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Welding With Flux Wire

Welding with Flux Wire

Flux Cored Arc Welding is a welding process that uses a self-shielding continuous wire that may be either coated or filled with flux.  During the welding process the flux will melt and form a shield around the weld puddle, eliminating contamination from the atmosphere.  This welding process is ideal for welders who need a portable welding method.  Since the flux replaces the need for a shielding gas, the welder doesn’t have to carry along a tank of shielding gas.  Because there isn’t a shielding gas to cool the welding puddle with this technique, it is important that the welder pay close attention to their heat and wire speed settings. 

The first step in this welding process is to load the MIG welder with a roll of flux-core welding wire.  You should also switch the feeder roll to accommodate the larger size of the flux-cored wire.  Failure to match the feeder roll to the size of the flux-cored wire may result in problems during the welding process.  Once this has been done, you will need to remove the welding top from the MIG gun and push the trigger to force the flux-cored wire through.

Once the wire has been properly loaded in the tip, replace the welding tip onto the torch and trim any excess flux wire using wire cutters.  Once these steps have been followed, you should put on all of the recommended welding safety gear.  This includes gloves, welding helmet and a welding apron if you wear one.  You should also insure that you are wearing the proper type of pants and work boots.

Before welding the primary pieces of metal you will be joining, it is recommended that you test your welding machine’s settings on a piece of scrap metal.  The scrap piece of metal should be placed on your welding table, and then you will want to place the tip of your MIG gun at least 1/2 inch above the surface of the scrap metal you will be using.  During this step you will want to make a small weld, stop and inspect it and then make any necessary changes to your equipment.

After you have set your welding gear to the proper settings, and are happy with the test weld, you can now begin welding the primary pieces.  The weld bead you create should be similar in looks to a weld bead that was created using a standard solid core MIG wire and shielding gas.  Once you have created a weld that you are happy with, you can now grind/polish the welded surface. 

Ed C.


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