![]() ![]() This machine will change amperage with a change of the CTWD. The FCAW-S process requires a constant voltage (CV) machine. A CC machine will change voltage with a change of the contact-tip-to-work distance (CTWD). The SMAW process requires the use of a constant-current (CC) machine, on which the operator sets the amps. This is because there is no need to stop to change out the stick electrode, reposition, and restart after each 8- to 12-in. With SMAW you can expect an average arc-on time of about 30 per cent with FCAW-S it will typically be closer to 45 per cent. Operator arc-on time can also rise with a wire-fed process. Depending on your wire diameter, you can expect to run 4 to 12 lbs./hr. Travel speeds, meanwhile, are typically roughly 10 to 12 IPM for FCAW-S, whereas SMAW typically averages 5 to 7 IPM. ![]() With SMAW that efficiency rate drops to between 60 and 65 per cent (which takes into account electrode stub loss, spatter, and fumes). The percentage of filler metal that ends up in your weld (minus loss through spatter and fumes) is around 85 per cent with FCAW-S. The deposition efficiencies – the amount of consumable deposited divided by the amount of consumable lost – can be substantially improved with FCAW-S. With FCAW-S, the wire just needs to be stored in a dry, enclosed environment in its original packaging. Time and temperature to which electrodes need to be reconditioned vary depending on the applicable code being used. If exposed to the atmosphere for extended periods of time, they will need to be reconditioned. With SMAW, take into consideration that some stick electrodes may need to be stored in an oven to keep them dry from hydrogen pickup. The benefit of using a wire-fed process compared to SMAW starts with material use. There is also the additional cost savings of not requiring gas cylinders on the job. The flux compound also makes this wire more forgiving and robust when working on material that is rusty, dirty, or otherwise contaminated. Instead, the flux compound inside the wire reacts with the welding arc to protect the weld pool.īecause the flux creates the shielding in FCAW-S, there is little concern about the loss of shielding when a strong wind blows. FCAW-S differs from gas metal arc welding (GMAW) in that it doesn’t require an external shielding gas, such as carbon dioxide or argon, to protect the weld pool from contamination. This article explains the basic distinctions between the two.įCAW-S is a wire welding process in which a tubular wire is continuously fed through a welding gun into the weld joint. But for those welders used to shielded metal arc welding (SMAW), the differences in equipment and technique can take some getting used to. Self-shielded flux-cored welding (FCAW-S) can be an excellent process for welders doing structural jobs outdoors. ![]()
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