磁通型电弧焊接（FCAW）解释了

Flux-cored arc welding (FCAW) is an automatic or semi-automatic process that uses a consumable tubular electrode in the electric arc to join metals. It was introduced as a solution to overcome the limitations ofshielded metal arc welding (SMAW)aka stick welding.

FCAW焊接已成为焊接亚铁金属的理想选择。这种焊接技术用于造船，建筑和机械行业。与其他焊接过程。

Let’s take a deeper look into this welding technique.

什么是磁通量弧形焊接？

Flux-cored welding is an arc welding process that deposits filler material with a shielding flux in the weld puddle. Fusion takes place when a welding arc is established between the flux-cored electrode and the base metals.

The tubular electrode wire is supplied through a spool and guided by a welding gun to the weld joint. As the electrode melts, the flux inside it releases a shielding gas to protect the weld pool from atmospheric contamination.

Flux-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.

Differences Between FCAW and GMAW (MIG/MAG)

通常，通量和气体金属电弧焊接均使用使用屏蔽层和连续的电线电极的原理。

FCAW weldinguses a flux-cored electrode that emits a protective shielding layer as it is deposited into the weld pool. FCAW emits toxic fumes from the flux which blocks the weld area from contaminants. This process is favoured for ferrous metals as it requires little-to-no pre-cleaning.

In some cases, FCAW can use shielding gas on top of the primary shielding flux to further protect the weld pool from oxidation. Dual-shielded FCAW offers more consistent mechanical properties and higher deposition rates than solid wire or stick electrodes.

GMAW (MIG/MAG welding)uses a solid wire electrode along with external shielding gas to prevent contamination of the weld metal. GMAW leaves more weld spatter than FCAW and offers less penetration. MAG andMIG welding提供多功能性以焊接各种金属。

GMAW has a bigger electrode wire (2 – 5 mm) compared to FCAW (0.9 – 3.2 mm).

Although these aretwo separate welding types, the only majordifference lies in shielding the weld zone using electrodes and shielding gases。

磁芯焊接工艺

FCAW工艺利用来自管状电极和工件之间产生的电弧的热量。电极是空心的，在沉积在焊接区域中时充当屏蔽剂的磁通芯。由于消耗了通量芯，它会产生屏障，以保护焊缝免受大气污染的影响。

执行FCAW有两个主要选择：

• fcaw-s（自我屏蔽）– Self-shielded welding solely relies on gaseous protection from the flux core and its slag deposits. This process is mostly used for outdoor projects that have unpredictable conditions.

• FCAW-G (Gas/Dual-shielded)– Dual shield welding uses flux-cored wires along with external shielding gas to provide additional protection for the weld area. This process allows higher deposition rates and offers better penetration against thicker metals.

Certain conditions can also influence the choice for the welding process, such as portability, desiredmechanical propertiesand base metal.

FCAW can be performed semi-automatically wherein a welding professional controls the welding torch, individually adjusting the parameters. It can also be performed fully automatically by implementing robots that can create consistent travel joints.

通量芯弧焊接变量

为了达到最佳结果，可以为每个操作调整以下参数：

• 电线进料速度

• 接触尖端距离

• 旅行速度

• 极性

• Travel and work angle

电极/电线

There are three main flux-electrode classifications for this welding method:

• Gas-shielded all position – All position flux cored welding wires are generally smaller than 1/16 inches (~1.6mm) with a fast-freezing flux core. These electrodes are mainly applied to offer more control when welding overhead. As a drawback, these can’t be used with a base metal that has high levels of contamination.

• Gas-shielded flat position – Flat position welding electrodes are usually greater than 1/16 inches (~1.6mm) and offer fast deposition rates, suited for thicker metals. These are mainly employed for horizontal or flat welding positions and it fares better than all position electrodes against base metal contamination.

• 自我屏蔽 - 这些电极可用于户外应用，例如施工或制造。它们也非常适合焊接镀锌钢，或者在极少数情况下很难到达气缸。

电极类型的选择主要取决于以下标准：焊接电流的类型，位置，所需的机械性能，化学成分和环境。

Materials

虽然磁通量弧焊接以焊接而闻名ferrous metals, it’s also popular for its versatility when welding the following metals:

• Stainless steel

• Low and mild alloy steel

• 碳素钢

• Cast iron

• 硬脸/面饰合金

Shielding Gas

双屏蔽焊接屏蔽气体来自气缸或储罐，通过供应软管到达焊接火炬。这些屏蔽气体可保护焊接池免受大气的影响，从而降低了孔隙率和脆性的风险。惰性气体和活性气体都可以用作气体屏蔽元件。

• 二氧化碳– FCAW welders prefer using carbon dioxide because of its low cost and deep penetration. Since CO2 is an oxidising gas, deoxidising elements are added to the flux-cored wire to remove the oxygen.

