Structural steel erection, bridge construction among others are some of the applications where FCAW has proved extremely beneficial. Furthermore, if you take a closer look at all the benefits FCAW offers, you will be convinced why FCAW is highly preferred for the said applications.
FCAW offers extremely high deposition rates, amazing chemical and mechanical properties, and in particular, the weldability required for such processes. Ask any welding organization or ask the flux cored wire suppliers and they will reveal to you that there are not many better welding techniques for outdoors welding occupations.
However, there is no denying the fact that FCAW too has some challenges and limitations of its own. Diffusion Engineers, one of the most reputable flux cored wire manufacturers in India, welding electrodes suppliers, and Diffcor suppliers have come up with few tried and tested tips to conquer the difficulties encountered during FCAW.
Specifically, they have thought of a practical solution for probably the most concerning issue in FCAW that is wire feeding. Read along to discover how to execute these practical tips, bid goodbye to all your wire feeding issues, and work on the quality of your FCAW welds.
Wire feed stoppages and wire feed glitches are probably the best reason for downtime on field. The most inconvenient of wire feeding issues are burnback and birdnesting. Both of these smother the welding arc before time, which can be the reason for weld imperfection.
At the point when the wire consumes and softens into a ball at the welding tip's end, you deal with the threatening issue of burn back. It ordinarily happens in light of 2 reasons - the wire feed speed is incredibly lagging, or potentially if the welding gun is held extremely close to the workpiece.
To forestall this issue, you should guarantee that you utilize the ideal feed speed for the chosen welding application and keep a separation of 3.5 cm between the contact tip and the workpiece. Birdnesting is a welding term for a wiring tangle that keeps the wire from being fed.
To determine this issue, or to keep it from happening, guarantee that you use knurled V-groove or knurled U-groove drive rolls in the wire feeder. Because of its design, the FCAW wire is extremely delicate.
In the event that you commit a mistake while picking the drive roll, the wire could undoubtedly get compact. Additionally, setting the drive roll pressure precisely could forestall issues, for example, leveling or tangling of wires.
To set the best wire tension, start by delivering the pressure constrained on the drive rolls. At the point when you feed the wire into your welding glove's palm, release the tension till one-half turn past the wire slippage. Most reasons for birdnesting relate to the liners - liner blockages, ill-advised management of liners, and so on.
In the event that you go over a blockage in the liner, replace it at the earliest opportunity, and guarantee that you trim the liner according to the manufacturer's recommendations. Guarantee that you are utilizing the best liner size as per the welding wire's size and affirm that there are no sharp edges on the liner.
Also Read: Tips To Ensure Safety during Welding Processes
These tips for staying away from wire feeding issues, given by reputed flux cored wire suppliers and wear plates manufacturers in India, should assist you with conquering this issue with least struggles.