Can GMAW replace FCAW?

[Thierry Nguyen]

Flux core welding has deep penetration, nice beads, and less spatter than when welding solid wire. Especially, there is less need to clean up slag splashes.
However, when welding with pulsed MIG welding machines, the spatter of solid wire is equivalent to that of flux-cored wire.
Therefore, I ask the question: In the future, when pulsed MIG welding machines are popular, can solid core wire replace flux core wire? Let's discuss. Thank you!!

 

[Erie Fred]

Multi pass welding with solid wire, you don't need to clean between passes.
Flux core you need to remove the slag between passes.

 

[hotponyshoes]

At the higher ends of the scale then the best process for the job will be chosen regardless of the cost or convenience.

At the lower/hobby end, not likely.

I own pulse migs but I also do a fair bit of welding on farms.
Most of it is odd repairs done with arc rods but if it's a bigger job I might take a small mig welder that will run from a 13a extension lead or old pto generator and run that on fluxcore just to save me dragging a bottle around.

I suppose eventually pulse migs will come down to the same price as a normal mig and as long as you have the option to turn pulse off there would be no reason not to buy one.
But, the price & availability of welding gas will need to drop first and I don't see that happening?
Just search through the threads on this forum and you will find plenty of people using fluxcore. Not always the best option for what they are trying to weld but normally the only option as they don't have room for a gas bottle or cannot justify the cost of one (or more)

 

[denlow60]

Multi pass welding with solid wire, you don't need to clean between passes.
Flux core you need to remove the slag between passes.

and what is salicate that you have to clean before you lay the next layer with massive wire.

 

[denlow60]

Flux core welding has deep penetration, nice beads, and less spatter than when welding solid wire. Especially, there is less need to clean up slag splashes.
However, when welding with pulsed MIG welding machines, the spatter of solid wire is equivalent to that of flux-cored wire.
Therefore, I ask the question: In the future, when pulsed MIG welding machines are popular, can solid core wire replace flux core wire? Let's discuss. Thank you!!

Is this welding with gas or without gas?

 

[hotponyshoes]

Is this welding with gas or without gas?

With the reference to availability of low cost pulse welders I'm presuming he was talking about self-shield/gas-free.
Ie, the little spools of 0.9mm that people run in a Clark welder that they buy from machine mart when the car fails the mot..

There are some industrial applications for that, mainly because you can lay down more weld with it so it can work out cheaper.

Dual-shield/outer-shield is what I would call a specialist application.
The people that I know that are using that have chosen it as it is the most effective process for that job.
They certainly know about pulse welding and have the budget to change equipment if it was a better option.

Sure, In the future, somebody might develop a machine or they will find something with a program/process that suits them better and they will change but, in reference to the op's original question, no. Its not the cost of a pulse welder that is having an influence on them using fluxcore currently.

 

[Erie Fred]

and what is salicate that you have to clean before you lay the next layer with massive wire.

Not a problem.
What do you mean by "Massive wire" anyways ?

 

[denlow60]

Not a problem.
What do you mean by "Massive wire" anyways ?

I mean by "Massive wire" / solid wire.

AWS A5.18/A5.18M - ER70S-3
EN ISO 14341-A - G 42 4 M 2Si

AWS A5.18/A5.18M - ER70S-6
EN ISO 14341-A - G 46 4 M 3Si1 / G 42 3 C 3Si1

 

[denlow60]

With the reference to availability of low cost pulse welders I'm presuming he was talking about self-shield/gas-free.
Ie, the little spools of 0.9mm that people run in a Clark welder that they buy from machine mart when the car fails the mot..

There are some industrial applications for that, mainly because you can lay down more weld with it so it can work out cheaper.

Dual-shield/outer-shield is what I would call a specialist application.
The people that I know that are using that have chosen it as it is the most effective process for that job.
They certainly know about pulse welding and have the budget to change equipment if it was a better option.

Sure, In the future, somebody might develop a machine or they will find something with a program/process that suits them better and they will change but, in reference to the op's original question, no. Its not the cost of a pulse welder that is having an influence on them using fluxcore currently.

Still, I think the type of wire should be mentioned.

OUTERSHIELD (gas shielded)
INNERSHIELD (self-shielded)

With "Massive wire" / solid wire I think you can control your weld pool better, and sheet metal work better under control.

I hope that people who weld with self-shielded wire do not weld indoors in a workshop/garage.