As the flux core is consumed, it produces a barrier protecting the weld from atmospheric contamination. The electrode is hollow, with a flux core inside acting as a shielding agent while it is deposited in the weld zone. The FCAW process utilises the heat from the arc generated between the tubular electrode and the workpiece. GMAW has a bigger electrode wire (2 – 5 mm) compared to FCAW (0.9 – 3.2 mm).Īlthough these are two separate welding types, the only major difference lies in shielding the weld zone using electrodes and shielding gases. MAG and MIG welding offer versatility to weld a wide variety of metals. GMAW leaves more weld spatter than FCAW and offers less penetration. GMAW (MIG/MAG welding) uses a solid wire electrode along with external shielding gas to prevent contamination of the weld metal. Dual-shielded FCAW offers more consistent mechanical properties and higher deposition rates than solid wire or stick electrodes. In some cases, FCAW can use shielding gas on top of the primary shielding flux to further protect the weld pool from oxidation. This process is favoured for ferrous metals as it requires little-to-no pre-cleaning. FCAW emits toxic fumes from the flux which blocks the weld area from contaminants. Generally, flux cored and gas metal arc welding both use the principle of using a shielding layer and a continuous wire-fed electrode.įCAW welding uses a flux-cored electrode that emits a protective shielding layer as it is deposited into the weld pool. Differences Between FCAW and GMAW (MIG/MAG) As the electrode melts, the flux inside it releases a shielding gas to protect the weld pool from atmospheric contamination.įlux-cored welding is often confused with gas metal arc welding (GMAW) as both welding techniques can be performed on the same or similar welding equipment but they do have subtle differences between them. The tubular electrode wire is supplied through a spool and guided by a welding gun to the weld joint. Fusion takes place when a welding arc is established between the flux-cored electrode and the base metals. VI Important Points to Remember What Is Flux-Cored Arc Welding?įlux-cored welding is an arc welding process that deposits filler material with a shielding flux in the weld puddle.
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