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Flux core wire welding (FCAW) is the process of uniting metal parts by heating and allowing the metals
to flow together through the use of an electrical arc. The electric arc is created between a continuous
consumable wire electrode (the welding wire) and the work piece. An atmosphere created by the flux
protects the weld puddle from contamination and enhances the welding capabilities of the electrical
arc.
Whether you have welded before or not, it is important that you become familiar with your new welder,
its controls, and the results achieved at different settings. We strongly recommend that you practice
with your new welder on scrap metal trying different heat settings, base metal thicknesses, and welding
position for each type and size of wire you will be using. By doing this you will gain a feel for how
changes in these welding variables affect the weld. Of course, if you have not welded before, you will
need to develop welding skills and techniques as well.
The self-taught welder learns through a process of trial and error. The best way to teach yourself how
to weld is with short periods of practice at regular intervals. All practice welds should be done on scrap
metal that can be discarded. Do not attempt to make any repairs on valuable equipment until you have
satisfied yourself that your practice welds are of good appearance and free of slag or inclusions.
Now that you are familiar with the main parts of the welder, make note of the following terms. You will
see them used throughout this manual.
Weld Puddle:
The localized volume of molten metal in a weld prior to its solidification.
Weld Angle:
The angle of the welding wire, as it extends from the welding gun in relation to the
item being welded.
Slag:
The protective coating that forms on the surface of molten metal.
Arc:
A sustained luminous discharge of electricity across a gap in a circuit.
Welding Bead:
The extended buildup of a weld, made by pushing or pulling the weld puddle.
The best way to hold the welding gun is the way that feels most comfortable to you. While practicing
to use your new welder, experiment by holding the gun in different positions until you find the grip that
works best for you.
POSITION THE GUN TO THE WORK PIECE
There are two angles of the gun nozzle in relation to the work piece that must be considered when
welding.
1. Angle A can be varied, but in most cases the optimum angle will be 60 degrees. The point
at which the gun handle is parallel to the work piece. If angle A is increased, penetration
will increase. If angle A is decreased, penetration will decrease also.
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Learning to Weld
Welding Terms
Holding the Gun
Summary of Contents for 125 FC
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