11/27/2023 0 Comments Flux core welding settings chart![]() Volume 2 is on Welding Processes and is full of good advice. The 'Welding Handbook' series has good material. Some of these pointers may be mentioned in books of reference available through AWS but will not be addressed by the codes themselves. You may need to concentrate the arc more on the 1/2" material and let it flow into the 1/4" without the arc pointed directly at the 1/4". That is not to say you may have to work on technique a little to make sure you don't get overlap, undercut, lack of fusion, etc. But with the minimal difference you mention it should be fairly easy to run with enough amps to penetrate into the 1/2" without causing problems with the 1/4". Plug welds are definitely the easiest to perform, however. What you will find is that there is a lot more clean-up work to be done after the weld is laid. Then you may run into a problem getting hot enough for the 1" without blowing through the 1/8". Flux core welders tend to produce more pin holes and, what I call, 'booger welds', but they will produce good welds for sheet metal joining and plug welds. With the parameters you have mentioned you are not dealing with a vast material difference such as 1" to 1/8". You may find some guidance from the manufacturer's specifications for the electrode, but overall it will be by experience. Those parameters are set to the application involved. That type of precise settings for volts, amps/wire feed speed is not dealt with in the D1 codes. If this does not remain constant, you will chase your machine settings all day and never figure out what is going on. EDIT BTW, the one thing that MUST remain constant is the ESO(electrical stick out) EDIT#2 In the chart they call it CTWD(contact tip to work distance), this is measured from the end of the contact tip where the wire exits to the work. If the arc burns back up inside the tip, you have one of two situations: Too much voltage for the WFS setting, or too little WFS for the voltage setting. Voltage and WFS(wire feed speed) If the sparks are flying all over and you have spatter the size of the welding wire or larger, you have one of two situations: Too much WFS for the voltage setting, or too little voltage for the WFS setting. There are only two knobs when wire welding that matter. While you are welding, so will be able to see what the puddle needs.more WFS or more voltage. Last Updated on NovemFrank Wilson Senior Editor Flux core welding sometimes referred to as tubular electrode welding, is a technique developed from the MIG welding process. Hi Kung fu, These charts are just starting points/rough settings to get your machine set somewhere fairly close, and then you will most likey have to fine tune the machine. ![]()
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