9.5 Chapter Conclusion
Cameron Kjeldgaard
Summary
This chapter explored FCAW in great depth. This versatile process, usable both with or without supplemental shielding gas, finds application in both shop and field welding environments. The process is mainly applied in heavy manufacturing and construction, with its primary drawback being that it is mostly limited to the welding of ferrous metals, including most steels, cast iron, and stainless steels, as well as some nickel alloys.
Review Questions
- FCAW can be used on which of the following materials? Select all that apply.
- Most carbon steels
- Aluminum
- Stainless steels
- Nickel alloys
- Cast iron
- FCAW wire electrodes (select all that apply):
- Have a solid construction
- Produce a slag coating on the weld
- Always require shielding gas
- Are constructed of a metal sheath filled with flux
- Are produced in diameters up to 0.25 inch
- In FCAW the wire electrode becomes electrically charged when it comes into contact with the:
- Drive rolls
- Gun cable liner
- Contact tip
- Workpiece clamp
- Gas nozzle
- Inside the wire feeding machine, the ________________ compress the wire electrode and feed it through the gun cable as they rotate.
- The distance from the contact tip to the workpiece is called ________________ and has a dramatic effect on welding amperage.
- The amount of pressure the drive rolls exert on the electrode can be adjusted with the ________________.
- An E81T-1 FCAW electrode has a tensile strength of ________________ psi and can be used in ________________ welding positions.
- List three consumable items of a welding gun that can be replaced and/or can be adjusted to troubleshoot and correct wire feeding problems.
- Briefly describe some of the advantages and limitations of the FCAW welding process.
- List the functions of FCAW electrode flux.