MIG Welding Wire Size

As a welder, I’ve found that mastering the art of MIG welding requires understanding the relationship between the material thickness and wire size. Here’s a chart I’ve used time and time again, illustrating the optimal wire sizes for different thicknesses of mild steel:

Flux Core Welding Wire Size

Similarly, for flux core welding, another technique I often employ, the wire size depends on the material thickness. Here’s my go-to chart for this scenario:

How Does Wire Size Impact Weld Quality

The size of your MIG welding wire significantly impacts the quality of your weld. A thinner wire will create a fine, clean weld that is ideal for thinner materials but may lack penetration for thicker materials. In contrast, a thicker wire offers greater penetration and a higher deposition rate, which is excellent for welding thicker materials but may be too robust for thinner ones.

So, proper sizing based on the material thickness is key to getting the best result.

Weld Penetration

As I mentioned before, wire size affects the level of penetration you can achieve. Larger wires will provide a deeper penetration which is essential when welding thicker materials. On the other hand, smaller wires will give a shallower penetration, which is ideal for thinner materials to prevent burn-through.

Weld Appearance

The size of the wire also influences the appearance of your weld. Smaller wires will produce a narrower, more concentrated bead, which can be desirable in certain situations where precision and aesthetics are important. Larger wires, on the other hand, produce wider, more substantial beads that can fill larger joints more effectively.

Weld Speed

The wire size can also affect how fast you can weld. Larger wires have a higher deposition rate, meaning you can lay down more metal quickly. This can be advantageous when speed is a factor, such as in production welding. However, if you’re working on a delicate or precision project, a smaller wire might be preferable because it allows for more control, even if it does mean slower welding.

How to Select the Correct MIG Welding Wire Size

The selection of the correct MIG welding wire size comes down to your project’s specifics – the material thickness and joint design. As a seasoned welder, I’ve found that a larger wire size is often more suitable for thicker materials and joints requiring deeper penetration, such as beveled joints. However, a smaller wire size is preferable for thinner materials or when precision is critical.

Material Thickness

First and foremost, look at the thickness of your material. The thicker the material, the larger the wire size you will typically need. This is because thicker materials require deeper penetration for a strong weld, which a larger wire can provide.

For example, if you’re welding a 1/2 inch thick steel, you’d typically use a .045 gauge wire. But if you’re working with thin sheet metal, a .023 gauge wire might be more appropriate.

Joint Design

The joint design also plays a crucial role. Different joint designs have different requirements for penetration and filler material. For example, a beveled or V-groove joint would typically require a larger wire size because it needs more filler material and deeper penetration. On the other hand, a lap joint or a butt joint might do just fine with a smaller wire size.

Type of Welding

The type of welding you’re doing will also influence your wire size. For instance, if you’re doing multi-pass welding, you might want to opt for a smaller wire size to prevent burn-through, especially on the first pass. The smaller wire will also allow for better control over the shape and size of your weld bead.

Amperage

Finally, consider your welder’s amperage. The more powerful your welder, the larger the wire you can use. If your welder has a lower amperage, you’ll need to stick with smaller wire sizes. So check your welder’s specifications before choosing your wire size.

Tips for Wire Size Selection

Here are a few practical tips from my own experience:

• Know your material: The material you’re welding is crucial in determining the wire size. Steel, for instance, usually requires a different wire size than aluminum.
• Consider the amperage: The wire size directly influences the welding current. Larger wire sizes require more current and, thus, a more powerful welder.
• Multi-pass welding: You might opt for a smaller wire to prevent burn-through but maintain a clean, sturdy weld.

Wire Size for Common Welding Scenarios

In my welding journey, I’ve encountered several scenarios where the wire size makes all the difference. Here are a few common ones:

Conclusion

Understanding the welding wire size chart is vital for a welder, from ensuring optimal weld quality to promoting efficient work. It’s not just about numbers, but understanding how each wire size interacts with different material thicknesses, joint designs, and welding scenarios.

With the right wire size, a good weld isn’t just likely—it’s a given. The right wire size selection can be the difference between a novice’s weak joint and a professional’s sturdy, clean weld.

The post MIG + Flux Core Welding Wire Size Chart appeared first on Beginner Welding Guide.

I’ve had my fair share of experiences with various welding techniques. One question I often hear from fellow welders and enthusiasts is which method is better: stick or flux core welding? I’ve decided to share my insights on these two popular welding processes to help you navigate the world of welding and make the right choice for your projects.

Quick Summary

Stick Welding Process

Stick welding, also known as Shielded Metal Arc Welding (SMAW), is one of the oldest and most widely used welding techniques. It’s simple, versatile, and cost-effective, making it a go-to choice for many welding projects.

The stick welding process utilizes a flux-coated consumable electrode, a metal rod, to create an electric arc between the electrode and the base metal. The electric arc generates heat, melting the base metal and electrode, and forming a weld puddle. As the weld puddle cools down, it solidifies into a strong joint, bonding the base metals.

One unique aspect of stick welding is the flux coating on the electrode. When the flux melts, it creates a protective gas shield around the weld, preventing atmospheric contamination. The flux also produces slag, a layer of solid material that covers and protects the weld from oxidation and other contaminants while it cools down. Once the weld is cool, the slag must be chipped away to reveal the finished weld.

Stick welding is incredibly versatile, making it suitable for various applications. It works well with multiple metals, including steel, stainless steel, cast iron, and aluminum alloys. Stick welding is effective on thick materials and can be performed in all positions: flat, horizontal, vertical, and overhead.

It’s not well-suited for thin materials, as the high heat can cause warping or burn-through. The process tends to produce more spatter and slag than other welding techniques, requiring additional post-weld cleanup. The learning curve for stick welding can also be steep, as it requires precise electrode control and the ability to maintain a consistent arc length.

Flux Core Welding Process

Flux Core Arc Welding (FCAW) is a popular and versatile technique that has gained popularity due to its speed, adaptability, and suitability for various materials.

Flux core welding is a semi-automatic or automatic arc welding process that utilizes a continuously fed tubular wire electrode filled with flux to create an electric arc between the electrode and the base metal. The heat generated by the arc melts both the base metal and the wire electrode, forming a molten weld pool. As the weld pool cools, it solidifies to create a strong joint, fusing the base metals.

The flux core wire used in this process serves a dual purpose. As the wire electrode melts, the flux within the wire releases a shielding gas that protects the weld pool from atmospheric contamination. Additionally, the flux generates slag, a solid layer that covers the weld and guards it against oxidation and other impurities as it cools. Once the weld has cooled sufficiently, the slag can be removed to reveal the completed weld.

One of the primary advantages of flux core welding is its ability to work well with thin materials and metals that may be dirty or rusty, making it ideal for repair and maintenance work. The process is faster and generally produces less slag than stick welding. Flux core welding can be performed in all positions: flat, horizontal, vertical, and overhead.

It typically requires more expensive equipment and consumables than stick welding, and the wire feed system can be more complex, potentially leading to issues if improperly maintained. The shielding gas generated by the flux may not be as effective as that provided by external gas shielding in other processes, potentially resulting in a higher risk of weld porosity.

Welding Materials and Thickness

Regarding material compatibility, stick welding and flux core welding work well with various metals, including steel, stainless steel, and cast iron. However, stick welding is generally more versatile, as it can be used with some aluminum alloys and other specialty materials, while flux core welding is primarily limited to steel.

The primary differentiator between stick welding and flux core welding is their performance with different material thicknesses.

Stick welding can handle thick materials, generally starting from 1/8-inch thickness and up. The high heat input of stick welding allows for deep penetration, creating strong welds on heavy plates and structural components. On the other hand, stick welding can be challenging when dealing with thin materials, as the high heat may cause warping or burn-through.

Flux core excels with thin materials, typically less than 1/8-inch thick. The process allows for better control of heat input, reducing the risk of warping and burn-through on thin metals such as sheet metal or automotive body panels. Flux core welding can also handle thicker materials, but it is not the best choice if deep penetration and strong welds are critical for the project.

Another factor to consider is the condition of the base metal. Flux core welding is more forgiving when working with dirty or rusty surfaces, as the flux helps protect the weld pool from contaminants. Stick welding, on the other hand, generally requires cleaner surfaces to ensure a strong, defect-free weld.

Learning Curve

Stick welding is often considered to have a steeper learning curve for beginners. The technique requires precise electrode control, maintaining a consistent arc length, and adapting to flat, horizontal, vertical, and overhead positions.

Also, proper electrode manipulation is crucial to avoid common issues like sticking, arc blow, and inconsistent welds. Stick welding also demands good hand-eye coordination and an understanding of the right electrode for a given material and application.

Flux core welding is generally considered easier to learn for beginners, particularly those with experience with wire-fed processes like MIG welding. Flux core welding relies on a wire feed system, providing a more consistent arc and requiring less manual dexterity than stick welding.

However, flux core welding still demands attention to detail, such as adjusting the wire feed speed and voltage settings to match the material thickness and welding position. The technique requires knowing how to set up and maintain the wire feed system, troubleshoot wire feeding issues, and choose the appropriate wire for the job.

Welding Position Flexibility

Stick welding is known for its versatility in handling different welding positions. The process can be performed in all four standard welding positions: flat, horizontal, vertical, and overhead. This adaptability is due to the manual control of the electrode, which allows the welder to manipulate the arc and molten puddle in various orientations.

However, this flexibility also contributes to the steeper learning curve of stick welding, as mastering the technique in each position demands practice and skill development.

Flux core welding can also be performed in all four welding positions. The wire feed system provides a consistent arc that can be controlled in various positions with the proper adjustments to the wire feed speed and voltage settings. Flux core welding’s ability to handle different positions makes it popular for numerous applications, from structural steel erection to automotive repairs.

Vertical and overhead welding with flux core may require specific wire types or shielding gas combinations to ensure strong, defect-free welds.

