Advice for FCAW qualification

[Nambirajan Avudaiappan]

Dear Experts,

We are currently conducting FCAW qualification on a 25mm thick SA-36 material plate. However, we are facing issues with slag inclusion during the process.

Despite performing thorough cleaning after every pass, slag inclusions are still observed.
We kindly request your advice and recommendations on how we can take effective control measures to eliminate this problem.

Your expert guidance would be highly appreciated.

Thank you and best regards,

Nambirajan A

[sridhar cn]

Dear Mr. Nambirajan,

The reasons for slag inclusion could be due to 

* high welding travel speed,

* improper in between pass cleaning,

* weld parameters like low current, low/high voltage, improper torch angle,

* align the weld beads properly to avoid slag entrapment in between,

* use 15 deg. drag angle during welding,

* use a power brush instead of a hand brush to clean the slag between each pass etc.

* also check your filler wire. Use a basic wire instead of rutile filled FCAW wire.

* avoid  a low cost Chinese made power source (if it is in use currently) and go for a 

   branded one like Lincoln, Esab, OTC (Japan make) etc.

Please provide the welding parameters you are using presently for your 1.2 mm size filler wire If it is OK

rgds,

C Sridhar.

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[Nambirajan Avudaiappan]

Hi shridar,

Thank you for your advice.

I am currently using Hyundai brand (E71T-1C) 1.2 mm filler wire.

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[Deerendra Karanth]

Sir, 

Sometimes switching to higher quality FCAW wire (like E71T-1C/M-H4) might solves the problem. However if slag isn't 100% removed visually after one pass, grind it again before depositing next pass. Most of the time Run a "buttering pass" (a small first pass) to better control root weld if joint prep is not perfect.If overlap is not good, slag from the earlier bead gets trapped under the next bead.

BR, 

Deerendra 

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[sridhar cn]

You have not spelled out the weld parameters like,

Current, Voltage, Stick out, Travel speed, and interpass cleaning, power source weld position etc.

CS.

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[Nambirajan Avudaiappan]

Weld	Pass	Process	Filler	Filler Metal Dia.	Current	Volts	Current Type & Polarity	Travel Speed (mm/min)	Heat Input
Layers	No.		Metal		(A)	(A)			KJ/mm
1	1	FCAW	E71T-1C	Ø 1.2	120-160	18-25	DCEP	175	0.74
2	2	FCAW	E71T-1C	Ø 1.2	150-180	20-25	DCEP	300	0.64
3	3	FCAW	E71T-1C	Ø 1.2	150-180	20-25	DCEP	300	0.64
4	4	FCAW	E71T-1C	Ø 1.2	150-180	20-25	DCEP	300	0.64

Interpass cleaning :- Grinding and brushing.

Weld position 1 g only .

Appreciate your feedback Mr.Sridhar

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[Nitesh Kumar]

Dear Sir,

I am grateful to you for supporting me, but if you have any welding matrix then please send it, I will get the reference

Thanks & Regards

Mr. NITESH

Mob No. : 9939998302

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[Mohammed shaibaaz]

I have seen thus issue the slag impression after removal also due to improper rod heating and placing material in oxidation condition.

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[Mohd Siraj]

is it self shielding?