• Argon and carbon dioxide– A combination of the two gases is sometimes used to generate less spatter. It is usually in the ratio of 75% argon and 25% CO2, with a filler metal resulting in higher strength properties than pure CO2 gas.

• Argon and oxygen– Pure argon is sometimes mixed with 1-2% oxygen to weld metals that can be corroded with CO2, such as不锈钢。该混合物还促进了焊接区域的溅射量较小，类似于氩气和二氧化碳的混合物。

焊接枪

• 气冷- 通常，气冷枪对于焊接电流少于500安培的项目就足够了。周围的空气足以冷却这些磁芯枪。有屏蔽气体进一步冷却焊接枪。此外，气冷枪更便宜，更轻，这使操纵和创建优质的焊珠变得更加容易。

• Water-cooled——建议有水冷枪支operations requiring a welding current greater than 600 amperes. Typically, it is the preferred choice for continuous flux-cored arc welding operation, where the gun is exposed to high temperatures for longer periods. Water-cooled guns allow water to flow around the nozzle and contact tube to quickly reduce temperatures.

电线馈线

The continuously fed tubular electrode is driven by a wire feed motor. The wire feed speed can be configured in this machine to control the delivery from the spool to the welding torch.

能量源

It is desirable to have a direct current (DC) as the power source for this welding method since it is mostly applied to ferrous materials. DC power supply also creates a more stable arc and offers better penetration.

• DC正极性（DCEP）是最常见的功率设置，因为它为焊接金属提供了深层渗透。当使用外部屏蔽气体安全地将填充金属沉积到焊接接头时，这也是首选。

• DC负极性（DCEN）用于焊接较薄的金属。虽然可以使用正极和负极性来使用自屏蔽磁通电极，但DCEN有时是实现一定结果的选择。

Applications of Flux Cored Arc Welding

General Repairs

Some prefer using flux-cored welding in performing general repairs for its portability. It can endure harsh outdoor conditions, at the same time it has the ability to weld ferrous metals.

Pipelines

由于FCAW焊接生产孔隙率最低的焊接，管道制造业更喜欢使用该技术运行。使用具有一致的机械性能的焊缝，管道具有无与伦比的强度和耐用性。

Manufacturing

The manufacturing industry takes advantage of automating the process of flux core arc welding through the use of robots. This results in a precise and consistent welding seam, while all the welding parameters are controlled.

造船

The continuously fed tubular electrode allows for an efficient operation in shipbuilding. With the number of minor components to weld together, shipbuilders have to constantly change welding positions. Flux-cored welding works best, as it is easy to perform while shipbuilders manoeuvre the welding torch at varying angles.

水下焊接

潜水员利用了磁通量电极产生的保护气层提供的保护。执行此湿焊接程序需要技巧和训练，因为危害与地面上的条件无法比拟。

Advantages of Flux Cored Arc Welding

1. FCAW offers higher penetration than MIG/MAG welding.

2. 由于电极脱氧碱金属，因此能够焊接亚铁金属。

3. More portable than MIG welding since we can use FCAW without a shielding gas tank.

4. 比坚持更容易学习提格焊接。

5. FCAW and MIG welding use the same machine.

6. 通量会产生屏蔽层，使其与室外焊接配合正常。

助力弧形焊接的缺点

1. Slag cleanup.

2. Semi-automatic FCAW results in poorer weld beads than TIG welds.

3. Flux tubular electrodes are more expensive than solid wires.

4. Flux disintegration results in excessive toxic fumes.

5. 被困的气体在金属变硬时，焊缝区域可以形成孔。

6. Changing filler metal is time-consuming since FCAW uses spools compared to some other processes that use short electrodes.

Important Points to Remember

磁通量弧焊接是一种多功能，高效的焊接过程，使其成为某些应用的更好选择。它更容易学习，并且它带给桌子的便携性使其成为一个有吸引力的过程。

FCAW is slowly replacing shielded metal arc welding (SMAW) in industries such as manufacturing and construction. The primary reason for that is automation wherein robots are taking over the assembly lines, welding with pin-point accuracy at any welding position.

我们可以明确地希望熔滴焊接快速眼动ain one of the more popular welding methods today, as continuous innovation further improves its efficiency and versatility.