Cost

Stick welding is generally considered a more cost-effective option when compared to flux core welding. The equipment required for stick welding is relatively simple and affordable, typically consisting of a power source, electrode holder, ground clamp, and welding leads. Consumables for stick welding are also relatively inexpensive and widely available.

Stick welding may have higher labor costs due to its slower speed and the need for post-weld cleanup.

On the other hand, flux core welding tends to have higher costs associated with equipment and consumables. The welding setup requires a wire feed system. These components can make the initial investment in flux core welding equipment more expensive than stick welding.

Flux core welding consumables, such as tubular wire electrode, are generally more costly than stick welding electrodes. Flux core welding can be more efficient regarding labor costs, as it is a faster process and typically requires less post-weld cleanup than stick welding.

Conclusion

I can attest that both processes offer unique advantages and challenges, which makes understanding their differences essential when selecting the proper welding technique for your projects. The choice between stick welding and flux core welding ultimately depends on various factors, including material type and thickness, surface condition, welding position, learning curve, and cost.

Stick welding is known for its versatility, ability to handle thicker materials and compatibility with a broader range of materials. While flux core welding excels with thin materials, is more forgiving on dirty or rusty surfaces, and is generally easier for beginners to learn.

The post Stick vs Flux Core Welding for Beginners appeared first on Beginner Welding Guide.

The Hobart Handler 140 is my top choice because it is both powerful and versatile for a wide range of tasks. It features simple controls and durable construction with a smooth arc. It is ideal for beginner welders looking for an affordable and reliable flux core welding machine.

Flux core welding machines are ideal for beginners because you don’t need to think about gas or leasing bottles. You can buy a pack of flux core wires and get started. They are generally cheaper than traditional MIG welders and are more portable.

Selecting from the hundreds of models of flux core welding machines can be difficult, so I have narrowed down your list to the top performers based on my personal experience. Some welding machines I own, some I have borrowed, and some I have used in friend’s workshops.

Best Flux Core Welder

Hobart Handler 140 MIG Welder

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

Check Latest Price on Amazon

Multi-Process

Forney Easy Weld MIG Welder

• Infinite Voltage and Wire Feed Speed Control
• Extremely Lightweight and Portable at 19 lb
• Can Weld up to 1/4" inch Mild Steel
• 30% Duty Cycle at 90 Amps

Check Latest Price on Amazon

Best Budget Option

Lotos MIG 140 Welder

• Only 110V Input Voltage
• 20% duty cycle at 90 amps
• 50 to 500 IPM wire feed speed
• 24 gauge to 3/16 inch steel weld

Check Price on Amazon

1. Hobart Handler 140 MIG Welder

The Hobart Handler 140 MIG welder is a powerful and versatile machine designed for beginners and experienced welders. It is a compact and portable welder that can be used for various applications, including auto body work, household repairs, and light fabrication.

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

Check Price on Amazon

Specifications

• Input Voltage: 115V
• Amperage Range: 25-140A
• Duty Cycle: 20% at 90A
• Wire Feed Speed Range: 40-700 IPM
• Weld Thickness Range: 24 gauge up to 1/4 inch
• Weight: 57 pounds

Pros

• Easy to set up and use, even for beginners
• Durable and well-built construction
• Can be used for a wide range of applications
• Smooth and consistent arc performance
• Comes with a regulator and a spool of wire, making it ready to use out of the box

Cons

• Limited duty cycle, which may not be suitable for larger welding projects
• Only suitable for use with 115V power supply
• The wire feed mechanism may occasionally jam
• Lacks advanced features found in more expensive welders, such as a spool gun for welding aluminum

Suitable For

• DIY projects
• Household repairs
• Auto body work
• Light fabrication

Things I Like:

As an experienced welder, I appreciate the Hobart Handler 140 MIG welder’s ease of use and consistent arc performance. The machine is very user-friendly, with simple controls that are easily adjusted.

I also appreciate the durable construction of the machine, which ensures that it can withstand regular use over time.

Things I Don’t Like:

While the Hobart Handler 140 MIG welder is a great machine overall, it does have some limitations that may not be suitable for all projects. For example, the limited duty cycle may be a problem for larger welding projects. The lack of advanced features may be a drawback for more experienced welders who require greater flexibility and control.

The duty cycle of 20% is only based on 90 amps, so when you jack it up to 140 amps, it will only weld for a very short time before requiring an extended cooldown.

Verdict:

Overall, the Hobart Handler 140 MIG welder is a great machine suitable for both beginners and experienced welders. While it may have some limitations, it is a durable and versatile machine with consistent arc performance and ease of use.

If you are looking for a reliable and affordable MIG welder, the Hobart Handler 140 is definitely worth considering.

2. Forney Easy Weld 140 MP Welder

The Forney Easy Weld 140 multi-process welder is a versatile Flux Core, MIG, TIG, and Stick welder designed for beginners and experienced welders. It may seem like overkill if you are only looking for a flux core welder, but if you want a wider range of welding processes, this is a good option.

• Infinite Voltage and Wire Feed Speed Control
• Extremely Lightweight and Portable at 19 lb
• Can Weld up to 1/4" inch Mild Steel
• 30% Duty Cycle at 90 Amps

Check Price On Amazon

Specifications

• Input Voltage: 120V
• Amperage Range: 10-140A
• Duty Cycle: 30% at 90A, 25% at 116A
• Wire Feed Speed Range: 70-300 inches per minute
• Weld Thickness Range: Up to 1/4 inch
• Weight: 25.8 pounds

Pros

• It can perform MIG, TIG, and Stick welding processes, making it suitable for various applications.
• Its user-friendly interface, simple controls, and easy setup make it ideal for beginners and hobbyists.
• The compact and lightweight design of the welder makes it easy to move around the workshop or job site.
• The welder produces high-quality welds with minimal spatter and good penetration.

Cons

• The welder’s maximum output is 140A, which may not be sufficient for heavy-duty welding tasks.
• The welder has a relatively short duty cycle, so it may need to be rested frequently to prevent overheating.
• No gas regulator included: Users must purchase a separate gas regulator to use the welder for MIG welding.

Suitable For

• Automotive repairs and fabrication
• DIY projects
• Home repairs and maintenance
• Farm and ranch welding

Things I Like

I appreciate the versatility, user-friendly controls, and compact design of the Forney Easy Weld 140 MP welder. The welder’s ability to perform multiple welding processes allows me to switch between techniques quickly, depending on the job.

Its lightweight and portable design makes moving around the workshop or take to job sites easy.

Things I Don’t Like

However, I find the welder’s limited power and short duty cycle somewhat limiting, mainly when working on thicker materials or longer welds.

Also, the fact that a gas regulator is not included in the package means that users need to purchase one separately, which can add to the overall cost of the welder. This isn’t relevant if you will only use it for flux core.

Verdict

Overall, the Forney Easy Weld 140 MP welder is an excellent choice for beginner welders or hobbyists who require a versatile and easy-to-use welder for various projects. Its compact and lightweight design makes it easy to move around, and its multiple welding processes provide flexibility.

However, more experienced welders may find the welder’s limited power and short duty cycle somewhat limiting for heavier-duty projects.

Nonetheless, its affordable price point and overall performance make it a worthwhile investment for most welding enthusiasts.

3. Lotos MIG 140 Welder

If you are looking for a budget-friendly option with decent power, the Lotos MIG 140 is worth a closer look. Although it does have a reputation for lower build quality, it has attractive specifications.

• Only 110V Input Voltage
• 20% duty cycle at 90 amps
• 50 to 500 IPM wire feed speed
• 24 gauge to 3/16 inch steel weld

Check Price On Amazon

Specifications

• Input Voltage: 110V
• Amperage Range: 30 to 140 amps
• Duty Cycle: 20% at 90 amps
• Wire Feed Speed: 50 to 500 IPM
• Weld Thickness Range: 24 gauge to 3/16 inch
• Weight: 54 pounds

Pros

• It is easy to set up and use, making it ideal for beginners.
• It can be used for various welding metals, including mild steel, stainless steel, and aluminum.
• Compact and lightweight, making it easy to move around.
• This relatively affordable welder makes it an excellent choice for those on a budget.

Cons

• This welder has a low duty cycle, making it unsuitable for extended welding tasks.
• The low amperage range means that it’s not suitable for welding thick metal.
• Quality control issues: Some users have reported quality control issues. One of the reasons to limit your choice to the more reputable brands

Suitable For

• Beginners who want a versatile and affordable welder.
• Hobbyists who need a welder for occasional use.
• Those who need a portable welder for small welding tasks.

Things I Like

There are a few things that I like about the Lotos MIG 140 welder. Firstly, its versatility means it can be used for various welding tasks, which is always a plus. Secondly, its compact size and lightweight make it easy to move around and use in tight spaces. Finally, its affordability means it’s accessible to those on a budget.

Things I Don’t Like

One thing that I don’t like about the Lotos MIG 140 welder is its limited duty cycle. This means that it’s not suitable for extended welding tasks, and you may have to take frequent breaks. Additionally, its low amperage range means that it’s not suitable for welding thicker metals, which can limit its usefulness.

Verdict

Overall, the Lotos MIG 140 welder is a versatile and affordable welder suitable for beginners and hobbyists. While it has some limitations, such as its low duty cycle and amperage range, it’s still an excellent choice for small welding tasks. Its portability, ease of use, and cost-effectiveness make it a popular choice for those looking for an entry-level welder.

I value durability and reliability and would be reluctant to move too far away from the big names in the industry, like Lincoln and Miller, to avoid any quality problems.

4. Everlast PowerMIG 200 Welding Machine

The Everlast PowerMIG 200 Welding Machine is a multi-process welder that can handle Flux Core, MIG, Stick, and TIG welding. It is designed to deliver reliable and efficient performance for various welding applications. The machine has advanced features and settings that allow users to adjust and customize their welding experience.

