Flux Core Welding: The Basics You Need to know

Weld.com
18 Jul 201606:38

TLDRThis video tutorial introduces the basics of flux core welding, a gasless MIG welding process that produces a raspy sound and light slag. It emphasizes the importance of using straight polarity DC electrode negative and proper drive roll tension for smooth wire feeding. The presenter demonstrates a fillet weld, explaining the process and appearance, and shows how to clean the weld for a quality result. The video promotes the cost-effectiveness and structural strength of gasless flux core welding for various projects and repairs.

Takeaways

  • 🔧 Gasless flux core wire is an alternative to MIG welding with shielding gas, suitable for smaller 110-volt machines.
  • 💡 Flux core welding produces a raspy process with lots of sparks and light slag, which is normal and should not be feared.
  • 🛠️ Flux core wire requires straight polarity DC electrode negative, which means changing the leads on the welding machine.
  • 🔄 Correct drive roll tension is crucial; too much pressure can collapse the wire, affecting its integrity.
  • 👀 During welding, it's important to watch for a light slag and the solidification of the weld bead behind the weld pool.
  • 🔧 The welding process with flux core wire is slower and may produce smoke and spatter, which is characteristic of this type of welding.
  • ⚙️ Adjusting the voltage and wire speed can help control the welding process and the appearance of the weld.
  • 🧼 Post-weld cleaning with a wire wheel or brush is necessary to remove spatter and discoloration.
  • 📏 A good weld profile and shape are achievable with flux core wire, even though the process may look messy initially.
  • 🏗️ Flux core welding is suitable for outdoor projects and repairs, offering a cost-effective solution for structurally sound welds.
  • 📚 Understanding the characteristics and requirements of flux core welding can help overcome initial apprehensions and improve welding outcomes.

Q & A

  • What is the main advantage of using gasless flux core wire for MIG welding?

    -The main advantage of using gasless flux core wire for MIG welding is that it eliminates the need for a regulator and a bottle of shielding gas, making it more cost-effective and suitable for smaller 110-volt machines.

  • What is the characteristic process of welding with gasless flux core wire?

    -Welding with gasless flux core wire is characterized by a raspy process with lots of sparks and a light slag production. It may look and sound different, but it can produce structurally strong and quality welds.

  • What polarity setting is required for running gasless flux core wire?

    -Gasless flux core wire requires straight polarity DC with electrode negative setting. This means you need to switch your leads to ensure proper welding.

  • Why is it important to adjust the drive roll tension when using gasless flux core wire?

    -Adjusting the drive roll tension is important because too much pressure can collapse the wire, distorting its integrity and affecting the welding process. The correct tension allows the wire to feed out smoothly and can be stopped with a finger.

  • What should you observe while making a weld with gasless flux core wire?

    -While making a weld with gasless flux core wire, you should observe the weld pool, the slag formation about an eighth of an inch up, and the edges of the material. It's also important to watch for any spatter and the overall appearance of the weld bead.

  • What is the recommended procedure for cleaning up a weld made with gasless flux core wire?

    -The recommended procedure for cleaning up a weld made with gasless flux core wire involves using a wire wheel on a grinder or hand grinder to remove spatter and discoloration, revealing the true profile and quality of the weld.

  • How does the appearance of a weld made with gasless flux core wire differ from other welding processes?

    -A weld made with gasless flux core wire may initially appear 'nasty' with a lot of spatter and smoke, but after cleaning, it can have a good profile, rounded edges, and an acceptable bead shape, especially for a 3/16 material thickness.

  • What is the recommended wire feed speed for gasless flux core welding?

    -The correct wire feed speed for gasless flux core welding is one where the wire can be stopped with a finger, indicating that the drive roll tension is set correctly and the wire is feeding out smoothly.

  • What should be the voltage and wire speed settings for a gasless flux core welding machine?

    -In the script, the welder sets the machine at 18 volts and 265 wire speed, with about 35 percent inductance. These settings may vary based on the specific machine and welding requirements.

  • How does the nature of gasless flux core wire affect the welding process?

    -The nature of gasless flux core wire affects the welding process by producing a lot of sparks and smoke, requiring a different polarity setting, and necessitating careful attention to drive roll tension and post-weld cleaning.

  • What is the significance of the inductance setting in gasless flux core welding?

    -The inductance setting in gasless flux core welding helps control the welding process by affecting the electrical characteristics of the arc. A higher inductance setting can make the arc more 'active,' producing more sparks and requiring careful control during welding.

Outlines

00:00

🔧 Gasless Flux Core Wire Welding Basics

This paragraph introduces the concept of gasless flux core wire welding, a method that allows MIG welding without the need for a shielding gas and regulator. The speaker explains that while the process is different, with a raspy sound and light slag production, it can produce structurally strong welds. The importance of using straight polarity DC with electrode negative is highlighted to ensure proper operation of the welding machine. Additionally, the paragraph emphasizes the correct drive roll tension to prevent wire distortion and the process of making a fillet weld, including the setup and observation of the weld pool and slag.

