What is FCAW (flux-cored arc welding) and when to use it?

FCAW (Flux Cored Arc Welding) is a semi-automatic process widely used in heavy construction and steel structures in Quebec.

How it works:

• A tubular wire (flux-cored) containing flux (filler, deoxidizers, alloying elements) is automatically fed
• The flux melts and creates a gas shield and slag that protects the weld pool
• Two types: self-shielded — no external gas needed, ideal in wind — and gas-shielded (with CO₂ or Ar/CO₂)

Advantages:

• High deposition rate: well above SMAW for the same welding time — the exact figure is on the wire manufacturer's data sheet
• Deep penetration: ideal for thick plates and T-joints
• Wind resistance: Self-shielded wire can weld in moderate wind (unlike GMAW)
• Productivity: No electrode changes — continuous feeding

Typical applications:

• Steel structures (beams, columns, gussets)
• Mining equipment (buckets, chassis, crushers)
• Shipbuilding
• Bridges and heavy structures

Cost: flux-cored wire costs more per kilogram than solid wire, but the price depends on diameter, quantity and supplier — it is obtained by quotation, and the platform publishes none.