• Reliable and Efficient Performance
• Multi-Process: Flux Core, MIG, Stick, TIG
• Low Duty Cycle
• Includes a Range of Accessories

Check Price On Amazon

Specifications

• Input Voltage: 120/240V
• Amperage Range: 10-200A
• Duty Cycle: 35% at 200A, 60% at 160A, 100% at 130A
• Wire Feed Speed Range: 50-500 IPM
• Weld Thickness Range: Up to 3/8 inch (MIG and TIG), up to 5/32 inch (Stick)
• Weight: 37 lbs

Pros

• Multi-process capabilities – can handle Flux Core, MIG, Stick, and TIG welding.
• Versatile and customizable settings allow for precise control and adjustment.
• Portable and lightweight design for ease of use and transport.
• Digital display for easy monitoring and adjustment of welding settings.
• Comes with a range of accessories, including a spool gun and TIG torch.

Cons

• I had issues with the wire feed mechanism that required regular cleaning and maintenance.
• The duty cycle may be insufficient for high-demand applications.
• The user interface may not be intuitive for beginners.

Suitable For

• Professional and hobbyist welders who require a versatile and reliable multi process welder
• Automotive, home repairs, and fabrication

Things I Like

I appreciate the Everlast PowerMIG 200’s multi-process capabilities, as it allows me to switch between welding types without having to switch machines. If you are only interested in flux core welding process, then this doesn’t apply to you.

I also appreciate the range of settings and customization options, allowing me to fine-tune my welding experience and achieve precise and consistent results.

Things I Don’t Like

One issue that concerns me as an experienced welder is the issues with the wire feed mechanism, which can affect the weld’s quality and consistency. I also note that the duty cycle may not be sufficient for high-demand applications, which could limit the machine’s usefulness in certain settings.

This machine is overkill if you only want to use flux core wire.

Verdict

Overall, the Everlast PowerMIG 200 Welding Machine is a versatile and reliable multi-process welder with various advanced features and settings. While it may have some limitations and drawbacks, it is a solid choice for professional welders and hobbyists requiring a versatile and portable welding machine.

5. Lincoln Electric EasyMIG 180 Welder

For a great welder that I personally use in my own workshop, check out the Lincoln EasyMIG 180. It has enough power with 180 amps to weld 95% of jobs that will ever come through your door. It does come with a higher price tag, but this is good value for money considering the build quality Lincoln Electric are famous for.

• Reputable Lincoln Electric Build Quality
• Spool Gun Ready for Aluminum
• Ideal for Auto Body Repair
• Simple Setup

Check Price On Amazon

Specifications

• Input Voltage: 230V
• Amperage Range: 30 to 180 Amps
• Duty Cycle: 30% at 130 Amps
• Wire Feed Speed: 50 to 500 IPM
• Can Weld: Mild Steel Up to 1/2 Inch Thick
• Weight: 66 Pounds

Pros

• The Lincoln Electric EasyMIG 180 Welder is user-friendly and easy to set up. It has a clear instruction manual that makes the setup process a breeze.
• Its high output power of 180A makes it suitable for a wide range of welding applications.
• The EasyMIG 180 has a spool gun ready design, which makes it ideal for welding aluminum.

Cons

• The wire feed mechanism can be a bit finicky and requires adjustments to work smoothly.
• I had some issues with the ground clamp, which are not as robust as I would like.
• The EasyMIG 180 is not a portable welder, and its weight can make it challenging to move around.

Suitable For

• DIY enthusiasts, hobbyists, and professional welders
• Auto body repair to farm maintenance

Things I Like

The setup process is straightforward, and the welder is easy to operate, even for beginners. The high output power of 180A makes it a versatile welder that can handle a wide range of welding applications. I also like the spool gun ready design, which makes it easy to weld aluminum.

Overall, the Lincoln Electric EasyMIG 180 Welder is a reliable and versatile tool I recommend to anyone looking for a MIG welder.

Things I Don’t Like

One issue I have with the EasyMIG 180 is the weight. At 66 lbs, it’s not the most portable welder, and moving it around can be a hassle. The wire feed mechanism can also be a bit finicky, and it may take some time to get it working smoothly. However, these are minor issues that don’t detract from the overall quality of the welder.

Verdict

The Lincoln Electric EasyMIG 180 Welder is a reliable and versatile MIG welder that’s easy to set up and use. It’s suitable for DIY enthusiasts, hobbyists, and professional welders who need a reliable tool for a wide range of welding applications. While it’s not the most portable welder, it’s a reliable and powerful tool built to last.

6. Miller Electric Millermatic 211

Miller are famous for building some of the best welding machines around. If I ended up with a Millermatic 211 in my workshop, I would be a happy welder. It is lightweight and portable, versatile with industrial voltage, and powerful with 230A max. This is a more expensive model, but is packed full of features.

• Powerful 230A Max Amperage
• Portable 38 Pound Design
• Clear Digital Display
• 40% Duty Cycle at 150A

Check Price On Amazon

Specifications

• Input Voltage: 120/240V
• Amperage Range: 30 to 230 Amps
• Duty Cycle: 40% at 150 Amps
• Can Weld: Up to 3/8 inch
• Wire Feed Speed: 60 to 600 IPM
• Weight: 38 pounds

Pros

• Can be used for both MIG and flux-cored welding, making it a versatile choice for welding different types of metals and thicknesses.
• User-friendly and easy to set up, making it a good option for beginners or hobbyists.
• The lightweight design of the Miller Electric Millermatic 211 makes it easy to transport to different job sites.
• The digital display on this welder provides clear information about the settings and makes it easy to adjust the parameters.

Cons

• On the expensive side compared to other MIG welders in its category.
• The duty cycle of this welder is limited to 40% at 150A, which means that it may not be suitable for continuous use in heavy-duty applications.
• A spool gun is not included with the welder and needs to be purchased separately, which can add to the overall cost.

Things I Like

From the point of view of an experienced welder, I appreciate the versatility of the Miller Electric Millermatic 211, which can handle both MIG and flux-cored welding. The digital display is a nice feature, providing accurate information about the settings and making it easy to fine-tune the parameters.

The lightweight design and portability of this welder are also appealing, allowing me to take it to different job sites as needed.

Things I Don’t Like

From the point of view of an experienced welder, I find the limited duty cycle of the Miller Electric Millermatic 211 to be a drawback, especially for heavy-duty applications. The price is also a concern, as it is on the expensive side compared to other MIG welders in its category.

Additionally, the fact that a spool gun needs to be purchased separately is inconvenient and adds to the overall cost.

Verdict

Overall, the Miller Electric Millermatic 211 is a high-quality MIG welder that is versatile, easy to use, and portable. While it is on the expensive side, the digital display and user-friendly design make it a good option for hobbyists and professionals alike.

The limited duty cycle and the need to purchase a spool gun separately may be drawbacks for some, but overall, this welder is a reliable and efficient choice for welding projects of various sizes and types.

7. ESAB Rebel EMP 215ic Welder

The ESAB Rebel EMP 215ic Welder is a versatile and powerful machine designed for both novice and experienced welders. It is a multi-process welder, meaning it can handle Flux Core, MIG, TIG, and Stick welding processes. The Rebel EMP 215ic is also lightweight, portable, and can be used for indoor and outdoor welding applications.

• MIG, Flux Core, Stick, and TIG Processes
• Intuitive Controls and Useful Manual
• 120 and 230V Input Voltage Supply
• Higher Price Tag

Check Price On Amazon

Specifications

• Input voltage: 120V/230V
• Amperage range: 5-240A
• Duty cycle: 40% at 240A, 100% at 110A
• Wire feed speed range: 50-500 IPM
• Weld thickness range: Up to 3/8 inch
• Weight: 40 pounds

Pros

• The Rebel EMP 215ic can handle MIG, TIG, and Stick welding processes, making it a versatile machine suitable for various welding tasks.
• Weighing only 40 pounds, the Rebel EMP 215ic is lightweight and easy to transport.
• The machine comes with a clear user manual and intuitive controls, making it easy to set up and use, even for beginners.
• The Rebel EMP 215ic produces high-quality welds with excellent penetration and arc stability.
• The machine can operate on 120V and 230V power sources, making it suitable for use in different settings.

Cons

• The Rebel EMP 215ic is a high-end machine and comes with a relatively high price tag compared to other welders in its class.

Suitable For

• Novice and experienced welders
• Outdoor welding applications

Things I Like

The machine’s ability to handle multiple welding processes and intuitive controls make it easy to quickly switch between different welding tasks. Additionally, the machine’s high-quality welds and excellent arc stability ensure that the end product is of the highest quality.

Things I Don’t Like

One downside of the Rebel EMP 215ic is its relatively high price tag, which may be a barrier for some welders. Additionally, the machine’s limited welding thickness and duty cycle may not be suitable for prolonged or heavy-duty welding tasks.

Verdict

The ESAB Rebel EMP 215ic Welder is an excellent machine with versatility, portability, and ease of use. While it may not be suitable for all welding tasks, it is an excellent choice for both novice and experienced welders who require a multi-process welder that can handle different welding tasks with ease.

Despite its relatively high price tag, the machine’s high-quality welds and user-friendly design make it an excellent investment for anyone serious about welding.

8. Lincoln Electric K2185-1 Handy MIG Welder

The Lincoln Electric K2185-1 Handy MIG Welder is a compact, portable machine ideal for small welding projects. It operates on 115V household current and has a maximum output of 88 amps.

Personally, I find the K2185-1 Handy MIG to be disappointing, considering how much it costs for such limited power. It does what it says on the tin, but nothing more. The main advantage of this machine is the Lincoln Electric brand painted on the side.