05:01

🛠 Post-Weld Cleanup and Evaluation

The second paragraph focuses on the post-weld process, starting with the cleanup of the weld using a wire wheel to remove spatter and discoloration. The speaker then evaluates the cleaned weld, noting its good profile, rounded edge, and acceptable bead shape for the material thickness. The paragraph concludes with reassurance about the quality and structural integrity of gasless flux core wire welds, emphasizing the cost-effectiveness and suitability of the process for outdoor welding or repairs, and encourages viewers to subscribe for more educational content.

Mindmap

Keywords

💡Flux Core Welding

Flux core welding is a type of arc welding process that uses a tubular wire filled with fluxing materials to lay the weld. In the video, the speaker discusses the basics of flux core welding, emphasizing its advantages such as not requiring a shielding gas, which simplifies the welding setup and reduces costs. The process is highlighted as suitable for smaller projects and repairs, making it an accessible welding technique.

💡Gasless Flux Core Wire

Gasless flux core wire is a specific type of welding wire that does not require an external shielding gas to protect the weld area from atmospheric contamination. The script mentions the benefits of using this wire, such as the reduced need for a gas regulator and gas bottle, making it more cost-effective and convenient for certain welding tasks.

💡MIG Welding

MIG welding, which stands for Metal Inert Gas welding, is a common arc welding process that uses a continuously fed consumable wire electrode and a shielding gas to protect the weld area. The video script differentiates between traditional MIG welding and gasless flux core welding, noting that the latter does not require a shielding gas.

💡DC Electrode Negative

DC electrode negative refers to a polarity setting on a welding machine where the electrode (the welding wire) is connected to the negative terminal of the power source. The script explains that flux core welding requires this polarity setting to function correctly, and incorrect polarity can lead to poor welding performance.

💡Drive Roll Tension

Drive roll tension is the pressure applied by the welding machine's drive rolls to the wire as it is fed through the machine. The script emphasizes the importance of setting the correct tension to ensure smooth wire feed without damaging the wire's integrity, which is crucial for a successful weld.

💡Slag

Slag is a byproduct of the welding process, typically a layer of solidified flux material that forms on the surface of the weld. The video mentions that flux core welding produces a light slag, which is normal and should not deter welders from using the process, as it can be cleaned off after the welding is complete.

💡Wire Feed

Wire feed refers to the mechanism by which the welding wire is pushed through the welding gun and into the welding arc. The script discusses the importance of smooth wire feed for successful welding and how too much drive roll pressure can negatively affect the wire feed.

💡Inductance

Inductance in the context of welding refers to a property of the welding machine that can affect the welding arc's stability and the wire feed speed. The script mentions adjusting inductance as part of setting up the welding machine for flux core welding.

💡Weld Bead

A weld bead is the raised area of metal formed by the welding process, which fuses the base metal together. The video script describes the appearance of the weld bead in flux core welding, noting that it may look different due to the slag and spatter but still provides a structurally sound weld.

💡Spatter

Spatter refers to small metal particles that are expelled from the welding area during the welding process. The script mentions that flux core welding can produce spatter, which is a characteristic of the process and can be cleaned off after welding to reveal the weld's true appearance.

💡Welding Machine Settings

Welding machine settings encompass a variety of adjustments that a welder can make to optimize the welding process, such as voltage, wire feed speed, and polarity. The script provides an example of how to set these parameters for flux core welding, emphasizing the need for correct settings to achieve quality welds.

Highlights

Introduction to running a gasless flux core wire for MIG welding without the need for a regulator and gas bottle.

Advantages of using smaller 110 volt machines for MIG welding with gasless flux core wire.

Gasless flux core welding produces a raspy process with a lot of sparks and light slag.

Quality welds can be made with gasless flux core wire that are structurally strong.

Gasless flux core wire requires straight polarity DC electrode negative for proper operation.

Importance of switching leads for gasless flux core wire to avoid welding issues.

Explanation of the correct drive roll tension for MIG welding with flux core wires.

Over-tightening the drive roll can collapse the wire and affect the welding process.

Demonstration of a fillet weld using gasless flux core wire.

Technique of leaning the welding torch backwards and oscillating for better weld visibility.

Observing the weld pool and slag for quality control during gasless flux core welding.

Setting up the welding machine at 18 volts and 265 amps for gasless flux core welding.

Characteristics of gasless flux core welding including smoke, spatter, and wire dancing.

Cleaning the weld with a wire wheel to remove slag and spatter.

Acceptable bead profile and shape for a 3/16 material thickness after cleaning.

Gasless flux core wire's suitability for outdoor welding and cost-effective repairs.

Encouragement to subscribe for more educational welding content.

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