OpERATION
FIREpOwER Fp-95
Operation
4-5
Manual 0-5122
Flux-Cored Arc welding (FCAw)
This process also known as Open Arc, Innershield, FAB
Shield, etc., is an electric arc welding process which fuses
together the parts to be welded by heating them with an
arc between a continuous flux filled electrode wire and
the work. Shielding is obtained through decomposition of
the flux within the tubular wire. The process is normally
applied semi-automatically; however the process may be
applied automatically or by machine. It is commonly used
to weld large diameter electrodes in the flat and horizontal
position and small electrode diameters in all positions. The
process is used to a lesser degree for welding stainless
steel and for overlay work.
Arc
Flux Cored
Electrode
Nozzle (optional)
Gas (optional)
Molten Metal
Molten
Slag
Solid Weld
Metal
Slag
Art: A-05104
Figure 4-3: FCAW Process
!
WARNING
Follow these instructions only after referring to the Safety
Instructions and Warnings chapter of this manual, and
the instructions in the Installation chapter
Check List Before Starting
Wire Feed Speed – 1 to 10
Voltage Range Switch Setting – MIN or MAX
Electrode Wire Stick-out – approx 3/8” (10mm)
4.06 Welding Gun Positions
The welding gun should be held at an angle to the weld
joint. Hold the gun so that the welding seam is viewed
at all times. Always wear the welding helmet with proper
filter lenses.
CAUTION
Do not pull the welding gun back when the arc is
established. This will create excessive wire extension
(stickout) and make a very poor weld.
The electrode wire is not energized until the gun trigger
switch is depressed. The wire may therefore be placed on
the seam or joint prior to lowering the helmet.
Direction of
Travel
90º
Transverse
Angle
5º to 15º
Longitudinal
Angle
Art: A-05105
Figure 4-4: Butt and Horizontal Welds
Direction of Travel
30º to 60º
Transverse
Angle
10 to 20º Longitudinal
Angle
30 to 60º
Transverse
Angle
10º Longitudinal Angle
Art: A-05106
Figure 4-5: Vertical Weld
5 to 15º
Longitudinal Angle
30 to 60º
Transverse Angle
Direction of
Travel
Art: A-05107
Figure 4-6: Horizontal Fillet Weld
Direction of Travel
30 to 60º
Transverse Angle
5 to 15º
Longitudinal
Angle
Art: A-05108
Figure 4-7: Overhead
