Different between SMAW & FCAW

[chinna durai]

Dear Experts,

              What  is the different  between SMAW & FCAW

               where will use this FCAW Process?


Thanks & Regards,
        Durai.P

[G Sreenivas Rao]

Dear Durai
SMAW- used flux coated electrode ( flux coated on filler rod for shielding ),
FCAW- flux is inside the electrode ( this is tubeler rod having flux inside)
Regards
GSR

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[hany alfy]

Dear Durai

SMAW-  used flux coated electrode ( flux coated on filler rod for shielding ), Manual welding ,(Travel speed Low)
FCAW-  flux is inside the Wire( this is tubeler rod having flux inside- External Gas shielded) , Semi Automatic ,(Automatic Wire feeder) , Travel speed Higher
Regards
H.A

---

From: G Sreenivas Rao <gsrin...@gmail.com>
To: material...@googlegroups.com
Sent: Saturday, October 13, 2012 2:57 PM
Subject: Re: [MW:15605] Different between SMAW & FCAW

Dear Durai
SMAW-  used flux coated electrode ( flux coated on filler rod for shielding ),
FCAW-  flux is inside the electrode ( this is tubeler rod having flux inside)
Regards
GSR

On Sat, Oct 13, 2012 at 3:14 PM, chinna durai <iar...@gmail.com> wrote:
> Dear Experts,
>
>              What  is the different  between SMAW & FCAW
>
>                where will use this FCAW Process?
>
>
> Thanks & Regards,
>        Durai.P
>
> --
> To post to this group, send email to material...@googlegroups.com
> To unsubscribe from this group, send email to

> materials-welding+unsub...@googlegroups.com

> For more options, visit this group's bolg at
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> http://www.linkedin.com/groups/MaterialsWelding-122787?home=&gid=122787&trk=anet_ug_hm
>
> The views expressed/exchnaged in this group are members personel views and
> meant for educational purposes only, Users must take their own decisions
> w.r.t. applicable code/standard/contract documents.
>
>

--
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[c sridhar]

Mr. Durai,

Flux Cored Arc Welding (FCAW) is made with flux inside a mild  or stainless steel  tube or with a strip formed as a tube. It gives continuous welds and
fed through 15 kg spool and 25, 100, 200 kg bobbins. Advantage - a low idle time and has high  productivity compared to SMAW and GMAW processes.

There are 2 types,

1. One with self shielding and gives non-radio graphic quality welds. Used on carbon steel plates and ideally suitable for structural, over-lay, surfacing works. .

2. Other with an additional  & external shielding.(like Argon, CO2, or Argon- CO2 mixture) and gives radiographic quality welds. Used for  plate & pipe
    welding  of  carbon, alloy, stainless steel etc. Could be used for flat, horizontal, vertical up (up to 1.2 mm size) positions and well suitable for heavy
    fabrication including ship building industry..

On the other hand SMAW process has flux coated on a mild or stainless steel core wire and used on plates, pipes. Gives x-ray   quality welds . It is used on
all  positions, good for structural, pressure piping applications but, productivity levels are low compared to FCAW. and GMAW processes.

Sridhar.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

On Sat, Oct 13, 2012 at 3:14 PM, chinna durai <iar...@gmail.com> wrote:
> Dear Experts,
>
>              What  is the different  between SMAW & FCAW
>
>                where will use this FCAW Process?
>
>
> Thanks & Regards,
>        Durai.P
>
> --
> To post to this group, send email to material...@googlegroups.com
> To unsubscribe from this group, send email to

> materials-welding+unsub...@googlegroups.com

> For more options, visit this group's bolg at
> http://materials-welding.blogspot.com/
> http://www.linkedin.com/groups/MaterialsWelding-122787?home=&gid=122787&trk=anet_ug_hm
>
> The views expressed/exchnaged in this group are members personel views and
> meant for educational purposes only, Users must take their own decisions
> w.r.t. applicable code/standard/contract documents.
>
>

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To post to this group, send email to material...@googlegroups.com

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[Prakash Hegde]

Dear Mr Durai The attached PDF may be helpful to know about basic welding process Regards   Prakash Hegde Welding consultant Pune +918805593046 --- On Sat, 13/10/12, c sridhar <sridh...@yahoo.com> wrote:

To unsubscribe from this group, send email to materials-weld...@googlegroups.com

[Muthu Samy]

Dear Durai,

Apart from the differences told by our experts,

The most preferable process is SMAW. There are so many restrictions to use FCAW due to full penetration weld achieved by SMAW is more than FCAW.

--

[c sridhar]

You said, "The most preferable process is SMAW.

Yes, if the weld is done for any position and for less than  12  mm or so..

For any thickness beyond that and for both butt & fillets, FCAW will be economical in spite of initial cost of power source, cost of consumables, extra gas shielding etc. .

No,  because of many other factors as mentioned below.

1. As mentioned earlier, the out put of weld deposit is low  compared to  FCAW,   GMAW & SAW  Processes.
Average output efficiency  of E 6010 is 60-70%, E 6013 is 70%. E 7016 is 70-75%. E 7018 is 115% with its iron powder addition.. If the stub end loss is more, say beyond 50 to 100 mm, then the % efficiency comes down drastically by an additional 10% or more.On the other hand, FCAW gives an average of 90% deficiency since there is no stub end and spatter loss at all.

Result: Weld deposit requirement is less in FCAW than in SMAW .
 
2. Considering economical evaluation of an electrode and the cost of one Kg. weld metal  deposit, It will work out more in SMAW than in FCAW   due to its high  productivity,  low  spatter loss etc.  i.e.,  Weld metal deposited  and volume ofproduction  per unit time or shift is more in FCAW.

Result: Cost of Weld deposit requirement is less in FCAW than in SMAW .
 

You said, “There are so many restrictions to use FCAW due to full penetration weld   achieved by SMAW is more than FCAW."

 

No. On the other hand, FCAW gives deeper penetration compared to SMAW. Only E 6010 gives deeper penetration while all other electrodes give only medium  Penetration . FCAW electrodes uses very high current density (compared to 16-18Amps/mm²  for  SMAW electrode  FCAW uses avg. 130 to 200 A/mm ² for any   size)

 

Result: FCAW process gives higher penetration compared to SMAW.

 

Additional Benefits:  Compared  to  60-70⁰ bevel angle for SMAW,  FCAW and GMAW processes  can have 50 to 60⁰ bevel

due to its low or no slag formation.

              
Result: Volume and Cost of Weld deposit requirement is less in FCAW than in SMAW.

 

There are many more advantages and I have mentioned few only.

 

Sridhar .

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To: material...@googlegroups.com

Sent: Monday, 15 October 2012 10:01 AM
Subject: Re: [MW:15635] Different between SMAW & FCAW