2.

SHIELDED ARC WELDING FCAW

i. WORKING PRINCIPLE

ii. LIST OUT THE FCAW APPARATUS/EQUIPMENT USED IN THE

WORKSHOP
 iii.CONSUMABLE RELATED TO FCAW PROCES
Consumable that are related to smaw process is

 Filler wire

iv.SAFETY MEASURES TO BE ADHERED TO WHEN CARRYING

OUT FCAW

a)Darker welding filters

The primary concern in regard to safety is the open arc and intensity, which is much
greater than that associated with MMAW electrodes. Thus a darker welding filter
than is normally used is required for GMAW – a filter one shade darker than that
used for welding at the same amperage with the MMAW process is required.
For example:
 up to 200 amps – a shade 11 is recommended
 200−300 amps – a shade 12 is recommended.
Clear safety glasses must be worn at all times, due to the high emission of UV
radiation, resulting in more frequent and severe arc flashes.

b)Body protection
This same arc intensity will also require the operator to ensure their body is
completely covered with protective clothing. Even extraneous light from the arc (ie
UV radiation bouncing from a reflecting wall) can result in a rather uncomfortable ‘ray
burn’. Experience has shown that cotton materials have less resistance to ultraviolet
rays than woollen materials. Cotton, and particularly synthetics, quickly break down
and eventually disintegrate. Consequently, it is preferable to wear leather or woollen
materials.
c)Ventilation
When arc welding, a toxic gas called ozone (O3) is given off from the arc. Processes
which employ higher current densities produce more ozone. Although ozone is not
dangerous under most conditions, it is advisable when working in confined spaces
(where ventilation is restricted) to use exhaust extraction. Natural ventilation and
exhaust fans can also be advantageous. Any ventilation system used must not
interfere with the gas shielding of the weld zone.

3.ADVANTAGE AND DISADVANTAGE OF FCAW PROCESS

a)Advantages of FCAW:

 FCAW may be an all position process.

 No shielding gas needed for some wires suitable in windy
conditions.
 Less cleaning of metal is required.
 Porosity chances are very low.
 High deposition rate.

b)Disadvantages of FCAW:

 Slag must be removed.

 More smoke comes out as compared to other processes like
GMAW and SAW.
 Spatter is more.
 Wire is more expensive.
 Equipment is expensive and complex.
4.EFFECT OF POLARITY IN FCAW PROCESS
DCEP Polarity - For DCEP the source of the heat is from the plate coming to the
electrode so the plate is in the hot side therefore it make the weld hotter and make
deep penetration into the base metal.The thickness of the bead is quit low but less
length in width.DCEP polarity when being used ,the welding will produce much
spatter

DCEN Polarity – For DCEN the heat source is coming from the electrode then
transfer to the plate,it melting the wire of but not enough to penetrate the base metal
thus producing shallow penetration. The weld created by DCEN is wider and
shallower.Otherwise DCEN polarity when being used ,the welding will produce less
spatter
5.COMMON DEFFECT IN FCAW PROCESS

Porosity

Defined as a pore or group of gas pores in the weld metal. Porosity may be
conveniently differentiated according to size and distribution

Lack of fusion

Defined as portions of the weld deposit which do not fuse to the surface of the metal
or the edge of the joint.

Lack of root penetration

Lack of root penetration is Defined as the failure of the weld metal to completely fill
the root of the joint
Excessive penetration

Defined as excess weld metal protruding through the root of a butt weld. This defect
normally only occurs on thin (sheet) materials or when the spray mode of transfer is
used.

Contour defects

Contour defects may be in the form of overroll or overlap, excessive convexity or

excessive concavity of the bead, or simply a rough, uneven appearance

Undercut

Undercut Defined as a groove or channel in the parent metal, occurring continuously

or intermittently along the toes or edge of a weld.
Cracking

Cracking Defined as discontinuities produced either by the tearing of metal in the

plastic condition (hot cracks) or by fracturing when cold (cold cracks).

Stray arcing

Stray arcing Defined as damage on the parent metal resulting from the accidental
striking of an arc away from the weld, or the accidental striking of an arc away from
the weld.

Excessive spatter

Excessive spatter Defined as the metal particles expelled onto the surface of the
parent metal or weld, during welding, and not forming part of the weld.