• Reputable Lincoln Electric Construction Quality
• Easy to Use for Beginners and DIYers
• Not Suitable for Industrial Scale Jobs
• Pricey Considering Its Low Power

Check Price On Amazon

Specifications

• Input voltage: 115V
• Amperage Range: 35-88 amps
• Duty cycle: 20% at 70 amps
• Wire feed speed range: 50-500 IPM
• Weld thickness range: Up to 1/8 inch
• Weight: 46 pounds

Pros

• Compact and portable
• Easy to use with simple, intuitive controls
• Suitable for light-duty welding tasks
• Made with Lincoln Electric’s high standards with excellent build quality

Cons

• Limited duty cycle
• Not suitable for heavy-duty welding projects
• Very expensive considering its small power

Suitable for

• Hobbyists and DIY enthusiasts
• Small welding projects
• Automotive repairs

Things I Like

I appreciate how easy it is to use the Lincoln Electric K2185-1 Handy MIG Welder. It’s lightweight and compact, which makes it easy to move around, and it produces high-quality welds on light-duty projects. The wire feed speed is also adjustable across a wide range, allowing me to customize the weld to my needs.

Things I Don’t Like

I find the duty cycle to be a bit limited for my needs. It’s unsuitable for heavy-duty welding tasks, and I need to be careful not to exceed the duty cycle. Additionally, I have to change the wire spool frequently, which can be a bit of a hassle.

I also don’t like the amperage control knob – rather than showing you the exact amperage you are selecting, it gives you a 1 to 10 scale. For someone who wants to dial in an exact power, this is frustrating.

Verdict

The Lincoln Electric K2185-1 Handy MIG Welder is an excellent choice for hobbyists and DIY enthusiasts needing a portable, easy-to-use welding machine. It’s ideal for small welding projects, such as automotive repairs, and produces high-quality welds.

However, it’s unsuitable for heavy-duty welding tasks, and the limited duty cycle may be a deal-breaker for some experienced welders. You will likely outgrow its limited power very quickly and need to upgrade unless your jobs will remain small scale.

Flux Core Welder Buying Guide

Welding machines are complex and require in-depth knowledge before making a selection. But there are a few key specifications you can narrow your search down to make your shortlist easier to review.

When buying a new welder, I have a concrete view of the max amps, input voltage, duty cycle, and wire size based on the work I intend to do with it.

Amperage Range

When choosing a flux core welder, you will notice that the more powerful the welding machine is, the more it costs. Therefore, you should pick a model that has sufficient power and no more.

The max amps are one of the most important considerations and will dictate the thickness of steel you can weld. This table will give you a rough idea of how much amperage you need based on your thickest jobs:

The amperage range also affects the quality of the weld. If the amperage is too low, the weld may be weak and ineffective, while if the amperage is too high, the weld may be overheated and prone to defects.

You may also want to review the minimum amperage – if you intend on welding very thin material, reducing your amperage is also important.

Input Voltage

Flux core welding machines can have different input voltages, affecting their suitability for various applications. The most common input voltages for flux core welders are:

• 120V – Flux core welders with a 120V input voltage are suitable for light-duty welding applications, such as household repairs, DIY projects, and small-scale welding projects. They are also ideal for use in areas with limited power supply.
• 240V – Flux core welders with a 240V input voltage are suitable for heavy-duty welding applications, such as industrial welding, construction, and fabrication. They are more powerful than 120V welders and can handle thicker materials and longer welding runs.
• Dual voltage – Some flux core welding machines have dual voltage capability, which means they can operate on both 120V and 240V power sources. Dual voltage welders are versatile and can be used in various applications, from light to heavy-duty welding.

It’s essential to choose a flux core welding machine with the appropriate input voltage for the type of welding you will be doing. If you are working on small-scale projects or DIY repairs, a 120V welder may be sufficient. However, if you will be welding thicker materials or working on industrial projects, a 240V or dual-voltage machine may be more appropriate.

PRO TIP: Don't buy a flux core welding machine that requires 240V if you don't have access to it in your workshop.

Wire Size

The most common flux core wire sizes for welding are 0.030 inch and 0.035 inch. However, other sizes are also available, including 0.025 inch and 0.045 inch.

The wire size of your flux core welder is an important consideration because it can affect the quality of the weld, the appearance of the finished product, and the overall welding experience.

When selecting a wire size for your flux core welder, consider the material being welded, the amperage range of your welder, and the specific requirements of your welding project.

Duty Cycle

Duty cycle indicates the amount of time a welder can operate without overheating. It is expressed as a percentage and refers to how long a welder can operate at a particular amperage before requiring a rest period.

For example, if a welder has a duty cycle of 60% at 200 amps, the welder can operate for 6 minutes out of a 10-minute cycle at 200 amps before requiring a rest period of 4 minutes to cool down.

A suitable duty cycle for a flux core welder depends on the specific welding application. Higher duty cycles are generally better for heavier-duty welding applications that require longer welding runs, while lower duty cycles may be sufficient for lighter-duty welding projects.

A typical duty cycle for a flux core welder is around 20% at maximum output. An important mistake to avoid is a low duty cycle at less than maximum amperage. For example, a 20% duty cycle at 90A on a 140A welding machine is a genuine concern, because the duty cycle at maximum amperage will be incredibly short.

Portability

Flux core welders are much more portable than MIG welding machines because you don’t need to transport a gas bottle. But, you shouldn’t ignore the weight and dimensions of your potential machine.

You may need to move your welder around your workshop or load it into your truck for dozens of reasons. Having a machine you can lift easily and transport with one person makes it significantly more useful.

It becomes a real pain when you need to upgrade to having a powerful welding machine in your workshop and a secondary smaller welder in your truck. The ability to do both with one machine is a real money saver.

Having said that, I also wouldn’t sacrifice power to save weight. Some of the smallest flux core welding machines have under 100 amps of power, which isn’t enough amperage for tasks I will likely encounter.

Conclusion

So many models are available on the market that it can be difficult to select the best flux core welder. Step one is to understand what you will be welding and how much amperage that requires. After this you can choose the best duty cycle, wire feed rate, and input voltage.

My recommendation is the Hobart Handler 140 MIG Welder. This is suitable for both beginners and experienced welders and is versatile enough and powerful enough to handle 90% of DIY welding jobs.

The post 8 Best Flux Core Welders for Beginners [2023 Ranked] appeared first on Beginner Welding Guide.

Flux-cored arc welding (FCAW) is a popular welding process widely used in constructing, fabricating, and repairing metal structures. One of the key components of this process is the flux core wire, which serves as the filler metal and shielding gas.

Using a flux core wire eliminates the need for a separate shielding gas, making it an ideal choice for outdoor and windy welding applications. However, with the wide range of flux core wires available on the market, choosing the right one for a specific welding job can be challenging.

In this article, I will provide an overview of the different types of flux core wires for MIG welding, their unique characteristics, and their typical applications. Whether a welding professional or a DIY enthusiast, this article will help you understand the options and choose a suitable flux core wire for your next welding project.

If you are looking to purchase a flux core welding machine, please read through our buying guide.

E70T-1C

E70T-1C is a low hydrogen, all-position flux core wire commonly used for welding pressure vessels, pipelines, and storage tanks. This wire provides excellent arc stability and weldability, minimizing the risk of hydrogen-induced cracking.

• Non-alloyed and fine grain steels
• .035" .045" on 10 lb / 33 lb Spool
• Stable and consistent with CO2 and mixed gas
• Easy Slag removal

Check Latest Price at Amazon

E70T-5

E70T-5 is a high-strength, low hydrogen flux core wire specifically designed for heavy fabrication, shipbuilding, and offshore structures. Its low hydrogen content makes it suitable for highly demanding applications, ensuring the weld’s integrity and durability.

E70T-1

E70T-1 is another low hydrogen, all-position flux core wire that shares similar applications with E70T-1C, including pressure vessels, pipelines, and storage tanks. This wire ensures excellent weldability and minimal hydrogen content to prevent hydrogen-related issues.

E70T-9

E70T-9 offers a high deposition rate and self-shielding capabilities, making it ideal for pipe welding, heavy fabrication, and shipbuilding. This wire provides excellent weld penetration and deposition efficiency, enabling faster completion of tasks.

E70C-6M

E70C-6M is a high-strength, low-spatter flux core wire for heavy fabrication, offshore structures, pipelines, and shipbuilding. This wire offers exceptional weld quality and minimal spatter, ensuring a clean and efficient welding process.

E71T-1

E71T-1 is a low hydrogen, all-position wire for welding pressure vessels, pipelines, and storage tanks. Like other low hydrogen wires, it minimizes the risk of hydrogen-induced cracking, providing reliable and long-lasting welds.

• .045" on 10 lb Spool
• All Positions
• Low Hydrogen

Check Latest Price at Amazon

E71T-11

E71T-11 is a self-shielding, all-position wire suitable for structural steel, sheet metal, agricultural equipment, and pipes. Its self-shielding properties eliminate the need for external shielding gas, allowing for easy use in various applications.

• .035" on 10 lb Spool
• Great for T-joints, butt welds & lap welds
• Low Spatter

Check Latest Price at Amazon

E71T-GS

E71T-GS is a self-shielding, all-position wire designed for light fabrication, home repair, and maintenance. This wire provides a user-friendly welding experience, making it perfect for DIY enthusiasts and professionals.

• .035" on 10 lb Spool
• Based in South Florida
• All Position Arc Welding

Check Latest Price at Amazon

E71T-1C

E71T-1C, like E70T-1C, is a low hydrogen, all-position wire suitable for pressure vessels, pipelines, and storage tanks. It ensures excellent weldability and reduces the risk of hydrogen-induced cracking, making it an ideal choice for critical applications.

E71T-12

E71T-12 is a self-shielding, all-position wire for welding structural steel, sheet metal, and pipes. Its self-shielding properties make it a versatile and convenient option for various applications, especially in areas where shielding gas is not easily accessible.

E71T-9C

E71T-9C is a self-shielding, all-position wire designed for welding steel plates, pipes, and metal structures. Its self-shielding characteristics provide flexibility and convenience, allowing for efficient welding in various environments.

E71T-7M

E71T-7M is a self-shielding, all-position wire ideal for light fabrication, home repair, and maintenance. It offers a user-friendly welding experience and is perfect for DIY enthusiasts and professional welders.

E71T-5C

E71T-5C is a self-shielding, all-position wire suitable for light fabrication, maintenance, and repair. Its self-shielding capabilities make it a convenient and versatile option for various welding applications.

