What is Flux Cored Wire Self-shielded and Why Do We Use Them?

Comparing the advantages of flux cored vs. MIG

MIG welding and flux-cored welding possess different characteristics that welders must evaluate when selecting which process to use. To achieve the best results, consider the following factors: thickness of the material, proper shielding gas, wire feed speed and voltage settings, location of the jobsite, and weld appearance.

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There is no one-size-fits-all welding solution, and all of the above variables will affect wire selection. This article will help the novice or occasional welders understand the basics of solid and flux-cored wire and how to maximize their advantages.

Solid wire/MIG basics

MIG power sources use a continuous solid wire electrode for filler metal and require a shielding gas delivered from a pressurized gas bottle. Mild steel solid wires are usually plated with copper to prevent oxidation, aid in electrical conductivity and help increase the life of the welding contact tip. The shielding gas protects the molten weld pool from contaminants present in the surrounding atmosphere. The most common shielding gas combination is 75% argon and 25% carbon dioxide. While welding outdoors, welders should use caution and prevent wind from blowing the shielding gas coverage away from the arc. Windshields may need to be used.

Flux-cored wire basics

There are two types of flux-cored wires — gas shielded and self shielded. Gas-shielded flux-cored wires require external shielding gas, and the slag is easy to remove. Consider using gas-shielded flux-cored wires when welding on thicker metals or in out-of-position applications. Gas-shielded flux-cored wires have a flux coating that solidifies more quickly than the molten weld material. As a result, it creates a shelf to hold the molten pool when welding overhead or vertically up. Self-shielding flux-cored wire does not require external shielding gas because the weld pool is protected by gas generated when flux from the wire is burned. As a result, self-shielding flux-cored wire is more portable because it does not require an external gas tank.

What to consider when choosing solid or flux-cored wire

Appearance

Many welders believe that weld appearance is an important factor. When working on materials less than 3/16-inch thick down to thin sheet metal (24 gauge), solid wire will produce a clean looking weld. For example, a short-circuit transfer with .030-inch solid wire set at 18-19 volts with 160-170 amps and using 75% argon and 25% carbon dioxide shielding gas will usually produce little spatter, create a smaller heat-affected area and reduce chances of burn-through. As a result, many automotive enthusiasts who specialize in bodywork or those who work with thinner applications prefer solid wire.

Location

The welder must also consider the location of the jobsite when choosing between solid and flux-cored wire. In environments such as windy locations, solid wire or gas-shielded flux-cored wire are more difficult to use because exposing the shielding gas to wind can compromise the weld integrity. Typically, the loss of shielding gas will produce porosity visible in the weld bead.

On the other hand, self-shielded flux-cored wire is ideal for welding outdoors or in windy conditions. The welder does not have to set up windshields to protect the shielding gases because the shielding gas is generated from the burning flux. Since self-shielded flux-cored wire does not require external shielding gas, it is also more portable than solid wire. This portability is ideal in agricultural applications where field equipment can break down far from the shop. If you are welding thicker metals (16 gauge and above), self-shielded flux-cored wire also provides excellent penetration.

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Thickness, type of application and parameter settings

Many novice welders attempt to use a one-size-fits-all wire and shielding gas combination for multiple applications. The most common wire and gas combinations (for solid wire) are .035-inch- diameter wire used with a 75% argon and 25% carbon dioxide shielding gas. When welding thicker material, however, consider the welding power source output, as well as welding wire diameter. If using a .035-inch wire for thicker materials, and the power source is plugged into a 115-volt circuit, the resulting amperage output may not be sufficient to make quality welds. This increases the risk of cold lap or lack of fusion.

Attempting to use too small of a solid wire for thicker applications (such as on A-frames of an automobile) increases the chance of lower penetration in the root and could require more than one welding pass. Misapplication of the solid wire (even though strong enough) may also not provide adequate penetration on thicker material.

Although more expensive than solid wire, flux-cored wire could help you gain productivity. Flux-cored wire typically has the ability to weld dirtier materials that may have higher levels of rust, mill scale or oil. Although cleaning is always the proper method of preparing the steel, flux-cored wires contain de-oxidizing elements that trap these contaminants in the weld pool and hold them in the slag coverage, typically preventing the associated weld problems found when welding dirtier steels. When compared to solid wire, flux-cored wire also increases penetration on the sidewalls and offers the advantage of better deposition rates (the amount of weld metal deposited in a given time period, measured in pounds per hour). Although the welder is initially spending more for flux-cored wire, the savings are realized in the decreased production time.

Which is better, solid wire or flux-cored wire?

