Weld with Flux-Core Wire

A. Finished-Project Specification

Outcome: one correctly configured FCAW station — self-shielded or gas-shielded per the approved procedure — and a set of flat-position stringer beads on identified mild-steel coupons, produced with verified parameters, controlled technique, complete slag removal, and documented visual inspection.

B. Setup and Bead Schedule (Component Schedule)

Item	Quantity	Specification Source	Setup/Acceptance Condition
Flux-cored wire	1 spool	Approved wire manufacturer classification and diameter	Dry, identified, undamaged, correct feed direction
Drive rolls	Matched set	Feeder manufacturer, matched to wire type and diameter	Correct groove profile, tension per starting condition
Shielding gas (gas-shielded wire only)	1 cylinder	Wire manufacturer gas requirement	Correct label, secured upright, leak-checked connections
Test bead	1 minimum	Approved starting parameter chart	Stable arc, acceptable spatter, approved before production beads
Practice coupons	Per instructor assignment	Chapter 4–6 prepared mild-steel coupons	Clean bright metal, marked bead lines and endpoints
Production beads	Per instructor assignment	This chapter's procedure	Consistent width, tie-in, complete slag removal, passed inspection

C. Material Takeoff

• Wire: one spool of the approved flux-cored classification and diameter, sufficient for the required test and production beads.
• Shielding gas: for gas-shielded wire only, one cylinder of the gas specified by the wire manufacturer, with sufficient volume for the setup leak check and all practice beads.
• Base metal: identified flat mild-steel coupons from Chapters 4 through 6, sufficient for one test bead and the number of production beads assigned by the instructor.
• Consumables: contact tips and nozzle sized for the approved wire diameter and shielding configuration.
• Fastener and hardware schedule: not applicable. This chapter produces practice beads, not a fastened assembly.

D. Acceptance Standards

Check	Standard
Wire and polarity	Matches the approved procedure's classification, diameter, and polarity before any arc is struck
Gas system (if applicable)	Leak-checked, correct gas, flow set within the approved starting range
Test bead	Stable arc, acceptable spatter and slag behavior, approved before production beads begin
Bead width and reinforcement	Consistent along the bead length within the approved procedure's range
Tie-in and toe transition	Smooth fusion into the base metal without undercut or overlap
Slag removal	Complete along the full bead length; no slag inclusion indicators visible after brushing
Porosity and worm tracks	None visible on the finished, cleaned bead surface
Starts, stops, and craters	Controlled per the approved crater-control method; no uncontrolled arc strikes

E. Preparation — Wire and Procedure Review

1. Identify whether the approved process uses self-shielded or gas-shielded flux-cored wire. Confirm the determination against the welding procedure specification or instructor direction before continuing.
2. Review wire classification, diameter, polarity, gas where applicable, contact tip, drive roll, material, and parameter range. Record each value on the FCAW Setup Record.
3. Confirm ventilation and respiratory requirements for the selected wire and material. Reassess local exhaust positioning for the specific fume volume expected from this wire.
4. Complete hot-work, PPE, fire, and area controls. Confirm the Chapter 1 readiness record remains current for this session.

F. Feeder and Wire Installation

1. Turn off and isolate the machine before feeder setup. Confirm the machine is de-energized before opening the wire compartment.
2. Inspect spool, wire, drive rolls, guides, liner, gun, contact tip, and nozzle. Confirm each component matches the selected wire type and diameter.
3. Install the approved wire in the correct feed direction. Verify the spool label against the recorded classification and diameter before installing.
4. Use drive rolls appropriate to the wire without crushing or deforming it. Confirm the groove profile matches the wire type.
5. Set spool brake and drive tension to approved starting conditions. Record the starting tension setting.
6. Verify polarity from the wire manufacturer information. Confirm output-terminal connections match the required polarity before energizing.

G. Shielding Gas Setup (Gas-Shielded Wire) or Configuration (Self-Shielded Wire)

1. For gas-shielded FCAW, secure and connect the approved gas system. Confirm the cylinder is upright, secured, and labeled for the correct gas.
2. Check gas connections for leakage. Use the approved leak-check method at every fitting.
3. Set gas flow only to the approved starting range. Record the flow rate on the FCAW Setup Record.
4. For self-shielded FCAW, remove or configure gas components as directed by the machine and wire instructions. Confirm the nozzle configuration matches the self-shielded setup.

H. Parameter Setting and Test Bead

1. Set voltage and wire-feed speed from the approved chart. Record both settings on the FCAW Setup Record.
2. Trim wire to the specified extension. Confirm the trimmed length matches the procedure before striking an arc.
3. Attach the work clamp to clean metal. Confirm clamp contact is sound and close to the test location.
4. Prepare and mark the flat coupon. Mark bead lines and endpoints per the procedure.
5. Perform a wire-feed and gas check. Confirm smooth feed and, for gas-shielded wire, correct flow before striking an arc.
6. Run a short test bead on matching scrap. Complete the test bead under instructor authorization before proceeding.
7. Inspect arc stability, slag, spatter, bead shape, and shielding. Compare the test bead against the acceptance standards in Section D.
8. Adjust only within the approved parameter range. Record any adjustment and the reason for it.

I. Running Flat-Position Practice Beads

1. Position the coupon flat and assume a stable stance. Confirm clear travel access along the full marked bead line.
2. Use the approved drag or travel technique for the wire. Confirm the technique matches the wire manufacturer's guidance rather than defaulting to GMAW technique.
3. Maintain contact-tip-to-work distance. Hold the distance recorded in Section H throughout the bead.
4. Maintain work and travel angles. Confirm both angles against the approved procedure.
5. Travel steadily while observing the puddle and slag. Watch the slag trailing behind the puddle as an indicator of stable travel speed.
6. Terminate the bead using approved crater control. Avoid an abrupt arc break that leaves an uncontrolled crater.

J. Slag Removal and Inspection

1. Allow the bead to cool before slag removal. Confirm the bead has cooled sufficiently for safe handling unless the procedure permits hot chipping.
2. Wear eye and face protection while chipping slag. Confirm safety glasses and face shield are in place before chipping begins.
3. Remove slag completely and brush the bead. Inspect the full bead length for any remaining slag before brushing is considered complete.
4. Inspect bead width, reinforcement, tie-in, undercut, overlap, porosity, slag inclusion indicators, worm tracks, spatter, and crater. Compare findings against the acceptance standards in Section D.
5. Compare multiple beads for consistency. Identify any bead-to-bead variation and its likely cause.
6. Identify whether defects relate to voltage, wire speed, stickout, travel, angle, contamination, gas, or wire condition. Record the probable cause for any rejected bead.
7. Make approved corrections one variable at a time. Do not change more than one parameter or technique element between beads.
8. Record wire, polarity, gas, settings, technique, defects, and accepted result. Complete the parameter log for every bead produced.

K. Shutdown

1. Close gas where used, shut down equipment, store wire, and complete fire watch. Confirm the cylinder valve is closed, the machine is de-energized, and the required post-work monitoring period is observed before leaving the area.