E71T-8

E71T-8 is a self-shielding, all-position wire for heavy fabrication, shipbuilding, and offshore structures. Its self-shielding properties allow for efficient and reliable welding in demanding environments without external shielding gas.

E71T-9M

E71T-9M is a self-shielding, all-position wire for welding steel plates, pipes, and metal structures. It offers excellent weld quality and self-shielding capabilities, making it a convenient option for various applications.

E71T-1M

E71T-1M is a low hydrogen, all-position wire suitable for pressure vessels, pipelines, and storage tanks. Its low hydrogen content ensures excellent weldability and reduced risk of hydrogen-induced cracking, making it an ideal choice for critical applications where weld integrity is crucial.

E70S-3

E70S-3 is a high-strength, low hydrogen flux core wire for heavy fabrication, shipbuilding, and offshore structures. Its low hydrogen content helps maintain the weld’s durability and integrity in demanding environments, ensuring long-lasting performance.

• .035" or .045" on 44 lb Spool
• General Fabrication Carbon Steel Welding Wire

Check Latest Price at Amazon

E70S-6

E70S-6 is a high-strength, low-spatter flux core wire suitable for heavy fabrication, offshore structures, pipelines, and shipbuilding. This wire offers exceptional weld quality and minimal spatter, resulting in a clean and efficient welding process that meets the needs of various industries.

• .030" on 1 lb Spool
• High Quality general purpose mild steel MiG wire

Check Latest Price at Amazon

Types of Flux Core Wire

Flux core wire is an essential component in the MIG welding process and comes in various types to meet different welding requirements.

The most common types of flux core wire used in MIG welding are E71T-1C, E70T-5, E71T-11, E71T-GS, E70T-1, and E70T-9. 

It is important to choose the right type of flux core wire based on the specific requirements and conditions of the welding project and to consult a welding professional or the manufacturer’s specifications before deciding.

Gas Shielded

Gas-Shielded Flux-Cored Wire: Gas-shielded flux-cored wire requires an external shielding gas, typically CO2 or Argon, to protect the weld from atmospheric contamination. The shielding gas is supplied to the weld area through a separate hose connected to a gas bottle.

Gas-shielded flux-cored wire is typically used for high-quality, critical welding applications and produces minimal spatter.

Self Shielded

Self-Shielded Flux-Cored Wire: Self-shielded flux-cored wire does not require an external shielding gas. Instead, the flux in the wire generates its own protective gas as it burns, shielding the weld from atmospheric contamination.

Self-shielded flux-cored wire is ideal for outdoor and windy welding conditions and is often used for production welding and welding on dirty or rusty surfaces.

Dual Shielded

Dual-Shielded Flux-Cored Wire: Dual-shielded flux-cored wire combines the benefits of both gas-shielded and self-shielded flux-cored wire. It requires an external shielding gas for added protection but also contains a self-shielding flux for use in outdoor and windy welding conditions.

Dual-shielded flux-cored wire is often used in welding applications that require both high-quality and efficiency.

Selecting the Right Wire and Gas

The right size of flux-cored wire to use depends on several factors, including the following:

Material Thickness

The thickness of the material being welded will affect the wire size needed. Thicker materials will require a larger wire size, while thinner materials will require a smaller size.

The most common sizes and their respective mild steel thickness are:

Welding Current

The welding current will also affect the wire size needed. Higher welding currents typically require a larger wire size, while lower ones require a smaller one.

Welding Position

The position where the welding takes place will also affect the wire size needed. Out-of-position welding may require a larger wire size to prevent sagging, while welding in a flat position may require a smaller one.

Welding Speed

The welding speed must also be considered when selecting the wire size. Faster welding speeds typically require a larger wire size to prevent overheating, while slower welding speeds may require a smaller one.

Conclusion

In conclusion, flux core wire is an essential component in welding and plays a crucial role in ensuring the quality of the final weld. The different types of flux core wire, such as gas-shielded, self-shielded, and dual-shielded, offer varying advantages depending on the application and welding conditions. Choosing the right type of flux core wire is important to ensure the best results and minimize potential problems.

Whether for welding on-site, in a fabrication shop, or heavy industry, a flux core wire can meet the requirements and ensure a successful welding outcome. Understanding the different types of flux core wire and their applications will help you make the best decision for your welding needs.

The post 18 Types of Flux Core Wire: Ultimate Guide appeared first on Beginner Welding Guide.

Using flux core welders on stainless steel can produce decent results if you choose the right wire and master the dragging technique.

How Can You Weld Stainless Steel With Flux Core?

Flux-cored arc welding (FCAW) relies on feeding consumable wires with the filler material, just like MIG. The main difference is the shielding mode.

The most common FCAW wire type is the shelf-shielded one. This wire is more than just a filler since it has a deoxidizer core that melts to release a shielding cloud. The cloud is what will protect the molten metal from reacting with the air.

It’s also possible to use double-shielded wires that protect the weld with both the core cloud and external gas.

Both flux core welding methods work just fine on stainless steel as long as the external layer on the wire you’re using is compatible with the piece’s SS grade.

The exact process and required equipment will differ based on the piece you’re working with, but here’s a general guide:

1. Clean up your stainless steel surface (optional for a sleeker finish).
2. Place the flux-cored wire in the nozzle.
3. Check what gas composition you need (for gas-shielded wires only).
4. Adjust the welder’s polarity to meet the wire’s recommendations.
5. Strike and pull while welding.
6. Clean up the slag with a chipping hammer or a steel brush.

Advantages of Welding Stainless Steel With Flux Core

There are a few things to love about FCAW for stainless steel.

Here’s where I think the method shines the most:

Good for Outdoor Welding Jobs

You can choose a flux core if you need to work outdoors often. The setup will be highly portable since you won’t have to carry a gas cylinder.

This also means that the FCAW method can work despite the wind that could blow away shielding gas. That’s why it can be a good fit for farm welders who need to weld stainless steel outside.

If you decide to work indoors, make sure you have adequate ventilation. The fumes from stainless steel flux-cored wires can be toxic.

Cuts Down the Costs

Using the FCAW method can help you save money if you only tackle welding jobs occasionally. That’s because you won’t need to invest in gas equipment, unlike with MIG or GMAW.

Just keep in mind that this applies only to self-shielded wires, not gas-shielded ones.

Suitable for Beginners

Welding stainless steel with a flux core can be easier than TIG. The high deposition rate also makes it good for thicker stainless steel pieces.

The learning curve shouldn’t be too hard to grasp after some practice. The key is finding the right settings.

I’d recommend getting scrap pieces of stainless steel and testing different settings before getting to the main project.

Disadvantages of Welding Stainless Steel With Flux Core

FCAW on stainless steel has its appeal, but there are still drawbacks to consider.

Requires Slag Removal

Flux cores usually leave a lot of spattering and bulky slag behind. That’s why it’s crucial to tackle the piece with a chipping hammer when you’re done welding. Brush bristles will do the trick for smaller splatters.

The catch is that you don’t want to overdo the clean-ups. Stainless steel shows scratch easily.

Keep in mind that you’ll be producing even more slag if you do a lot of passes. Thicker wires can leave more slag, too.

You could opt for TIG or MIG  if you don’t want to deal with slag on your stainless steel.

Good Wires Are Hard to Come By

You need to match the wire’s composition to the grade of stainless steel that you’re working with. You also have to consider the wire thickness.

One downside is that you won’t always be able to find suitable stainless steel wires. The available options are usually more expensive than regular wires, too.

Some people might use mild steel flux-cored wires. It might work as a temporary fix, but I wouldn’t recommend it as a go-to option. Stainless steel welds with non-compatible cores can rust quickly. Any splatter around the welded area will also be prone to rust.

Remember that the main appeal behind stainless steel is its shiny appearance and corrosion resistance. Using the wrong flux wire can compromise all that.

Equipment Required to Weld Stainless Steel With Flux Core

Here’s the basic equipment you’ll need to weld stainless steel with the flux core method:

• FCAW welder
• A Spool of flux-cored wire (to match your SS grade)
• Gas shielder (for double-shielded wires only)
• PPE (leather apron, welding goggles, helmet, boots, and gloves)
• Chipping hammer or a steel brush

The common flux-cored SS wire grades are 308 and 309. You can pick up a spool of 316 if you’re working on surfaces that come in contact with food.

You might have to opt for gas-shielded wires if you need to work in vertical positions, though.

3 Stainless Steel Welding Tips

Let’s move on to three simple tips to keep in mind when you’re using flux core welds on stainless steel.

Always Drag With FCAW

Welding methods that produce slag require dragging. This means pulling the wire instead of pushing it. You can start with a drag angle of 10 degrees and see how it goes for your welds.

Check Your Settings

You’ll need to play around with the FCAW settings and find something that matches your skill level. This ensures the best results for your stainless steel welds.

You also need to check the welding parameters recommended by the manufacturer, including:

• Wire speed (high speeds can be hard to control, and low speeds increase splatter)
• Polarity
• Amperage

Prioritize Safety

Some welders could get distracted by the splattering caused by the flux core.

Don’t worry too much about the slag and splattering since you’ll clean them up later. Just make sure you’re prioritizing your safety by watching where your beads are going.

Just like any other welding technique, you still need to stick to the recommended protective gear with FCAW.

Conclusion

Self-shielding FCAW is a portable option for welding stainless steel. It’s great for outdoor jobs since it eliminates the need for gas cylinders. The main downside is that you have to pick compatible wires if you want to avoid quick rusting.

Other welding options, like TIG, might be a better fit if you weld stainless steel indoors only.

The post Can You Weld Stainless Steel With Flux Core? appeared first on Beginner Welding Guide.

If you’re used to the Gas Metal Arc Welding (GMAW/MIG) technique, you must be familiar with it using a wire instead of an electrode. 

Traditional MIG welding requires an inert gas (the “I” in MIG) to shield the base metal from atmospheric gases. This improves the weld quality and makes the metal pool less porous and brittle.