Neither wire is superior to the other. They simply have different properties that work better on certain applications. As far as performance is concerned, both wire types produce sound welds with good weld bead appearances when applied correctly and used within the proper parameter settings. Solid wire provides deep penetration in the root and usually has little spatter. Flux-cored wire has a larger ball-type transfer and produces low spatter levels. In addition, flux-cored wire produces a rounder penetration profile with excellent sidewall fusion.

As far as user appeal, both solid wire and flux-cored wire are relatively easy to use. This makes them ideal for novice and occasional welders working in automotive, farming and home hobby applications. Welders may prefer solid wire on thinner applications because there is no slag to remove, it is ready to paint and the weld beads may be more aesthetically pleasing.

A final word on flux cored vs. MIG

Most important, remember not to fall into the one-size-fits-all mindset. Solid wire, self-shielded flux-cored wire and gas-shielded flux-cored wire all work well — provided they are applied correctly. The type of wire you choose will be contingent upon the location of the jobsite, thickness of the application, proper shielding gas combination and the type of equipment available. You should always clean the workpiece before welding to ensure optimum weld quality and prevent impurities from becoming trapped in the weld bead. To achieve the best possible results, be willing to make adjustments based on the jobsite variables and consider having both solid and flux-cored wire available.

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Flux-Cored Arc Welding (FCAW) is a versatile process that essentially combines the efficiency of MIG welding with the simplicity of Stick welding! It comes in two forms: self-shielded (FCAW-S) and dual-shielded (FCAW-G). Both methods have distinct advantages and applications, and choosing the right one can make all the difference in your welding projects. So let’s break down these processes, starting with the basics! When comparing self-shielded and dual-shielded FCAW, the first major difference is the type of wire used. Self-shielded FCAW uses a wire that contains flux, which generates the shielding gas needed to protect the weld from contamination. This type of wire is designed for outdoor and high-wind conditions since it doesn’t rely on an external gas cylinder.

On the other hand, dual-shielded FCAW combines flux inside the wire with an external shielding gas (usually either 100% CO₂ or a 75/25 Argon/CO₂ mix). This setup provides additional protection and leads to cleaner, stronger welds, especially in critical structural applications. The setup for both FCAW processes can be pretty confusing and it differs based on the wire and shielding gas requirements. The good news is, pretty much any machine you can MIG weld with, you can use for FCAW!

The best thing to do is to first consult the manufacturer’s recommendations- they should have a catalog available that shows you how to choose a wire that is appropriate for your job. Or if you already have the wire, it is best to cross reference the information on the spool to determine the best practices. After that, you’ll have to make sure you are equipped with the correct drive rolls for your wire and you’ll need to ensure that your machine is set to the correct polarity. Self-shielded FCAW is designed for fieldwork, making it ideal for windy environments where shielding gas might otherwise blow away. However, it requires a few key practices to get the best results:

• Maintain a slightly longer arc length to minimize spatter + ensure proper weld penetration.
• Use a drag (backhand) technique rather than pushing, which helps keep the weld bead clean.
• Control your work angle and travel speed to avoid undercutting or insufficient fusion.
  
  

Self-shielded FCAW runs smoothly but produces more spatter compared to dual-shielded FCAW. The flux core generates a protective gas that shields the weld puddle, but it also creates slag that must be chipped away after each pass. While it offers good penetration and strength, it lacks the precision and smooth finish of a gas-shielded process. Dual-shielded FCAW combines the best of flux-cored welding with the benefits of external gas shielding, resulting in cleaner, more aesthetically pleasing welds. However, it does require more precise setup and gas management, making it less ideal for fieldwork but perfect for fabrication shops and indoor environments. To get the most out of dual-shielded FCAW, follow these best practices:

• Optimize your shielding gas flow: Too little gas can cause porosity, while too much can disturb the arc.
• Use a drag (backhand) technique rather than pushing, which helps keep the weld bead clean.
• Clean your base material thoroughly to avoid contamination.
  
  

Dual-shielded FCAW runs smoother and produces less spatter compared to its self-shielded counterpart. The addition of shielding gas creates a more stable arc, leading to better puddle control, increased deposition rates, and overall higher-quality welds. This method is ideal for thick materials and critical structural applications. Choosing between self-shielded and dual-shielded FCAW depends on your project needs. If you’re working outdoors or in conditions where portability and simplicity are key, self-shielded FCAW is the way to go. But for precise, high-quality welds in a controlled environment, dual-shielded FCAW is the superior option. Understanding the differences between these methods will help you select the right one for your welding application and ensure optimal results every time! Need help navigating these choices? Just stop by one of our showrooms in Maryland or Pennsylvania and our team will help you find the right supplies for the job! BALTIMORE