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26.6.2 Self-Shielded Flux-Cored Welding The self-shielded flux-cored arc-welding process is an outgrowth of shielded metalarc welding. The versatility and maneuverability of stick electrodes in manual welding stimulated efforts to mechanize the shielded metal-arc process. The thought was that if some way could be found to put an electrode with self-shielding characteristics in coil form and to feed it mechanically to the arc, welding time lost in changing electrodes and the material lost as electrode stubs would be eliminated.The result of these efforts was the development of the semiautomatic and full-automatic processes for welding with continuous flux-cored tubular electrode wires. Such fabricated wires (Fig. 26.4) contain in their cores the ingredients for fluxing and deoxidizing molten metal and for generating shielding gases and vapors and slag coverings.

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Barcodes.java .... setCode(code); Cell cell = new Cell().add(new Image(barcode. ... 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

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FIGURE 26.4 Principles of the self-shielded flux-cored arc-welding process. The electrode may be viewed as an inside-out construction of the stick electrode used in shielded metal-arc welding. Putting the shield-generating materials inside the electrode allows the coiling of long, continuous lengths of electrode and gives an outside conductive sheath for carrying the welding current from a point close to the arc. (The Lincoln Electric Company.)

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In essence, semiautomatic welding with flux-cored electrodes is manual shielded metal-arc welding with an electrode many feet long instead of just a few inches long.

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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.

Compared to other projects we did in our pasts of long-time software development, iTap was a small-scale project. We ll summarize the main challenges because, even for a small project like iTap, it is never wise to underestimate the quality requirements that are necessary to be successful.

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By pressing the trigger that completes the welding circuit, the operator activates the mechanism that feeds the electrode to the arc. The operator uses a gun instead of an electrode holder, but it is similarly light in weight and easy to maneuver. The only other major difference is that the weld metal of the electrode surrounds the shielding and fluxing chemicals rather than being surrounded by them. Full-automatic welding with self-shielded flux-cored electrodes goes one step further in mechanization the removal of direct manual manipulation in the utilization of the open-arc process. One of the advantages of the self-shielded flux-cored arc-welding process is the high deposition rates that are made possible with the hand-held semiautomatic gun. Higher deposition rates, plus automatic electrode feed and elimination of lost time for changing electrodes, have resulted in substantial production economies wherever the semiautomatic process has been used to replace stick-electrode welding. Decreases in welding costs as great as 50 percent have been common, and in some production welding, deposition rates have been increased as much as 400 percent. Another advantage of the process is its tolerance of poor fitup, which in shops often reduces rework and repair without affecting final product quality. The tolerance of the semiautomatic process for poor fitup has expanded the use of tubular steel members in structures by making possible sound connections where perfect fitup would be too difficult or costly to achieve.

2663 Gas Metal-Arc Welding Gas metal-arc welding, popularly known as MIG welding, uses a continuous electrode for filler metal and an externally supplied gas or gas mixture for shielding The shielding gas helium, argon, carbon dioxide, or mixtures thereof protects the molten metal from reacting with constituents of the atmosphere Although the gas shield is effective in shielding the molten metal from the air, deoxidizers are usually added as alloys in the electrode Sometimes light coatings are applied to the electrode for arc stabilizing or other purposes Lubricating films may also be applied to increase the electrode feeding efficiency in semiautomatic welding equipment Reactive gases may be included in the gas mixture for arc-conditioning functions Figure 265 illustrates the method by which shielding gas and continuous electrode are supplied to the welding arc.

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