FCAW (Flux Cored Arc Welding) /MIG (Metal Inert Gas) / CO2


MIg Harfacing	Hardbanding

Flux-cored arc welding (FCAW) is a common arc welding process. FCAW requires a continuously fed consumable tubular electrode containing a flux and a constant voltage or, less commonly, a constant current welding power supply. The use of an externally supplied shielding gas is optional creating the primary process variation: * FCAW-S (self-shielded or “open-arc”)* FCAW-G (gas-shielded).

MIG (Metal Inert Gas Welding) is a common arc welding process. MIG require continuously fed wire electrode in wire form & constant voltage supply. It requires an externally supplied shielding gas.

Hardfacing / Cladding
Metal parts often fail their intended use not because they fracture, but because they wear, which causes them to lose dimension and functionality. Hardfacing, also known as hard surfacing, is the application of buildup or wear-resistant weld metal to part’s surface by means of welding or joining.

Benefits of Hardfacing / Cladding

Reduces Cost: Restoring a worn part to “as new” condition generally cost between 20-70% of a brand new replacement part.
Prolongs Equipment Life: Service life increases of 3 to 10 times are common with properly overlaid parts.
Reduces Downtime: Parts last longer and fewer shutdowns are required.
Less Spare Parts Inventory: There is no need to keep numerous spare parts when worn parts can be rebuilt.

What base metals can be hardfaced?

Carbon and low-alloy steels with carbon contents of less than 1 percent can be hardfaced. High-carbon alloys may require a special buffer layer.
The following base metals can be hardfaced: Stainless steels, Manganese steels, Cast iron, and steels, Nickel-base alloys Copper-base alloys

Deposition Rate of different welding processes

Procedure	Deposition Rate (lbs./hr.)
FCAW	8 to 25
PTA	5 to 20
GMAW	5 to 12
SMAW	3 to 5
SAW	8 to 25
GTAW	3 to 5
OFW	5 to 10

Mig Hardfacing

Note: It can be seen that FCAW has highest deposition rate among all common processes.

Common Materials Used in Hardfacing / Cladding

Hardfacing are good for substrate materials that are suitable for welding, such as low-carbon steel. The most common hardfacing materials are nickel alloys and iron / chromium alloys used in wear resistance and high stress abrasion. Common materials for hardfacing are listed as follows:

Metal Alloy	Purpose
Cobalt-base alloy	wear and corrosion resistance
Copper-base alloys	rebuilding worn machinery parts
Iron chromium alloys	high stress abrasion
Manganese steel	wear application
Nickel-base alloys	Metal-to-metal wear resistance
Tool steel	tooling, wear application
Tungsten carbide	high stress abrasion

Applications:

FCAW/MIG is used for all Overlaying, Hardfacing & Cladding applications.
Typical application area of the FCAW/MIG technology are extruding machine screws, valves, valve seats of internal combustion engines (motorcar, marine, locomotive etc.), accessories for ships, petroleum chemistry and power generation, cutting tools (milling cutters, broachers, knifes), Equipment for mining, crushing, rolling, road building and tunneling, Process equipment in ceramics and cement production, Molding and forging dies, Pulp and paper industry equipment, Agricultural equipment, parts for nuclear plants, parts for chemical plant.

Advantages of FCAW

It is a process which can be very easily automated to the highest degree, as compare to any other welding process.
Deposition efficiency & deposition speed is very high.
It has got very high electrical efficiency (low heat input)
FCAW used spray transfer for deposition of metal to job.
All the above results in a very low deformation in the job.
It is possible to add alloys through the core (flux) to give the final desire composition.
It is possible to work on site / outdoors.

Model	250	300	400	500	600
Input Volts	380-440, 3Ø, 50Hz	380-440, 3Ø, 50Hz	380-440, 3Ø, 50Hz	380-440, 3Ø, 50Hz	380-440, 3Ø, 50Hz
Output Rating	250A	300A	400A	500A	650A
OCV	18-44V	18-44V	18-52V	18-56V	18-60V
Duty cycle	70%	70%	70%	70%	70%
KVA	10	14	18	24	24
Cooling	Forced Air	Forced Air	Forced Air	Forced Air	Forced Air
Insulation Class	H	H	H	H	H
Permissible Wire O in mm	0.8-1.2	0.8-1.2	0.8-1.6	0.8-1.6	0.8-2.4
Overall Dimension (approx) in mm
Length mm	685	685	685	740	740
Width mm	590	590	590	640	640
Height mm	930	930	930	1030	1030
Weight (Kg)	190	205	230	300	325