3 Flux Core Welding Myths DEBUNKED

Weld.com
13 Dec 201911:49

TLDRThis video from 'well calm' debunks common myths about flux core welding, a process often misunderstood as inferior. The host addresses misconceptions like excessive spatter, lack of penetration, and porosity, demonstrating with practical examples how to achieve better results using the correct polarity and techniques. The video also provides tips on wire feeding issues and using anti-spatter spray for easier clean-up, encouraging hobbyists and beginners to consider flux core welding for their projects.

Takeaways

  • 🔧 Flux core welding is often misunderstood but has many benefits, especially for home hobbyists.
  • 🛠️ Switching from DC+ to DC- polarity can significantly reduce spatter and improve weld quality in flux core welding.
  • ⚙️ Proper polarity settings (DC-) lead to better heat distribution, with 70% of the heat on the base metal and 30% on the electrode.
  • 🌐 Flux core welding can achieve good penetration, comparable to or even better than short-circuit MIG welding.
  • 🔍 The misconception of lack of penetration with flux core is debunked through a comparison with solid wire MIG.
  • 💨 Porosity in flux core welding can be caused by improper storage of electrodes or too short a contact tip to work distance.
  • 🔨 Maintaining the correct contact tip to work distance is crucial for preventing porosity in self-shielded flux core welding.
  • 🔄 Wire feeding issues can arise from incorrect drive rolls; knurled rolls are recommended for flux core applications.
  • 🛡️ Anti-spatter spray can protect the welding area and make clean-up easier, saving time and reducing the need for grinding.
  • 📏 The recommended stick out for 0.035-inch diameter flux core wire is 3/8 to 1/2 inch to avoid porosity.
  • 📐 Flux core welding is suitable for thicker materials and can be used confidently for projects like building a welding cart.

Q & A

  • What is the main topic discussed in the video script?

    -The main topic discussed in the video script is debunking common myths about flux core welding and explaining its benefits, especially for home hobbyists.

  • Why might someone choose flux core welding over other processes?

    -Flux core welding might be chosen over other processes due to its benefits such as faster welding speed, better deposition rates, and suitability for those who do not have access to a gas bottle or other welding processes.

  • What is one common misconception about flux core welding mentioned in the script?

    -One common misconception mentioned in the script is that flux core welding results in a lot of spatter and a high, narrow bead profile.

  • What is the recommended polarity setting for flux core welding?

    -The recommended polarity setting for flux core welding is DC- (direct current straight polarity), as opposed to DC+, which can cause excessive spatter.

  • How does switching polarity from DC+ to DC- affect the welding process?

    -Switching polarity from DC+ to DC- results in a much smoother bead appearance, virtually eliminates spatter, and provides better penetration and a wider spread of the weld.

  • What is the recommended wire feed speed and voltage for the demonstration in the script?

    -The recommended wire feed speed for the demonstration is 180 inches per minute, and the voltage is set at 17 volts.

  • Why might a welder experience lack of penetration when using flux core welding?

    -A welder might experience lack of penetration when using flux core welding due to improper polarity settings or other welding parameters not being optimized for flux core processes.

  • What is the recommended contact tip to work distance for flux core welding with a 0.035 inch diameter wire?

    -The recommended contact tip to work distance for flux core welding with a 0.035 inch diameter wire is 3/8 to 1/2 inch stick out to ensure proper preheating of the flux before it interacts with the weld pool.

  • What can contribute to porosity in flux core welding?

    -Factors that can contribute to porosity in flux core welding include improperly stored electrodes and an incorrect contact tip to work distance, which can prevent the flux from preheating properly.

  • How can wire feeding issues be addressed in flux core welding?

    -Wire feeding issues in flux core welding can be addressed by ensuring the correct drive roll type (knurled rather than V-groove) is selected, and that the wire tension is not too tight to avoid crushing the wire.

  • What is an effective way to reduce spatter and clean up after welding?

    -An effective way to reduce spatter and clean up after welding is to use an anti-spatter spray on the surface before welding, which allows for easy removal of spatter after the welding process is complete.

Outlines

00:00

🔧 Understanding Flux Core vs. Solid Wire MIG Welding

The video script begins with a viewer's question about using flux core versus solid wire MIG for a welding cart project. The host addresses common myths surrounding flux core welding, emphasizing its benefits for home hobbyists without access to gas bottles. The script details the advantages of flux core, such as faster welding speeds and better deposition rates compared to stick welding. The host demonstrates flux core welding on an ISA Rebel 235, using specific wire feed speed and voltage settings, and explains the importance of polarity in reducing spatter and achieving a narrow bead profile. The correct polarity setting (DC-) is shown to significantly reduce spatter and improve weld quality, with a comparison of amperes before and after the adjustment.

