FAQ - Find Answers to Questions We Often Get From Welders MIG TIG Stick...

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Flux core welding is a process during which an electric arc is used to join a continuously-fed tubular electrode to a base material. Closely related to metal inert gas welding (MIG), the FCAW process uses a hollow tubular electrode filled with flux rather than the solid metal electrode used in MIG. The flux-cored electrode comprises a metal sheath containing a core of mineral compounds and powdered metals. The weld bead is covered by slag (melted and solidified flux), helping to protect the weld from the atmosphere. The flux is usually removed easily after the weld is completed. Flux-cored welding has a reputation for being a flexible welding method. Using a flux core welder is suitable for all welding positions when used with the correct filler metal and flux composition. FCAW provides high deposition rates, enhancing the process's productivity and quality welds with an excellent appearance. Flux Core Welding Advantages The flux-cored welding method works well on thicker sections and can even produce a fully-penetrated weld on both sides of a half-inch plate with one pass. Here is a list of the advantages that flux core arc welding has to offer: A deposit rate that's nearly four times greater than stick welding Excellent appearance from a high-quality weld deposit Works well on carbon steel, stainless steel, and low-alloy steels It can be used on metals over a wider thickness range High electrode efficiency and duty cycle Excellent weld penetration A visible arc that is easy to work with Flux core welding typically requires less pre-cleaning than MIG Self-shielded electrodes eliminate flux handling or gas equipment FCAW is more tolerant of windy conditions Flux Core Welding Disadvantages Here are some disadvantages of flux core welding: It cannot be used with most non-ferrous metals, including aluminum Produces a slag covering that requires a secondary operation to remove More fume is usually generated than with MIG welding Electrodes and equipment are more expensive compared to stick welding

Yes, you can weld aluminum. However, aluminum requires different welding techniques, shielding gases, and processing, both before and after welding. For starters, wire brushing or chemically cleaning the aluminum beforehand will help to prevent un-melted aluminum oxide particles from contaminating the weld. Also, specific aluminum alloys, such as 6061-T6, are artificially aged to boost their strength. The heat from welding negates any benefits derived from aging, so another round of artificial aging after welding could be required to renew the aluminum’s strength. Top 3 Aluminum Welding Methods Here are three methods recommended for welding aluminum: TIG (Tungsten Inert Gas) Welding TIG is arguably the most popular welding method for aluminum. TIG welding is relatively clean, preventing the aluminum from being contaminated by the atmosphere. The process does not require mechanical wire feeding. Instead, the filler material is held by the operator and fed into the weld puddle. The welder must choose a filler material that is as close to the aluminum workpiece as possible. MIG (Metal Inert Gas) Welding MIG is another appropriate choice for welding aluminum. This welding method typically has higher deposition rates and faster travel speeds than TIG. However, MIG welding uses a mechanical wire feeding system, and the operator will be feeding the consumable electrode and filler through a spool gun. As with the TIG process, the filler alloy should be similar to the base material, and it is crucial to follow the filler manufacturer’s recommendations on shielding gas. Stick (Shielded Metal Arc) Welding Stick welding aluminum is not usually the choice method for large manufacturers, but it works well for smaller fabrications shops and home shop welders. Experienced welders can lay some decent-looking welds and weld thinner aluminum using this process. However, stick welding aluminum is mostly reserved for the jobs in which cosmetics are not the primary concern, such as in structural applications. Back to Welding FAQ

Arc welding is the process of using an electric arc to generate heat of about 6,500 degrees Fahrenheit, melting the base metals, and creating a pool of molten metal to join the two pieces. The arc is formed between an electrode and the workpiece. A welding operator moves the electrode along the joint of the pieces being joined. Welding electrodes are lengths of wire or rods connected with your welding machine to create an electric arc. Current passing through this electrode produces an arc, generating enough heat to melt and fuse metal. Types of Arc Welding Electrodes The two primary types of electrodes are consumable and non-consumable: Consumable Electrodes Consumable electrodes are a crucial component in metal inert gas welding (MIG) and stick welding, officially known as shielded metal arc welding (SMAW). They are also used in a process called flux-cored welding (FCAW). MIG employs a continuously-fed wire and a shielding gas, such as carbon dioxide, helium, or argon, to protect the metals from contamination. With stick welding, the arc is created between a flux-coated metal rod and the workpiece. As the metal melts, it forms a weld pool, while the flux melts to form a shielding gas. Similar to MIG welding, the gas-shielded flux-cored wires used in flux-cored welding eliminate the need for external shielding gas. This welding technique works well for outdoor welding and thicker metals. Non-Consumable Electrodes The most common non-consumable electrode welding method is tungsten inert gas welding (TIG). Also referred to as gas tungsten arc welding (GTAW), TIG generates an electric arc with a non-consumable tungsten electrode and protects the weld from air contamination with shielding gas. TIG is the preferred welding method when quality and precision are paramount. Plasma arc welding (PAW) also uses an electric arc between a non-consumable electrode and a base metal. This method contrasts with TIG welding in that the electrode is placed in a torch, and the plasma-forming gas is separated from the shielding gas, producing narrow and deep welds.