But what if you’re welding in windy weather that can disperse the compressed gas? Well, the answer is Flux Core welding wire.

What Is Flux Core Welding Wire?

MIG welding wire is made of solid metal alloy shielded externally by a compressed gas tank. The gas shoots out from the MIG gun and prevents the weld pool from combining with oxygen, nitrogen, or water vapor.

These atmospheric gases oxidise the weld pool, causing inclusions of gas particles that make the weld brittle and unusable. That’s why using a shielding gas or a flux material is crucial to the final result of the weld.

Flux core wire is made of similar alloys to the solid wire. The only difference is that it has a core of flux chemicals that, when heated, vaporize creating a cloud of shielding gas and a slag layer that protects the weld.

You can use flux core wire for the same applications as solid core MIG wire. It provides similar performance and allows for comparable results to the solid core wire.

Different Types of Flux Core Welding Wire Types

Flux core welding wires come in two types:

1. Self-shielded
2. Gas-shielded

Self-shielded Flux Core Wires (FCAW-S)

Self-shielded welding wires are called that because they have a core of flux material that vaporizes when the arc initiates and the heat increases. This helps the wire create its own cloud of shielding gas to protect the welding site from atmospheric gases. 

They’re meant to be used as a standalone alternative to solid core MIG wire with no gas cylinder. This makes sense in windy conditions, where the compressed gas won’t linger for long enough around the welding site to do its job.

That gives self-shielded wires a great advantage, since they require much less equipment to haul around than gas-shielded wires. 

Also, there are time savings when you use self-shielded wire. That’s because the continuous wire doesn’t require downtimes for electrode changes like you do when the electrode is spent in stick welding. This ends up being more convenient, especially in larger-scale jobs.

There are a few downsides to self-shielded flux core wires, though. The first is the increased amount of smoke and sputter resulting from using this type of wire. This makes the welding process arduous because of low visibility. It also makes the cleanup more time-consuming.

Self-shielded flux core wires are available in 0.035, 0.045, 0.052, 1/16, 5/64, 3/32, and 7/64 inch diameters, which is the industry standard.

Gas-shielded Flux Core Wires (FCAW-G)

Gas-shielded flux core wires are exactly what they sound like. They’re MIG wires that utilize the effect of pressurized gas cylinders, as well as a flux core, to shield the weld pool. 

They have an advantage over solid core welding wires because they are easier to manipulate. However, they truly shine when compared to their self-shielded counterparts.

Self-shielded flux core wires require a higher percentage of flux material inside the core to form their own gas shield. This causes the deposition rate of the wire to be around 65%. 

Compare that to gas-shielded flux core wires, which deposit with a 75–85% efficiency, and you can clearly see the winner.

That’s still lower than solid core wire efficiency, which should be around 100%. But with the ease of use and more aesthetic results, it ends up being up to the operator’s preferences.

The major downside here is cost, since gas-shielded flux core wires are more expensive than solid core, and also require the added cost of a gas cylinder. They’re less expensive than self-shielded flux core wires, but those don’t have any additional costs to worry about.

That said, gas-shielded flux core wire is a pretty popular choice in workshop settings, since it doesn’t require any physical barriers like it would in the windy outdoors.

Just like the self-shielded variety, gas-shielded wires come in 0.035, 0.045, 0.052, 1/16, 5/64, 3/32, and 7/64 inch diameters.

How to Read Welding Wire Numbers

The American Welding Society (AWS) has a code for all types of electrodes used for welding. Whether you’re using a solid core welding wire (code A5.18), or a flux core wire (code A5. 20), you can find out how to read the wire number to know more about its specifications below.

Solid Core Welding Wire (AWS A5. 18)

Let’s take this example of a solid core wire: ER70S-3 H4

• ER – The E stands for electrode and the R stands for rod. That’s because solid welding wires can be used as welding rods with a TIG gun when cut to standard lengths.
• 70 – These two or three digits denote the tensile strength of the wire metal measured in KSI (Kilopounds per square inch).
• S – Stands for Solid Core, optional in the naming
• 3 – This number denotes whether the alloy was treated with metal deoxidizers or any other chemical additives that affect the polarity of the wire. Number 3 is relatively additive-free.
• H4 – This stands for diffusible hydrogen requirements. H4 wires can take less than 4 ml/100gm.

Common Solid Core Wire Numbers:

• ER70S-6: mild steel wire with deoxidizers
• ER5056: aluminum wire with high ductility
• ER5356: aluminum wire with high tensile strength
• ER308–L: stainless steel wire, the L stands for low carbon

Flux Core Welding Wire (AWS A5. 20)

Let’s examine this code of a gas-shielded flux core welding wire: E70T-1C H8

• E – Stands for electrode, no R this time around because flux core wires aren’t used for TIG welding.
• 7 – Tensile strength in 10 KSI or PSI x 10,000
• 0 – This number denotes the positions of the weld. A zero means for flat and horizontal welding only, a number one is good for all positions
• T – Stands for Tubular wire
• 1 – Denotes performance capabilities of the wire in terms of additives. The numbers go from 1–14, with 1 being the most acidic slag system and 14 the most basic slag system.
• C – Stands for the use of CO₂ shielding gas only. An M  in its place would stand for a mixture of argon and CO₂
• H8 – Diffusible hydrogen requirements of less than 8 ml/100g.

Common Flux Core Wire Numbers:

• E71T-H8: self-shielded wire. This is the AWS code for Lincoln Electric’s NR-232 wire.
• E71T-9C/M
• E70T-3
• E71T-12C/M

How to Pick the Correct Welding Wire Type

You should have an idea about the specifications of the welding wire you choose depending on your project. Physical factors of the wire affect the weld quality, strength, and longevity, almost as much as the welding technique.

Here are a few things to consider when choosing the correct wire type for your project:

Appearance

This one mostly depends on the thickness of the base metal you’re using. Thinner metal sheets usually require more precise welds with less slag to clean off before painting. That’s why solid core welding wire is better for these applications than flux core.

Working Location

Using solid core wires for MIG welding requires relatively sheltered working conditions, like the inside of a workshop. That’s because wind can cause rapid dispersal of the inert gas shield, causing the weld to become porous and unusable.

Self-shielded flux core wire is the direct answer to this problem, since it doesn’t need a compressed gas cylinder to do its job.

Wire Gauge

You should use thicker-gauge wires with thick metal sheets. This one should be a no-brainer, but some welders believe using a one size fits all approach to different projects is okay. 

While it can work for some projects, you should be attuned to the requirements and look for the best final results. That’s true even if you should learn how to work with some new material or technique for each new project.

Final Thoughts

Learning about flux core welding wire types and applications can help you find what you need for your next welding project. This is especially important if you do a lot of outdoor welding work that requires being in windy conditions, where a regular MIG setup wouldn’t work.

Flux core wire is either self-shielded or gas-shielded. The former type doesn’t need any compressed gas to protect the weld pool as it produces its own. This makes it perfect for locations where carrying a gas cylinder would be difficult.

As for gas-shielded wire, it requires the help of either compressed CO₂ or a mix of the inert gas argon and CO_2. That means it’s closer to solid core wire than self-shielded. That said, this type is easier to manipulate than solid core and is known to produce better results.

The post Self-Shielded vs Gas-Shielded Flux Core Welding Wire appeared first on Beginner Welding Guide.

If you want to find out more about flux core welding, its types, and how it works in addition to its advantages and disadvantages, keep on reading this guide.

What Is Flux Core Welding?

Flux Core Arc Welding, also known as (FCAW), is a welding process involving an electric arc between the workpiece and a wire electrode.

In principle, this process is very similar to Metal Inert Gas (MIG) welding, in which a continuous consumable electrode is fed through the welding gun and a high voltage electric arc melts it during the welding.

The main difference here is that, unlike MIG welding, where the shielding process is carried out by an inert gas that is fed through the gun, this process depends on the flux contained within the tubular electrode.

As the high voltage arc passes through the electrode, the flux core also melts, creating a shielding cloud that prevents atmospheric gasses from reacting with the molten weld. 

However, different types of flux have various degrees of shielding, depending on the type of Flux core welding. 

Since the flux core contributes to the shielding process, flux core arc welding is also called “dual shield welding”.

The extra shielding properties of the flux core make it a highly portable and convenient welding technique in outdoor and windy conditions.

How the Welding Process Works

In flux core welding, the welding machine produces a high voltage electric arc that travels through the electrode. 

This arc generates enough heat to melt the electrode and the flux material over the base metal to create the weld pool and fuse it to the joint area.

Since the electrode is consumable, the machine provides a continuous feed of the flux-filled wire using knurled rollers, which makes it a major improvement on standard stick welding or manual metal arc welding (MMA).

Similar to MIG welding, this type of welding relies on shielding gasses for protection against atmospheric gasses, particularly oxygen and nitrogen that can oxidize and weaken the weld.

However, in some types of flux core welding, the shielding is created by the melted flux itself by forming a layer of slag as well as protective gasses that provides enough protection to the weld.

Types of Flux Core Welding

The process of flux core welding can take two different routes, depending on the method by which the weld pool is shielded from the atmosphere. As a result, we now have two different types of flux core welding, so here’s a quick look at each one of them:

Self Shielded Flux Core

This one is known as FCAW-S. In this type, the electrode’s flux agent is designed to melt and create a protective cloud that completely protects the weld pool from reacting with atmospheric gasses like oxygen and nitrogen.

This eliminates the need for using gas shielding equipment, which is not only large and inconvenient to move around, but also adds to the overall costs.

As a result, self shielded flux core welding is remarkably convenient for welding just about anywhere due to its portability. 

In addition to its convenience, since this method doesn’t rely on gasses for shielding, it’s quite practical for welding in particularly windy areas, such as open sites.

Gas Shielded Flux Core

In gas shielded flux core welding, the flux within the wire still creates a protective cloud that shields the molten metals like self shielded flux core welding.

