3 Flux Core Welding Myths DEBUNKED

Weld.com
13 Dec 201911:49

TLDRThis video dispels common myths about flux core welding, a technique often misunderstood as inferior. The host addresses misconceptions like excessive spatter, lack of penetration, and porosity, demonstrating proper polarity and technique to achieve clean, strong welds. The video also compares flux core to solid wire MIG, showing that with the right settings, flux core can offer better penetration and less spatter, making it a viable option for hobbyists and professionals alike.

Takeaways

  • 🔧 Flux core welding is often misunderstood and sometimes considered inferior, but it has its advantages, especially for home hobbyists.
  • 🛠️ A viewer asked about using flux core versus solid wire MIG for a welding cart, sparking a discussion on common flux core myths.
  • 🚫 One myth is that flux core welding results in a lot of spatter and a high, narrow bead profile, but this can be avoided with proper polarity settings.
  • ⚡ The correct polarity for flux core welding is DC-, not DC+, which is a common mistake leading to spatter and poor weld quality.
  • 🔨 Switching from DC+ to DC- polarity can drastically improve weld quality, reduce spatter, and increase penetration.
  • 👀 Another myth is the lack of penetration with flux core, but tests show it can provide good or even better penetration compared to other processes.
  • 🔍 The video demonstrates cutting and polishing weld samples to compare penetration between flux core and short-circuit MIG.
  • 💨 Porosity is a concern with flux core welding, often 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 to prevent porosity in flux core welding.
  • 🔄 Wire feeding issues can occur with flux core due to improper drive rolls selection; knurled rolls are recommended over V-grooves for better grip.
  • 🛡️ Using anti-spatter spray can protect the work area and make clean-up easier after welding, saving time and reducing the need for grinding.

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, particularly for home hobbyists and those who may not have access to other welding processes.

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

    -Flux core welding might be preferred due to its benefits such as faster welding speed, better deposition rates compared to regular stick welding, and the convenience of not needing a gas bottle.

  • What is the first welding myth discussed in the script?

    -The first myth discussed is that flux core welding results in a lot of weld spatter and a high, narrow bead profile, which is actually not true when the correct welding techniques are used.

  • 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 lead to excessive spatter and a narrow bead profile.

  • How does switching polarity affect the welding process?

    -Switching polarity to DC- can significantly reduce spatter, provide a smoother bead appearance, and improve penetration and welding into the toes of the weld.

  • What is a common misconception about the penetration quality of flux core welding?

    -A common misconception is that flux core welding does not provide enough penetration compared to other processes like short-circuit MIG, but the script suggests that this is not the case.

  • What is the recommended contact tip to work distance for flux core welding with a 71 T-11 wire?

    -The recommended contact tip to work distance for flux core welding with a 71 T-11 wire is 3/8 to 1/2 inch stick out to prevent porosity and ensure proper flux preheating.

  • What can cause porosity in flux core welding?

    -Porosity in flux core welding can be caused by improper storage of electrodes, and more commonly, by having an incorrect contact tip to work distance that is too short.

  • Why is wire feeding issue a common problem in flux core welding?

    -Wire feeding issues in flux core welding often stem from using the wrong drive roll type (V-groove instead of knurled) or improper wire tension that is too tight, which can crush the wire.

  • What is one way to reduce spatter and protect the welding table?

    -One way to reduce spatter and protect the welding table is by using an anti-spatter spray on the surface before welding, which allows for easy removal of spatter after welding.

  • What is the final recommendation for someone who is new to welding and considering flux core welding?

    -The final recommendation for someone new to welding is to not hesitate in using flux core welding for thicker materials, ensuring they understand the proper techniques, settings, and equipment to achieve quality welds.

Outlines

00:00

🔧 Debunking Flux Core Welding Myths

The script addresses common misconceptions about flux core welding, particularly in comparison to solid wire MIG welding. It highlights that flux core is not an inferior process and can be advantageous for home hobbyists without access to gas bottles. The speaker shares personal experience using flux core for structural steel, emphasizing its speed and better deposition rates. The video aims to guide viewers through common problems and solutions to improve their flux core welding skills, especially when it's their only available option. The demonstration uses an ISA Rebel 235 with specific wire feed speed and voltage settings, and the importance of using the correct polarity (DC-) is discussed to avoid spatter and achieve better penetration and bead profile.

05:04

🛠 Flux Core vs. Solid Wire MIG: Penetration and Porosity

This section of the script focuses on dispelling myths about penetration and porosity in flux core welding. It challenges the belief that flux core welding lacks the penetration power of other processes by showing a comparison between flux core and short-circuit MIG welds on quarter-inch plate. The results indicate that flux core may even provide better penetration. The script also discusses the issue of porosity in self-shielded flux core welding, attributing it mainly to improper electrode storage and contact tip to work distance. A demonstration of how close contact can cause porosity is provided, emphasizing the need for correct preheating of the flux before it interacts with the weld pool.

