FCAW uses tubular wire filled with flux that provides slag protection and arc stabilizers, available in self-shielded (no external gas) and gas-shielded variants. Gas-shielded FCAW with CORGON® 25 produces superior mechanical properties and appearance, while self-shielded offers portability for outdoor structural work where gas coverage is difficult.
FCAW Fundamentals: Flux-Cored Arc Welding Gas Considerations
FCAW Process Setup and Optimization
- Wire Classification Selection. E71T-1 for gas-shielded indoor work, E71T-11 for self-shielded outdoor applications. Gas-shielded provides better properties and appearance.
- Gas Selection for Gas-Shielded FCAW. Use CORGON® 25 (75% Ar + 25% CO2) for optimal penetration and slag detachability. Higher CO2 content than solid wire MIG due to flux interactions.
- Flow Rate Optimization. Set 25-35 L/min due to flux outgassing creating turbulence. Higher flows needed than solid wire MIG to maintain coverage.
- Polarity Configuration. Always use DCEP (electrode positive) for proper arc characteristics and flux performance. DCEN causes poor transfer and excessive spatter.
- Parameter Setting. Start with 28-32V for 1.6mm wire, adjust for desired penetration profile. Higher voltages than solid wire due to arc length requirements.
FCAW Optimized
CORGON® 25 (Ar + 25% CO2)
Structural GradeWhy CORGON® 25 ideal for gas-shielded FCAW: Higher CO2 content provides deep penetration essential for structural applications while argon maintains arc stability despite flux outgassing. Optimized for outdoor structural work where FCAW excels.
FCAW parameters with CORGON® 25: Flow rate 30-35 L/min, suitable for all weather conditions with windscreens. Excellent for structural steel 6-50mm thickness in all positions.