However, its shielding capabilities are secondary and may not be enough for full protection, so high pressure shielding gasses are the primary method of shielding.

This one is known as FCAW-G, and in this type, the flux agent is mainly there to deoxidize the weld pool while high pressure gas is mainly responsible for shielding the weld.

Although this one may not be as reliable as self shielded flux core welding, the gas shielded counterpart is better suited for thicker welds that require advanced shielding because it’s relatively faster and more penetrating power.

It’s also a better option for supporting the weld while working in awkward positions, such as vertically up or overhead.

How to Flux Core Weld

Now that you know more about the principle of flux core welding, here’s a simple guide that shows you how to do it:

1. Gather Your Equipment and Put On Your Safety Gear

Flux core welding involves high voltage and flashing electric arc, so make sure that you prepare all the necessary tools and safety equipment before you start. This includes:

• The flux welder machine
• Flux core wire
• Welding gloves
• Welding mask
• Safety goggles
• Wire brush
• Slag chipping hammer
• Cleaning rag for the surface

2. Prepare the Working Surface

Flux core welding can work through rust and dust. However, cleaning your surface gives you more consistent welds and cleaner results. 

Wipe the surface with a dry cloth and/or wire brush, and make sure that the clamping areas are also clean before connecting the ground clamp to the workpiece.

3. Load the Proper Flux Wire in the Feed

There are different flux wire thicknesses out there. A good all-around choice here would be .030 inch diameter wires. Larger wires like .0350 inch will leave more slag on the weld, so only use them for thicker welds.

4. Set the Machine to the Right Settings

Refer to the welding machine’s manual in order to find out more about the right settings for your welding machine. 

This includes adjusting the machine’s amperage, voltage, and wire feed speed that is suitable for the project and your skills.

5. Pull the Trigger to Start Welding

Press the trigger to start the feeding process until the flux wire pokes out of the welding gun (about 1/2 to 3/4 inches is enough).

Tap the flux wire to the workpiece where you want to weld in order to strike the arc. Use the “strike and pull” technique as you continue to move through the joint area. 

Keep pressing the trigger to release more wire for welding. If you’re a beginner, maintaining proper drag angle and pace might take some trial and error, but you’ll eventually get the hang of it.

6. Remove the Slag 

After you’re done, turn off the welding machine and inspect the weld, then use the chipping hammer to remove the layer of slag left by the flux wire. You can also use a wire brush for a cleaner finish and remove tiny slag leftovers.

Equipment Required

Whether it’s a gas shielded or self shielded system, most flux core arc welders will include the following equipment:

• The welding gun with flux releasing trigger
• The power supply unit
• The flux core welding wires
• Wire feeder unit
• Controls that are responsible for voltage, polarity, wire feeding speed

In advanced flux core welders with advanced features, additional items like motion sensors and seam followers might also be included within the main unit.

In addition to the previously mentioned equipment, the gas shielded welders will also include the gas shielding system itself.

Advantages of Flux Core Welding

Flux core welding comes with many benefits that make them suitable for elaborate weld projects. In this section, I’ll walk you through some of them:

Easy to learn

Compared to TIG and stick welding, flux core welding is quite easy, as you can grasp flux core welding in a short time, especially if you have previous experience in MIG welding.

Suitable for Outdoor Applications

Flux core welding, especially the self shielded type, creates reliable protection against wind drafts and powerful air currents, which makes it suitable for welding in open areas, such as construction sites and farms.

Highly Portable

Since self shielding flux core welders don’t require additional gas shielding systems, they’re easily moved around in the form of a single unit.

Versatile and Convenient

You can easily choose between self shield and gas shielded wire depending on the project you’re working on, which allows you to work on a wider variety of conditions without making drastic changes to your setup.

Flux core welding also gives you the ability to work at various angles and in awkward positions, even with rusty metals.

Provide Thicker Welds

Flux cored wire, especially gas shielded type, has a high penetration power and creates a larger weld pool with a relatively large deposition rate, so it can work on thick metals that solid core welders can’t.

Cost Effective

Flux core wire isn’t necessarily cheap, but it gives you more versatility and penetrating power while saving the added costs of gas shielding (while using self shielded wire), so it can end up saving you money in the longer run.

Disadvantages of Flux Core Welding

Despite all its merits, flux core welding is not perfect, so here’s a quick look at some of the disadvantages of using this technique:

Expensive Electrodes

The special design of the flux core wire makes it a bit more expensive than regular solid core wires used in other types.

It produces more Spatter

Another major drawback of flux core welding is that its welding beads are bulky and unappealing due to high penetration power. The flux core also leaves a layer of slag that you need to clean away after welding. I have written a guide to reduce spatter that you may find interesting.

Not Suitable for Thin Workpieces

While the high penetration power is great for thicker metals, you’re better off using solid wires while welding thin metals (anything smaller than 3/16 inches thick)

When to Use Flux Core Welding?

Flux core is not always the optimal choice for welding, but there are some applications where it displays relatively better results than other types of welding. These conditions include:

• You do most of your work in open areas with plenty of wind (self shielding)
• You do your welds on-site where portability is essential for you (self shielding)
• You typically work on unclean or rusty workpieces 
• You typically work on thick metals (gas shielding) 
• You don’t mind after-weld cleanup and finishing

Power Source in Flux Core Welding

When it comes to Flux Core welding, most power supplies are either single phase or three phases with a frequency of around 50 to 60 Hz, and provide a power source of 230 or 460 volts and 200 or 575 volts to a lesser extent.

Ideally, all flux core welders use battery-like direct current to operate but can operate at different polarities. 

The operation methods depend on the type of flux core welder and work as follows:

• Self Shielded Flux Core: The wire is usually the negative pole while the workpiece is usually positive. This is called “Straight Polarity” or “DCEN”
• Gas Shielded Flux Core: The wire is usually the positive pole while the workpiece is usually negative. This is called “Reverse Polarity” or “DCEP”

Different manufacturers may have different polarity systems, so make sure that you check the operating manual before setting the polarity of your system.

Shielding Gasses in Flux Core Welding

Carbon dioxide is the most popular gas used in shielding flux core welding, available in cylinders or bulk form. 

Argon is also used in combination with carbon dioxide for improved shielding, with 75% Ar and 25% CO2 being the most common blend, especially for thick and challenging welds.

Electrodes in Flux Core Welding

The most common electrode wires used in flux core welding are steel wires with carbon inner flux. 

As the arc passes through the wire, the steel melts and the carbon oxidizes into carbon dioxide to shield the metal from reacting with atmospheric gasses. 

Stainless steel electrodes are also used because they break down into steel and carbon. They’re more resistant to corrosion but they’re more expensive than regular carbon flux steel wires.

Final Thoughts

To sum up, flux core welding is an arc welding process that relies on a consumable tubular electrode with an inner flux material designed to either fully shield the weld pool or provide extra shielding to support the CO2 gas.

The process is similar to MIG welding, but the flux core’s additional shielding greatly saves the costs of shielding gasses and provides a remarkably high deposition rate. However, the process creates more smoke and spatter chances than other types.

The post What Is Flux Core Welding for Beginners appeared first on Beginner Welding Guide.

Wire thickness is important and can affect overall weld quality. Mechanical properties like tensile strength and elongation can be dictated by wire diameter. I am asked quite often about the differences between .035 and .030 wire, as well as if there is a definitive answer as to which size is better.

The answer is not always straightforward, as it depends on the specific project at hand. In this post, you will learn everything you need to know about choosing between .030 and .035 flux core wire size.

What is Flux Core Wire?

Flux core wire is a self-shielding welding wire that uses an external flux to create a shielding gas around the arc. The flux core wire produces a high-quality weld without external shielding gas like carbon dioxide (CO2) or argon.

The flux in the wire is designed to protect the molten metal from exposure to oxygen and nitrogen, which will create porosity and inclusions in the weld.

This way, welding with such wire is more economical, less time-consuming, and more environmentally friendly compared to using a more expensive CO2 or argon mix.

Where is the flux-cored wire used?

The main application for flux-cored wire is in construction, farm repairs, automotive manufacturing, and structural steel erection. It’s also used in pipelines and general fabrication.

Why use Flux core wire instead of MIG filler wire?

MIG welding is a process that uses gas to protect the weld from atmospheric contamination. The process is more expensive than flux-cored wire and time-consuming too. In addition, flux-cored welding can be done outdoor, even in a strong wind, while MIG welding cannot.

TIP: If your metals are slightly rusted, you will have more chance of creating a better weld with flux core wire than MIG.

Disadvantages of using Flux Core Wire instead of MIG filler Wire?

When welding with Flux Core Wire, there will be a lot of spatter present. In addition, flux-cored wire produces more fumes and toxic gasses than MIG welding.

When you analyze weld look, Flux-cored is just not as pretty as MIG welds. In most cases, you will need to help yourself with an angle grinder to remove all the spatter made during the welding process.

Difference between 0.030 and 0.035 flux core wire size

.030 and .035 flux core wires are two common thicknesses and this post is all about explaining them more in detail. We will start with the most important differences.

Amps Needed

To maintain a consistent and proper welding arc, the wire thickness has to be proportional to the amount of electricity. Selecting the correct amperage is crucial to achieving a quality weld.

Thick .035 wire needs higher amps than .030 wire in order to maintain the same arc. So, if you’re using a machine with lower amps, you’ll need to go for the .030 wire size.

Porosity and Inclusions

The .035 flux core wire generally produces less porosity and inclusions so If you’re welding on rusty metal, it will be more suitable from the start.

Ease of Use

The .030 Flux core wire is easier to use when welding on thinner metals or when you are still learning how to weld. It is mainly because .035 thickness requires higher amperage.

Deposition Rate

The deposition rate is how fast the weld puddle is deposited. A higher deposition rate means more weld metal is deposited in a given time period.

In practice, it will mean that when you use .030 wire, you will need to work slower than using .035 to achieve the same weld deposition.