10:09

🔄 Overcoming Wire Feed Issues and Spatter Management

The final paragraph tackles wire feeding issues and managing spatter in flux core welding. It suggests that problems often stem from improper drive roll selection, with V-groove rolls being unsuitable for flux core wires due to their crushing effect. Knurled rolls are recommended instead, as they provide the necessary grip. The script also advises on the correct wire tension to prevent wire crushing. As a practical tip for managing spatter, the use of anti-spatter spray is introduced, which helps protect the work area and allows for easy removal of spatter after welding. The video concludes with an invitation for viewers to join a welding community for further support and feedback, and a reminder to continually improve welding skills.

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. This method is popular for its ease of use, especially in outdoor and fume-free environments, as it doesn't require shielding gas. In the video, the host aims to debunk myths about flux core welding, asserting its benefits and suitability for home hobbyists and situations where other types of welding might not be feasible.

💡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 belief that it produces excessive spatter or lacks penetration compared to other welding processes. The host works to dispel these misconceptions through demonstration and explanation.

💡Polarity

Polarity in welding, specifically in arc welding, refers to the direction of the electric current flow between the electrode and the workpiece. The script mentions that running on DC+ instead of DC- can lead to issues like excessive spatter and a narrow bead profile in flux core welding. Correcting polarity to DC- can significantly improve the welding outcome.

💡Spatter

Spatter refers to the small metal droplets that are expelled from the weld pool during the welding process. Excessive spatter can be a sign of improper welding technique or settings. The video demonstrates how changing the polarity from DC+ to DC- can reduce spatter in flux core welding, leading to a cleaner and more professional-looking weld.

💡Deposition Rate

Deposition rate is the measure of how much weld material is transferred from the electrode to the weld pool in a given time. Flux core welding is highlighted in the video for its better deposition rates compared to stick welding, which can make it faster and more efficient for certain applications.

💡Penetration

Penetration in welding is the depth to which the weld metal extends into the base material. A common myth discussed in the video is that flux core welding does not provide enough penetration. However, the host shows through demonstration that flux core can achieve good, if not better, penetration compared to other methods like short-circuit MIG welding.

💡Porosity

Porosity refers to the presence of small holes or voids within the weld metal, which can be caused by various factors such as improper gas shielding or moisture in the flux. The video addresses porosity as a misconception associated with flux core welding, explaining that it can be avoided with proper technique and equipment setup.

💡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 contact tip to work distance to prevent issues like porosity in flux core welding. An improper distance can lead to the flux not preheating correctly, affecting the weld quality.

💡Wire Feed Speed

Wire feed speed is the rate at which the welding wire is fed into the weld pool. It is a critical parameter in controlling the size and shape of the weld bead. In the script, the host sets the wire feed speed to 180 inches per minute for the demonstration, illustrating how adjustments in wire feed speed can affect the welding process.

💡Anti-Spatter

Anti-spatter is a substance used in welding to reduce the amount of spatter produced during the welding process. It creates a protective layer on the work surface that allows spatter to be easily wiped away after welding. The video mentions using anti-spatter to protect the work area and the material being welded, making for easier cleanup.

💡Drive Roll

Drive rolls are components in a welding machine that grip and pull the wire through the wire feed unit. The video discusses the importance of selecting the correct type and size of drive roll for flux core welding to prevent wire feeding issues. Using the wrong drive roll can crush the wire and disrupt the welding process.

Highlights

Flux core welding is often misunderstood and considered inferior, but it has many benefits, especially for home hobbyists.

Flux core welding can be used effectively for projects like building a welding cart.

Common myths about flux core include high spatter and a narrow bead profile, which can be mitigated with proper technique.

Polarity is crucial in flux core welding; using DC+ instead of DC- can lead to spatter and poor penetration.

Switching to DC- polarity can drastically reduce spatter and improve weld quality.

Flux core welding can achieve good penetration, contrary to the myth that it lacks compared to other processes.

A comparison between flux core and short-circuit MIG shows that flux core can provide better penetration on thicker materials.

Porosity in flux core welding is often due to improper storage of electrodes or incorrect contact tip to work distance.

Maintaining proper contact tip to work distance is essential to prevent porosity in flux core welds.

Wire feeding issues in flux core welding can be resolved by selecting the correct drive rolls and ensuring appropriate wire tension.

Using anti-spatter spray can protect your work area and make clean-up easier after welding.

Flux core welding is suitable for thicker materials and provides a smoother, cleaner weld compared to short-circuit MIG on certain applications.

The video demonstrates the debunking of myths through practical examples and comparisons with other welding processes.

Flux core welding can be faster and provide better deposition rates compared to stick welding.

The importance of using the correct polarity and settings for optimal flux core welding outcomes is emphasized.

The video concludes with a call to action for viewers to share their experiences and seek help on the weld.com community.