FCAW Questions

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I have the first round of tests for a supervisors position at a shipyard. The welding test is gonna be in FCAW in 2,3,and 4G. Its been a while since I have welded flux core but I was always good at it. I remember saying if you cant flux core weld you cant weld with anything. I feel pretty confident on the test except for setting the new high tech machines. They use inverters there im pretty sure. I have welded fluxcore in the past with ceramic tape backing on half inch plate and completed the weld in a single pass, but I cant remember what size wire. Im not sure how thick the test plates are gonna be, but I want to be sure of a good starting point on the settings. Anyone know a good guide to use as a starting point?I have been practicing on a Millermatic 250 with the polarity reversed and no gass. Im pretty sure that is what they do there. But my wire is only .035 The next round of tests are TIG welding, then pipe.Welding everything, from the crack of dawn to a broken heart.
Reply:Here you go. http://www.millerwelds.com/resources...calculator.phpDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Nice, thanks dude!Welding everything, from the crack of dawn to a broken heart.
Reply:Is this going to be a welding supervisor job?
Reply:Damn, ya know what sucks. That Miller guide only goes up to 5/8" thick material. I have a test on thur. that is 2, 3, and 4G, 1" plate. I cant seem to find any other guide tables for machine set up on material that thick. I already took a test  that was a 3F and 4F, "welding assessment" I used the miller numbers for 5/8 and they were way hot for even 3/4" plate. Adjusted it and did fine. Flux core is sooo easy. But I am still a little nervous because flux core is easy IF you have the machine set right. Anyone have some good starting settings for 1" plate? ...and why doesn't Miller list them? Already been through the welding assessment, two interviews and a background check. Still have to go for another welding test at a separate certification facility, a written test and a drug test. Then another interview. Holy crap, they dont make it easy that is for sure.Welding everything, from the crack of dawn to a broken heart.
Reply:.045 with 75/25 would be my pick.  28v and 220 amps with 3/4" ESO.  JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:Thanks weldgualt. Took that test yesterday, it went OK just ok. I should have taken pics. They gave us WPD sheets specifying the parameters including settings. That were hot. 3/4" plate with 1/4" gap ceramic tape backing. The root pass was 35-40 amps and the wire speed was 400-450. Then a hot pass of multiple stringers, multiple weaves for the 3G.  Colder on the cap. I wasn't comfortable with the weaves or the amount of passes specked in the WPS. The amount of stringers specified for the 2G made it so that the welds had to be huge and I had to put a lot of motion to the gun to make them. On the 3G there were large weaved weld stringers to fill. With it being so hot it was very difficult get it where I wanted. I wasn't happy with my performance, though the instructor said it will be fine.  The root pass was great, just the cap welds are ugly and there is a bit too much reinforcement on the 2G. What frustrated me is that there were other testers and they just did multiple welds the way they wanted to and didnt follow the pattern that was specified. For example: On the 2G test the sheet specified 4 passes to cap. The guy in the booth next to me had six passes as a cap. If I did it the way he did I would have nailed it. And The 3G specified two wide weaves as the cap pass. Again he capped with six stringers instead. I asked the instructor if I had to follow the stringer patter specified in the WPS provided and he said "Well, no" Argh!. I wish I had known. Anyway, he said I will be OK because the root pass looked great when we removed the ceramic tape and that he watched the slag curl up off of each of my subsequent passes. But I know I could have done much better. people say flux core is easy, it is if you have been doing it, but man this heavy stuf is hot as **** and it was tough. Plus I get a little flustered during tests. Ill post when I find out what they say, guess it all depends on how many guy they need and how many they have passing tests to their liking. Maybe I will be OK. I have some TIG SS pipe tests coming up for another company. They are gonna tell me the specs up front and give me time to practice. Thank god.Welding everything, from the crack of dawn to a broken heart.