Tensile Strength and Elongation

Tensile strength is the maximum amount of stress a material can withstand before breaking. On the other hand, Elongation is the measure of how much a material will stretch before breaking.

The .030 wire has a lower tensile strength and elongation than .035 so may not be able to handle as much stress, leading to a weaker weld.

Price

The price of flux core wire can vary depending on the manufacturer and the quantity you purchase. However, in general, .030 wire is cheaper than .035.

Which Flux Core Wire To Choose?

Your choice will largely depend on the type of welding you will be doing.

Amps in your welder

The higher the amps available in your welder, the thicker the wire you can use. If you need to set your welder to max power when using 035. Flux Core wire, it will take you more time to finish your project. In addition, you will need to weld in Short bursts.

TIP: If you haven't bought a welding machine yet, search for one capable of higher amps.

Material being welded

Metals that have a thinner material thickness of around 1/8 inches or less are good for .030 wire. Anything above and up to 1/2 inches you might want to go with the .035. because it will have better penetration and less chance of warping the metal.

NOTE: Experienced welders have a high chance of success with 035. Flux Core wire is even with slightly thicker metals but a learning curve is needed.

Your skill level

As a beginner welder, you might find it easier to use 030. flux core wire because the lower amperage is less likely to cause problems.

Size of wires in your spool

The last thing you need to consider is the size of the wire in your spool. If you’re using .030, the flux core wire will be coiled around a smaller spool than if you’re using .035.

NOTE: If you are using a welder with a smaller wire feed capacity, you might have trouble feeding the thicker 035 wire through the machine. In this case, you will have to choose 030 flux core wire instead.

Related Questions

Read Next

• MIG welding – Gas or Flux Core?
• Difference between Spot and MIG Welding
• What gas to use for MIG welding?
• MIG Welding tips for Beginners
• MIG vs TIG Welding

The post How To Choose Between 0.030 and 0.035 Flux Core Wire? appeared first on Beginner Welding Guide.

Welding – Joining two metals together by melting the base metals while adding filler materials, can be both rewarding and fun.

Most Welders make a good living since welding is utilized in a lot of different applications in today’s world.

With advancement in welding technology, welding can now be carried out in any environment including underwater.

Understanding the basics is significant. Once you understand the basics of how two metals are joined together in one arc welding process, learning the other methods will be easier.

Most importantly one needs to know the three basic types of welding before learning other things such as technique and machine settings.

Even welders experienced in one method will often need some training when it comes to welding using methods they are not experienced in.

One such area of confusion is often whether one should push or pull the arc when wire welding.

A simple answer to this question is whenever the welding process produces slag, always pull the arc. And since flux core welding produces slag the arc should be pulled along as opposed to being pushed.

It should be noted that the pulling technique is also called dragging.

The Different Types of Welding

While typically not explained in these terms, the different methods either produce slag or they don’t.

The Production of slag depends on how the gas is produced that protects the molten weld puddle from the atmosphere.

A lesser know fact about welding is that gases in the air we breath are not good for the weld’s overall strength and should be shielded from the molten puddle.

Most people are familiar with electrode welding. That is welding using the metal rods that are about a foot in length and covered with a hard substance called flux. This is also known as stick welding.

It is the easiest and cheapest form of welding.

When melted, the flux on the outside of an electrode produces the shielding gas. This gas protects the weld from atmospheric impurities.

It does so by producing non-harmful gases immediately on top of the weld puddle which pushes the harmful atmospheric gasses away.

The hard flux also leaves a residue that covers the weld bead when the molten puddle cools and hardens. This residue is called slag.

Flux core welding also uses a solid flux. But instead of being on the outside, like on an electrode, the flux is contained inside the hollow flux core wire.

Just like with an electrode the flux inside flux core wire burns and produces a gas that shields the puddle from the atmosphere. Consequently, it also produces slag.

Supplied Gas for Shielding Against Impurities

Wire welding with solid wire requires the shielding gas to be blown down on top of the molten puddle from an external source.

This is called MIG welding which stands for Metal Inert Gas Welding.

There will always be an external bottle or tank of gas attached to the MIG welding cart to accommodate the need for shielding gas.

The supplied gas is fed down the welding lead and again, is expelled directly on top of the weld during the welding process.

TIG or Tungsten Inert Gas Welding also uses shielding gas from a bottle. Both MIG and TIG welding are performed best with the push method.

That is, the angle of the tip of the wire or tungsten rod is pointed slightly in the direction the weld is to go.

Basic Welding Tips

Cleaning your weld   

The quality of all welds will be improved by simply cleaning the base metals as completely as possible.

Only electrode welding, in some circumstances, can be performed with base metals that are not completely free of rust and residue.

Reverse Polarity when switching from MIG to Flux Core

Be sure to switch the polarity of the current when switching back and forth between MIG and Flux Core welding.

Depending on the machine, this may need to be done by switching the lead cables where they attach to the machine.

There you have it! If it produces slag, you must drag!

More Information

• How To Choose Between 030 and .035 Flux Core Wire?
• Difference between Spot and MIG Welding
• Flux Core vs MIG Welding
• What is Flux Core Shielding Gas

The post Do You Push or Pull Flux Core Wire? appeared first on Beginner Welding Guide.

So, you are considering purchasing your first wire welding machine and want to know a bit more about them. The bright-colored little boxes are not all that complicated, but there are a few questions you need to answer before plunking down the cash.

Nothing is worse than an expensive little machine collecting dust in the corner of your garage because it wasn’t really what you needed.

We will step you through several options to help you determine which machine and wire type is most likely the best choice for you today and soon.

Difference Between GMAW and FCAW

School is still out for me regarding the acronyms applied to the various welding methods designated by the American Welding Society. I’m not convinced they are helpful; some may find them confusing initially.

But, they are inescapable in the welding world. We will only be dealing with the two associated with wire welding for this article.

What is GMAW Welding?

GMAW, which is short for Gas Metal Arc Welding is better known as MIG or Metal Inert Gas welding. To break it down further, it is welding with solid wire using an inert gas to shield the weld from atmospheric contamination.

GMAW is not good for welding outside or in drafty conditions. This is because the shield gas tends to blow away before it can do its job. Compared to FCAW the welds will be more visually appealing and have no slag to chip off. GMAW also welds thin metals with less burn-through compared to FCAW.

What is FCAW Welding?

FCAW which is short for Flux Core Arc Welding is done with the same wire machine as GMAW but doesn’t use gas to shield the weld. The wire is hollow and contains flux powder to shield the weld from atmospheric contamination instead of gas.

FCAW is not as good as GMAW at welding very thin materials as it tends to burn through easier. It also leaves a coating of slag on the finished weld that must be chipped off. However, welding outside is not an issue with FCAW, and penetration rates are typically better.

It can handle a little debris on the surfaces to be welded, whereas GMAW needs the welding surfaces to be very clean.

Selecting a machine that can perform both MIG and Flux Core welding is ideal to give you more versatility for your welding.

Should I Use Gas or Flux Core when Welding?

You should ask yourself, what is the thickness range of the metals you will be welding? This will help determine if a 115v will be adequate for building your projects and making repairs.

Every home will have several 115v outlets to plug a machine into. Therefore, a portable 115v machine looks attractive and is worth looking into.

Scenario One:

All your welding is expected to take place indoors on clean metals 24 to 12 gauge thick. 12 gauge is slightly less than 1/8″ thick. 24 gauge is less than 1/16″ thick. 

If all of your planned projects and repairs fall within the parameters of this scenario, I suggest a 115v MIG welder like Hobart 50059 using gas with .025 diameter wire. The smaller wire will make it easier to weld the 24 gauge material. .030 wire will have a higher deposition rate and could also be used. The 115v will be the best for you in this scenario economically.

Scenario Two:

All your welding is expected to take place indoors on clean metals 1/8″ to 1/4″ thick.

For MIG welding with gas and .035 wire on metals within this thickness range, I suggest you step up to a higher capacity 230v machine. This upgrade in amperage and wire diameter will allow you to make fewer passes. Thus, saving you a lot of welding time in the process.

NOTE: For MIG welding metals in excess of 1/4" thick, a truly industrial machine with higher capacity will be necessary.

Scenario Three:

All of your welding is expected to take place both indoors and outdoors on metals 20 gauge up to 1/4″ thick.

We’ll need to move away from MIG and switch to .035 Flux-Core wire. This will not require a gas bottle, but the positive and negative leads will need to be switched on the machine. What is great is that a 115v machine will be sufficient to do the job.

NOTE: this is more than double the thickness that can be GMAW welded with a 115v machine. 

Scenario Four:

All of your welding is expected to take place both indoors and outdoors on metals 1/4″ to 1/2″ thick.

We’ll need to stay with Flux-Core wire and step up to the .045 diameter. This will require a 230v machine. This amperage and wire diameter upgrade will allow you to make fewer passes. This will save you a lot of welding time in the process.

NOTE: this is more than double the thickness that can be FCAW welded with a 115v machine. 

In Summary

The main questions that will determine the best machine, welding method and wire size are:

• What is the thickness range of the metals you expect to be welding?
• Where will you be welding, indoors or out?
• How clean will the metal surfaces be?

I hope we have at least provided the answers to these three main questions in a manner that is easy to understand.

For a deeper understanding of the differences between Flux and Shield Gas, please read my post called, “What is the purpose of flux and shield gas in the welding process“.

You may also find, “As a beginner what do I need to start welding“ helpful.

Read More

• Best Welding Machine for Beginners
• Which is Best Footwear for Welding?
• Best Welding Helmets for the Beginner
• 8 MIG Welding Beginner tips
• Do you push or pull flux core wire?
• Are Welding Machines Hard to Use?
• MIG vs TIG Welding
• What gas to use for MIG welding?
• Whats is difference between Spot and MIG Welding
• Differences Between 030 and .035 Flux Core Wire
• Magnetic Welding Clamps pros and cons

The post MIG Welding – Gas vs Flux Core appeared first on Beginner Welding Guide.