How you could avoid wire feeding problems in flux cored arc welding?

Over the years, Flux Cored Arc Welding (FCAW) has been established as a proven and trusted method for applications such as structural steel erection, bridge construction, etc. And if you look at all the advantages it offers, then it shouldn’t be a surprise for you. FCAW offers very high deposition rates, fantastic and highly desirable chemical and mechanical properties, and most importantly, the weldability needed for such jobs. Ask any welding company or ask the flux cored wire suppliers and they will tell you that there are few better welding processes for open-air welding jobs. 

But just like it is with everything in life and welding, FCAW too has some challenges of its own. However, Diffusion Engineers, one of the most pre-eminent flux cored wire manufacturers, welding electrodes suppliers, and welding consumables manufacturers and suppliers in India, have come up with a string of ideas to overcome the challenges presented with FCAW. in particular, they have come up with a very practical and easily executable solution to one of the biggest problems in FCAW - ‘wire feeding’. Read on to find out how to execute these ideas, bid adieu to all your wire feeding issues, and improve the quality of your FCAW welds. 

The wire feeding problem and how to resolve it

Wire feed stoppages and wire feed malfunctions are one of the greatest causes of downtime on job sites. The most troublesome and frequently occurring types of wire feeding problems are burnback and birdnesting. Both of these extinguish the welding arc prematurely, which can be the cause of many a weld defect. 

When the wire burns and melts into a ball at the welding tip’s end, you face the menacing problem of burn back. It usually occurs because of 2 reasons - the wire feed speed is extremely slow, and/or if the welding gun is held in extreme proximity to the workpiece. In order to prevent this problem, you must ensure that you use the perfect feed speed for the welding application at hand and maintain a distance of 3.5 cms between the contact tip and the workpiece.

Also, Read - An introduction to welding consumables

Birdnesting is a welding term for a wiring tangle that prevents the wire from being fed. To resolve this problem, or to prevent it from occurring, ensure that you use knurled V-groove or knurled U-groove drive rolls in the wire feeder. As a result of its tubular design, the FCAW wire is very soft. Hence, if you err while choosing the drive roll, the wire could very easily get compressed. Also, setting the drive roll tension accurately could prevent issues such as flattening or tangling of wires. In order to set the ideal wire tension, start by releasing the tension forced on the drive rolls. When you feed the wire into your welding glove’s palm, increase the tension till one-half turn past the wire slippage. 

Also, Read - 3 Handy tips for flux core arc welding

Most other causes of birdnesting pertain to the liners - liner blockages, improper trimming of liners, etc. If you come across a blockage in the liner, replace it as soon as possible, and ensure that you trim the liner as per the manufacturer’s recommendations. Ensure that you are using the ideal liner size in accordance with the welding wire’s diameter and confirm that there are no sharp edges on the liner.

These tips for avoiding wire feeding problems, provided by one of the best flux cored wire manufacturers in India, should help you overcome this problem with minimum fuss. Thank us (and them) later!