05:04

🛠 Debunking Misconceptions About Flux Core Welding

The script continues by debunking several misconceptions about flux core welding. It discusses the myth of lack of penetration, comparing flux core to short-circuit MIG and showing that flux core can achieve equal or better penetration. The host then addresses the issue of porosity, which can be caused by improper electrode storage or an inadequate contact tip to work distance. A demonstration is provided to show the effect of a too-short distance on weld porosity. Additionally, the script covers wire feeding issues related to drive rolls and wire tension, recommending the use of knurled rolls for flux core applications and ensuring proper wire diameter and tension settings.

10:09

🚫 Combating Spatter and Encouraging Best Welding Practices

The final paragraph focuses on combating spatter during welding, a common issue that can be mitigated with the use of anti-spatter spray. The host demonstrates how this spray can protect the work surface and the material being welded, allowing for easy removal of spatter after the welding process. The script concludes with a summary of the myths debunked and an invitation for viewers to engage with the community for further questions, comments, and support. The host encourages continuous improvement in welding skills, emphasizing the importance of making every weld better than the last.

Mindmap

Keywords

💡Flux Core Welding

Flux core welding is a type of arc welding process that uses a tubular wire filled with flux as the consumable electrode. The flux inside the wire helps to shield the molten weld pool from atmospheric gases and provides a more stable arc. In the video, the host aims to debunk myths about flux core welding, showing that it is not an inferior process and can be beneficial, especially for home hobbyists.

💡Myth

A myth is a widely held but false belief or idea. In the context of the video, several myths about flux core welding are discussed, such as the misconception that it produces excessive spatter or lacks penetration compared to other welding processes.

💡Polarity

Polarity in welding refers to the direction of the electrical current flow between the electrode and the workpiece. The video explains that using the wrong polarity, such as DC+ instead of DC-, can lead to problems like excessive spatter and a narrow bead profile in flux core welding.

💡Spatter

Spatter refers to the small metal droplets that are ejected from the weld pool during the welding process. The script mentions that flux core welding is often mistakenly believed to produce a lot of spatter, but this can be mitigated by using the correct polarity and settings.

💡Deposition Rate

Deposition rate is the amount of weld metal deposited per unit of time or per unit length of weld. The video script highlights that flux core welding offers better deposition rates compared to regular stick welding, making it faster and more efficient.

💡Penetration

Penetration in welding is the depth to which the weld metal extends into the base material. The script addresses the myth that flux core welding does not provide enough penetration, showing through a demonstration that this is not the case.

💡Wire Feed Speed

Wire feed speed is the rate at which the welding wire is fed into the welding arc. In the video, the host sets the wire feed speed to 180 inches per minute, which is a crucial setting for achieving the desired weld characteristics in flux core welding.

💡DC+ and DC-

DC+ and DC- refer to direct current electrode positive and direct current electrode negative, respectively. The video demonstrates that using DC- (straight polarity) instead of DC+ can significantly reduce spatter and improve weld quality in flux core welding.

💡Porosity

Porosity in welding refers to the presence of holes or voids in the weld metal. The script discusses how improper storage of electrodes and incorrect contact tip to work distance can contribute to porosity in flux core welding.

💡Contact Tip to Work Distance

This refers to the distance between the contact tip of the welding gun and the workpiece. The video emphasizes the importance of maintaining the correct distance to prevent issues like porosity in flux core welding.

💡Wire Feeding Issues

Wire feeding issues occur when the welding wire does not feed smoothly into the welding gun. The script explains that using the wrong drive rolls or improper wire tension can cause these issues in flux core welding.

💡Anti-Spatter

Anti-spatter is a substance applied to the work area to prevent spatter from sticking to surfaces. The video mentions using anti-spatter to protect the work table and materials, making cleanup easier after welding.

Highlights

Debunking myths around flux core welding, explaining its benefits especially for home hobbyists.

Flux core welding is faster and offers better deposition rates compared to stick welding.

Common problems with flux core welding and how to overcome them for better results.

ISA Rebel 235 setup for flux core welding demonstration.

The importance of using the correct polarity for flux core welding to avoid spatter and achieve better penetration.

DC+ polarity causes high spatter and narrow bead profile, while DC- polarity provides a cleaner, wider weld.

Switching polarity from DC+ to DC- results in a 71% difference in heat distribution, leading to better weld quality.

Testing the depth of penetration in flux core welding versus short-circuit MIG, dispelling the myth of lack of penetration.

Flux core welding can achieve more or the same penetration depth as other processes, even on thicker materials.

Addressing the misconception of porosity in flux core welding and the role of contact tip to work distance.

Proper storage of electrodes and maintaining the correct distance between contact tip and workpiece to prevent porosity.

Wire feeding issues in flux core welding and the importance of selecting the right drive rolls.

Using V-groove drive rolls for solid wire but knurled rolls for flux core to avoid wire crushing and feeding issues.

Adjusting wire tension to prevent crushing the wire and causing spatter.

Using anti-spatter spray to protect the work area and easily remove spatter after welding.

The practical demonstration of cleaning the work area with anti-spatter spray, saving time and preventing additional grinding.

Encouraging viewers to ask questions and share their experiences on the weld.com community for feedback and support.