FCAW for site welding of structural steel
FCAW for site welding of structural steel
(OP)
Is flux cored arc welding a good process for site welding of structural steel?
Has there been any history of weld cracking associated with this process?
Thoughts and experiences would be appreciated.
Has there been any history of weld cracking associated with this process?
Thoughts and experiences would be appreciated.





RE: FCAW for site welding of structural steel
Please provide more data
Thanks and regards
Sayee Prasad R
Ph: 0097143968906
Mob: 00971507682668
email: sayee_prasad@yahoo.com
The whole of science is nothing more than a refinement of everyday thinking!!!
RE: FCAW for site welding of structural steel
I don't quite know how to "take" your question. The process is so common that I am curious why you are not familiar with it.
Rod
RE: FCAW for site welding of structural steel
FCAW-S (flux core arc welding-self-shielded) is the most common welding process for field welding of structural steel. It is portable, equipment and consumables are readily avaiable. I've only seen FCAW-G (gas-shielded) used locally once. The contractor switched to self-shielded electrodes about half way through the job when wind overcame the tents and they got tired of lugging gas cyliders around the job site.
There is a substantial amount of info available on weld failures for this process used in structural applications. Most include incorrect selection of electrode classification, workmanship and technique. Notch toughness (or lack thereof) of electrodes proved to be a major factor after the Northridge earthquake. Technique (bead width, thickness, etc.) were also noted to be major factors.
This process may be specified provided the above concerns are addressed in the welding specifications; strict adherance to a WPS and/or PQR if required, QC does their job and monitors parameters with a calibrated meter, etc. It is the fastest and most economical process for most structural steel field welding.
Many designers are not welders nor welding engineers. There is justified concern on their part with regards to this process. Many designers, owners and contractors now retain welding consultants or engineers for complex structural applications. Check out faq 725-513.
RE: FCAW for site welding of structural steel
You hit the rod, I mean nail on the head
Thanks and regards
Sayee Prasad R
Ph: 0097143968906
Mob: 00971507682668
email: sayee_prasad@yahoo.com
The whole of science is nothing more than a refinement of everyday thinking!!!
RE: FCAW for site welding of structural steel
In our application we have used gas-sheilded process to weld 60ksi structural steel. Welding environment was offshore / windy but full protection and monitoring was provided.
Some "cracking" was reported. Various theories have been put forward (lack of pre-heat, fatigue of partially completed connections). However, latest reports have made reference to LOF (it would be nice to get a straight story from our offshore guys!).
I will post final diagnosis if its interesting.
RE: FCAW for site welding of structural steel
RE: FCAW for site welding of structural steel
I would also have to agree with stanwelds post that lack of fusion could ,and in my opinion,does, result from improper torch manipulation,more so in thicker materials. The optimum torch angle that should be used is a bit shallower than other processes, around 20 degrees or so.As sayeeprasadr has stated,the yield rating of any wire usually surpasses what they say,if used correctly.
We use 8100 W (dual shield) wire ,as required in New York as we make expansion systems for bridges.It's a very "operator friendly" wire.
We have never had any cracking problems when used in parameters. Ours are (.045) 30v- 290a.