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FIREPOWER FP 95 FC
Flux-Cored Arc Welding (FCAW)
This process also known as Open Arc, Innershield, FAB Shield,
etc., is an electric arc welding process which fuses together the
parts to be welded by heating them with an arc between a con-
tinuous flux filled electrode wire and the work. Shielding is ob-
tained through decomposition of the flux within the tubular wire.
The process is normally applied semi-automatically; however
the process may be applied automatically or by machine. It is
commonly used to weld large diameter electrodes in the flat and
horizontal position and small electrode diameters in all positions.
The process is used to a lesser degree for welding stainless steel
and for overlay work.
Gas (optional)
Molten Metal
Solid Weld
Metal
Molten
Slag
Slag
Figure 4-3: FCAW Process
WARNING
!
Follow these instructions only after refer-
ring to the Safety Instructions and Warnings
chapter of this manual, and the instructions
in the Installation chapter
Check List Before Starting
Wire Feed Speed – 1 to 10
Voltage Range Switch Setting – MIN or MAX
Electrode Wire Stick-out – approx 3/8" (10mm)
4.06 Welding Gun Positions
The welding gun should be held at an angle to the weld joint.
Hold the gun so that the welding seam is viewed at all times.
Always wear the welding helmet with proper filter lenses.
CAUTION
!
Do not pull the welding gun back when the
arc is established. This will create exces-
sive wire extension (stickout) and make a
very poor weld.
The electrode wire is not energized until the gun trigger switch
is depressed. The wire may therefore be placed on the seam or
joint prior to lowering the helmet.
Manual 0-5122
Nozzle (optional)
30 to 60º
Transverse
Flux Cored
Angle
Electrode
Arc
Art: A-05104
4.07 Establishing the Arc and Making
Before attempting to weld on a finished piece of work, it is
recommended that practice welds be made on a sample metal of
the same material as that of the finished piece.
The easiest MIG welding procedure for the beginner to experi-
ment with, is the flat position. This equipment is capable of flat,
vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 or 18
gauge (0.06" 1.5mm or 0.08" 2.0mm) mild steel plate 6" x 6"
(150 x 150mm). Use 0.024" (0.6mm) wire.
4-4
5º to 15º
Longitudinal
Angle
90º
Transverse
Angle
Figure 4-4: Butt and Horizontal Welds
10º Longitudinal Angle
Direction of Travel
Figure 4-5: Vertical Weld
5 to 15º
Longitudinal Angle
Direction of
Travel
Figure 4-6: Horizontal Fillet Weld
Direction of Travel
30 to 60º
Transverse Angle
Art: A-05108
Figure 4-7: Overhead
Weld Beads
OPERATION
Direction of
Travel
Art: A-05105
10 to 20º Longitudinal
Angle
30º to 60º
Transverse
Angle
Art: A-05106
30 to 60º
Transverse Angle
Art: A-05107
5 to 15º
Longitudinal
Angle
Operation
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