Welder World Blog

Posts Tagged ‘Flux’

Flux Cored Welding is not a “new” process, being dated back to the 1920′s. Instead of having the protective/stabilizing flux on the outside of the wire, as in “stick” rods, it is at the core of the wire. This flux does the same job as do the gases used Gas MIG Welding.

At Weyerhaeuser Timber Company, we periodically built rail-car “car sills”. These are the heavy metal frames upon which the railroad boxcar sits. We would use a “pantograph” machine for semi-automatically cutting out parts for the sill. Then we’d weld many of the parts with “jet rod” (7024 type), which is super easy to run on flat welds. The welds looked VERY nice.

For most other welding, we used heavy duty MIG welders. We’d fiddle with “gas” settings & wire speeds till it was just right. Then we’d just go & go till we got to the end of the pieces. We never had to worry about “duty cycle”, we just kept going. We could get a LOT done with those MIGS. If you are going to do a LOT of welding, you may want to start with a wire feed welder.

I prefer a flux cored welder because there’s no “gas” bottles nor pressure adjusting, nor are there issues with welding outside in the wind. It’s a personal decision; gas or flux cored. I would use the recommended setting ranges, running on the “hotter” side just to get the feel and coordination of running beads. An in-expensive, occasional use flux cored machine for the little jobs is fine. For my bigger jobs I go to my stick welder.

More tips and ideas for flux cored welding:
* If you go through eBay to but one, you may want to first go to welding supply shops & see them in person.
* Flux cored welders are mainly for the thinner materials. If you’re going to work on cars & the like, you would probably prefer wire feed over stick.
* I’ve done a lot of sheet-metal work with stick rods, but I needed to use really small rods, plus do a lot of “touch & go” welding, rather then continuous welds.
* One of your first accessories should be a pair of “MIG pliers”. They are great for helping you keep your equipment clean & to be able to easily convert to other wire sizes.
* When you install your 1st wire spool, don’t mess with bending it around much, or it may break. Re-threading & pulling out any that’s already in the guide tube can be a pain.
* Again, use recommended settings, then make adjustments as needed. Some machines are really limited for adjustments, so you may have to experiment with your gun positioning & arc length.
* I’d bet that there are as many variations for adjustments as there are different manufacturers & models. Be patient & keep trying.

Machine Selection:
* This is primarily dependent on your budget, then on exactly what type of welding you’ll be doing. If you feel that you might go beyond just doing your own thing, then get the best you can afford.
* The cheaper units are all pretty much the same: for light duty at home projects. The mid-priced ones can get you started in your business, but you’ll likely be up-grading as soon as you can afford to.

Flux Cored Troubleshooting:
* Don’t let go of the wire end when you’re loading a new spool! It may not feed right even if you can get it all un-raveled & fed through.
* If you feel the wire pushing against the bottom of the puddle, turn the speed down or the heat up (or both).
* Try not to keep the nozzle end too close to the puddle. That can make more splatter get into the tip piece.
* When you first start the weld, stay put momentarily to allow the puddle to form & fill the initial crater.
* Uneven feeding? Make sure the wire guide isn’t twisted or kinked.
* Can’t see an actual puddle? Clean you helmet lens & get closer. If all you’re seeing is a bunch of sparks, you’re not really seeing what’s going on. And again, you need to go at a speed that gives enough time for a puddle to form.

Brazing is an effective thermal joining process commonly used in engineering. It is often preferred over other process like welding. Brazing can join almost all the metals and alloys. In this process, a molten brazing alloy is drawn into a capillary gap between the metals being joined. Many forms of brazing alloys are used for fulfilling this requirement. Brazing rods are perhaps the most popular forms of brazing alloys used world over by professionals.

What is a Brazing Rod?

Brazing rod is a piece of metal in the shape of a rod. It melts during the brazing process and attaches to the separate pieces of metals in order to join them together once cooled.

What are the Metals Used for Making Brazing Rods?

Brazing process has the ability to join different metals and components of dissimilar size and mass. However, for this, the perfect form of brazing alloy (filler metal which melts above 450˚C but below the temperatures at which metals being joined melt) has to be present. Therefore, brazing rods have to be made from different metals like aluminum, silver, steel, bronze etc.

What is Flux Coated Brazing Rod?