Yes, you can TIG weld aluminum. As a matter of fact, TIG is the method most frequently chosen to weld aluminum, especially in the lighter gauges. In addition to the TIG welding machine, the process requires a non-consumable tungsten electrode, a high-quality filler metal, argon shielding gas, and a meticulously-cleaned surface to remove all oxide buildup. (Oxide has a higher melting point than aluminum and could end up unmelted in the weld). Yes, you can TIG weld aluminum. As a matter of fact, TIG is the method most frequently chosen to weld aluminum, especially in the lighter gauges. In addition to the TIG welding machine, the process requires a non-consumable tungsten electrode, a high-quality filler metal, argon shielding gas, and a meticulously-cleaned surface to remove all oxide buildup. (Oxide has a higher melting point than aluminum and could end up unmelted in the weld). Because aluminum is an excellent conductor of heat, it requires lots of heat initially. However, as the process moves along, the heat starts to move ahead of the arc, pre-heating the base metal and demanding a current reduction. For this reason, welding operators should have a foot pedal that allows them to decrease the current without interrupting the weld. How to TIG Weld Aluminum Properly control the heat: Welders can control when they add the filler metal. They establish the weld pool and ensure proper penetration before adding it. As the weld progresses, the heat must be controlled (reduced) to prevent a runaway pool or burn-through. A shorter arc length can help contain the heat to a smaller area. Use the correct polarity: Even though the aluminum is adequately cleaned, an oxide layer can begin re-forming. This makes it essential to use alternating current (AC) polarity with TIG welding. AC polarity provides a cleaning action, removing any oxide layer on the aluminum and allowing the welder to see the molten weld pool. Set the right amperage: The rule of thumb for aluminum TIG is one amp for every thousandth (0.001”) of material thickness. That means a 1/8” (0.125) thick aluminum part would require about 125 amps. Getting that “stacked dimes” look: Adding more filler material creates a cooling effect on the backside of the weld puddle, producing the stacked-dimes appearance of the finished weld.

The different types of welding are: Gas Metal Arc Welding (MIG) Gas Tungsten Arc Welding (TIG) Shielded Metal Arc Welding (Stick) Flux Core Arc Welding (FCAW) While these are not the only welding techniques available, they are the four primary types and cover the welding needs in almost any situation. Here are the details: MIG (Metal Inert Gas) Welding MIG welding comprises a continuously-fed solid electrode that heats the metals to be joined, a direct current power source to melt the electrode, and an externally supplied shielding gas to protect the weld. With four main metal transfer methods--globular, short-circuiting, spray, and pulsed-spray—MIG welding has become the most popular industrial welding process. TIG (Tungsten Inert Gas) Welding In TIG welding, a non-consumable tungsten electrode heats the metal, and a shielding gas protects the weld pool from contaminants in the air. The TIG process produces clean, high-quality welds in various metals including, aluminum, steel, stainless steel, copper, and brass, to name a few of the most common types. The advantages of using a TIG welder include what you will not get with the technique: spatter, slag, flux, smoke, or fumes. Stick Welding Appropriately called shielded metal arc welding, stick welding uses an electrode (stick) and electric current at the weld pool to join various metals. The electrode consists of a solid metal rod surrounded by compounds and metal powders. Mostly used on steel and iron, a stick welder is a versatile and straightforward welder used in construction and fabrication settings. Flux Core Welding Flux core welding is a wire welding process, similar to MIG, that does not require an external shielding gas. Instead, the wire contains a flux compound that reacts with the welding arc to form a gas protecting the weld pool. A flux core welder is ideal for outdoor welding and on dirty materials.

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