need to clean this tip quite more frequently than with GMAW...  Also, "worm holes"  what causes them?  Every now again I will get a few to start off... splatter balls?   More splatter? = need more wire speed? Thanks again David...
Reply:Worm holes in the weld or on top of the weld under the slag?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:In the weld...
Reply:If you could coll it porosity, then its from improper technique.  Wrong gun angle, improper stickout (3/8" to 1/2").  Drag or backhand only for flux core.   It looks like you have got the hang of it.Don't be afraid to mess with the controls to see what it does to your weld.  You will only get better.I have really good luck with NR211 in 1/16".DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Drag only?  No one told me that one.. LOL... This is .035 wire... and it might be at 5/8 stick out.. but I doubt it.. usually I am right at 3/8... But I will try and pay more attention to it next time.. Odds on it is improper angle... I moved booths to this machine and it is set up odd...  I have to go right to left on everything...  But going on what you say, dragging it...  I guess I could go left to right...  then I could see the puddle/electrode...
Reply:"If its got slag, drag it".David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:If by worm holes you mean swiss cheese in the welds,thats one thing.  Worm tracks, which basically look like impressions in the surface of the weld, can be caused by your voltage being excessively high.
Reply:Originally Posted by David R"If its got slag, drag it".David
Reply:Who wears drag? LOL..Thanks for the input guys... I will look into it.. but odds on, voltage to high... because the welds in those pictures were what I set the machine up to.. I believe 19.5 and 290 IPM?   And the guy "helping" me set it to 22.5 and 330...
Reply:Well fella's... I gone and done it.. LOL...  passed my 2G FCAW tests today... and started on a 3G... but ran out of time...  so I brought it home and took a few pics..   One stringer (slow and stead for nice burn through) and then a couple of weave passes...You might notice if you look closely.. at the very top, there is some "holes/worm holes?" not exactly sure what causes/caused it.. but the just I got from several people is that my angle was to far up.. and the gas was not fully penetrating.. which very well could be... this booth I am in is set-up funny, but I do the best I can with what I have...Any input is appreciated as always...
Reply:Well, the porosity/worm holes did that test plate in..  however.. I passed the next two test plates and 3G FCAW in the process... 4G FCAW here I come... (on thursday, next welding class).. can't wait to finish FCAW and move on to GTAW.. where I know, I will fail for quite some time.. but I will enjoy the challenge...Last edited by smokeshow; 01-29-2008 at 10:25 PM.