There are many types of brazing processes which are conducted in different atmospheres. In the one which is not contained within an inert or reducing atmosphere environment (for example a furnace,) flux is needed to prevent oxides from forming when the metal is heated. Not only this, flux also cleans up any contamination that is left on the brazing surfaces. Flux too comes in various forms like flux paste, liquid, powder or pre-made brazing pastes that combine flux with filler metal powder. Sometimes, flux is applied to brazing rods either in the form of a coating of flux or a flux core. This flux flows into the joint when the brazing rod is applied to the heated joint and is displaced by the molten filler metal entering the joint.

To know more about brazing rods as well as other forms of brazing alloys, read Brazing Rod

Video Rating: 5 / 5

• ETL approved flux wire welder
• Adjustable positions and cycles
• Comes with two pounds of flux wire and more

Product Description
90 Amp Flux wire, 120Volt / 60Hz, ETL approved. No Load Voltage: 31 Volt, adjustment positions: 2 steps. Range of current 50 to 80 Amp. Duty cycle: 15% at 80A, 20% at 65A. Rated duty cycle: 10% at 90amps. Insulation Class: F, welding wire size is 035 to 040 inches. Includes: Welding torch, tip, grounding cord with clamp Brush / hammer, Face shield, Flux cored wire .030 inch (2 pounds).

MIG 100 Flux Wire Welder

Forney 95FI – #00304 Ready to weld right out of the box! Welds all types of carbon steel. Simple to operate and portable, weighs just 43 pounds. Two power settings for accurate welding control. Convenient 120V input power. Automatic thermal overload protection. Electronic wire speed control. Tweco® compatible welding torch. Includes face shield, combination chipping hammer & brush, welding torch, ground clamp, and starter roll of flux cored welding wire. Tough, scratch resistant cabinet. Main Votlage: 120V Max. OCV: 27V DC Duty Cycle: 20% @ 60 Amps Output Range: 20 Amps – 95 Amps Wire Diameter: .030, .035″ Weight: 43 lbs Welds up to 3/16″ material

Join veteran educator Karl Hoes of the Lincoln Electric Welding School as he covers some basic welding topics sure to appeal to any farmer, rancher, or welder. The Welding Workshop is seen regularly on the Successful Farming Machinery Show on RFD-TV

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Got some new parts for the welder. Decastar 130 Flux core welder

• Robust steel case for portability and durability
• Infinite wire speed control allows adjustment for smooth even weld bead
• Thermal overload protection automatically shuts off to avoid overheating
• Professional torch equipped with trigger activated arc for easy support

Product Description
Campbell Hausfeld 115V Flux Core Wire Feed Welder. Easy to use, with professional results every time! SAVE BIG! Portable performer makes easy work out of welding! Welds from 24-ga. to 3/16″ steel, with adjustable, consistent wire feed for smoother, more even welds every time, even if you’re a novice! Perfect around the home or the shop. The clear choice for pros and novices alike! Details: Robust steel case for jobsite-tough durability over the long haul; Works with standard 15 or 20-amp household outlets; Capable of welding mild and stainless steel from 18-ga. to 3/16″; 4 heat settings for varying metal thicknesses; Thermal overload shut-off protects welder by shutting down when the duty cycle has been exceeded; Duty cycle: 20% @ 70A; 5-yr. limited manufacturer’s warranty; Weighs only 46 lbs.; Includes Flux core wire and 2 extra tips. Make sure you’ve got the right tool for the job! Order yours today! Campbell Hausfeld 115V Flux Core Wire Feed Welder

Campbell Hausfeld WF2150 Flux Core Wire Feed Welder

• Self regulating feed control
• Thermal protection with warning light
• Input: 110volt, single phase
• Wire capacity: 0.035″ or 0.030″
• No Gas Needed

Product Description
This flux core welder handles .023, .030 and .035in. wires and welds 18-gauge to 3/16in. steel. Self-regulating feed control; wire feed speed 0-400 IPM. Duty cycle: 10% @ 90 Amp, 19V; thermal protection with warning light.

Speedway Series 7117 125 Amp 110 Volt Single Phase Wire Feed Flux Welder

I got the welder in a trade and it came with flux core wire in it but doesn’t weld worth a dang.Is the the problem with it?Does it have to have gas?