Disadvantages
Of course, all of the usual issues that occur in welding can occur in FCAW such as incomplete fusion between base metals, slag inclusion (non-metallic inclusions), and cracks in the welds. But there are a few concerns that come up with FCAW that are worth taking special note of:
- Melted Contact Tip – happens when the electrode actually contacts the base metal, thereby fusing the two
- Irregular wire feed – typically a mechanical problem
- Porosity – the gases (specifically those from the flux-core) don’t escape the welded area before the metal hardens, leaving holes in the welded metal
- More costly filler material/wire as compared to GMAW
Read more about this topic: Flux-cored Arc Welding