Each of these categories offers its own unique set of properties ideal for the applications mentioned using Flux Core Welding Wire, which is why this type wire seems to be a go-to choice among many welders. But like anything, even experienced welders can mess up and do sub-par work. Knowing what these common pitfalls are and how to avoid them can go a long way towards improving your welds.
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In this article we will discuss five common pitfalls that occur when using Flux Core Welding Wire, and how you could avoid making them.
## 1. Improper Wire Feed Speed
Setting The Incorrect Wire Feed Speed – Using Flux Core Welding Line Wrongly If the feed speed is set too fast, it can cause a poor weld with not enough penetration. However, if the feed speed is too high it can lead to excessive spatter and diminished arc stability.
Avoidance = Always refer to the manufacturer’s guideline for recommended wire feed speed according: material thickness & type of welding **??? Furthermore, carry out a test weld on some scrap metal to dial in the perfect feed speed for best results.
## 2. Incorrect Polarity
Incorrect polarity is another common error which causes poor welding quality. A typical Flux Core Welding Wire needs a polarity setting, typically direct current electrode negative (DCEN) or straight polarity. Poor arc performance, excessive spatter and weak welds are just some of the consequences using incorrect polarity.
**Prevention:** Always check the requirements of your Flux Core Welding Wire, and make sure that you set up a welding machine with right polarity. Always read instructions of polarity wise on different wires by the manufacturer before starting your welding project.
## 3. Poor surface Preparation
If you want a successful Flux Core Welding Wire welding then the first thing that needs to be done is properly deposit the electrode. If welding is done in the wrong hands it can mean sloppy looking beads or weak joints, caused by dirty/lubricated surfaces. This is something that beginners are likely to make, as they may not realize how crucial cleaning the base material properly can be.
**How to Prevent:** Prior to starting your job, make sure the welding surface is clean. Remove rust, oil and other contaminants via a wire brush or grinder as well as with the aid of chemical cleaners. A clean material that is free of contaminants will allow your weld to penetrate and make a water-tight seal which provides stronger, more visually appealing welds.
## 4. Wrong Travel Speed and Angle
Travel angle with Flux Core Welding Wire is crucial in maintaining good weld quality as well_travel angles and speed. As stated before, the most common misalignment on travel angles are too little or too much push So, welds can have more spatter and poor penetration as well an unfair weld bead. Continuing with this example, welding too fast can produce weak welds that lack fusion and not all the layers of metal are joined together correctly as a result which is bad. Similarly to this, by making Welding go slow it creates build up so therefore burn through becomes more common.
**Prevention:** Travel with your gun at a 10 to15 degree angle from vertical. GET IT RIGHTNext time, try using a more consistent travel speed to ensure proper penetration and fusion of the weld metal. If your weld bead appears to have inconsistencies in shape, you may need to alter the travel angle and speed based on what results you are experiencing.
## 5. Not Checking Gas Flow Rate
Flux Core Welding Wire can be used with or without shielding gas depending on the application but in some situations an additional flow rate of gas is required to maintain a galvanized appearance. Failure a Gas Flow Rate Check and Adjustment Improper gas flow will lead to inadequate shielding which causes weld contamination, porosity.
**Prevent:** In the case of welds set with a shielding gas, make sure it is accurately regulated based on manufacturer specifications. Gas flow rate should be verified using a gas flow meter, and any necessary adjustments made. Good gas coverage is necessary to shield your weld from contamination and results in cleaner, stronger, better looking welds.
## Conclusion
Flux Core Welding Wire is recommended for versatile and strong welding projects, but if you skip on the most common mistakes your results are not going to be that great. With consideration to wire feed speed, polarity, surface preparation, travel angle and speeds as well as your gas flow rate you can improve welding results greatly. Knowing and fixing these 7 most common pitfalls, like; Advantages Over Mig Welding Wire should help provide you with the best welds each time possible when working together with your Flux Core Welding cable.
