Flux-Cored Welding Basics: Tips for Flux-Cored Welding

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Learn some welding basics on self-shielded flux-cored welding. Because this welding process does not require any shielding gas, it's the ideal wire welding process for use outdoors and for working with dirty metal. Miller® technician Joel Ort shares his tips for equipment setup and techniques that cover flat joints, lap joints, T joints, horizontal, vertical and overhead configurations.
To read more on flux-cored welding, visit www.millerwelds.com/resources...
Chapters:
0:00 What is flux-cored welding?
0:57 Material and equipment preparation for flux-cored welding
2:04 Flux-cored welding flat joints
2:49 Flux-cored welding t-joints
3:11 Flux-cored welding lap joints
3:30 Flux-cored welding horizontal joints
3:47 Flux-cored welding vertical joints
4:19 Flux-cored welding over-head joints
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6 авг 2024

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Комментарии : 316

@Z33Garage 10 лет назад

My left ear enjoyed this tutorial

@60Wattube 10 лет назад

I listened a 2nd time with the head phones on backwards. So the right ear could confirm what the left heard. :-)

@Z71Ranger 10 лет назад

James A Watt Thanks I will try that next time....

@chicken_permission 8 лет назад

this is just the best comment.

@Joebunkyss1 8 лет назад

+Thank Jesus For Romania why not spite your face completley.

@doggonemess1 4 года назад

Thanks so much for this video. I was having trouble getting good welds with my flux core welder and didn't realize that the techniques were different from MIG. This is a great help!

@chillyspoon 7 лет назад

Excellent video from a guy who knows what he's doing and can explain it in simple terms.

@MrRainbowrooster 9 лет назад

Thank You for taking the time to make this video. Guys like me appreciate it as I have many welding needs around my place and can't afford a welder's time. With this video, I am far less intimidated with the thought of trying it out. I came across about 100 pounds of welding wire in an estate sale. Now, I know what to do with it. Thanks again.

@anonymousproactivist1756 5 лет назад

A lot more than just wire. Wire size, flux core or hard wire, is it for stainless steel etc. Hope that worked out for you 3 years ago because eelders arent cheap & paying a welder is a waste of money when someone myself works in a burn shop 9 hours a day 5 days a week lol

@Kawaiiization 12 лет назад

I guess this is the best type of welding so efficient yet still easy to use

@MillerWelders 11 лет назад

We do recommend Flux Core shields. We offer them for our line of MIG guns. This lengthens the life of your nozzle so it’s not full of spatter when you want to weld with shielding gas. Your nearest Miller distributor should have them.

@marshall621 9 лет назад

one of the better flux core clips on here. thanks!

@soap498 11 лет назад

nice clear instructions for an experienced mig welder like myself, just about to use flux cored for the first time

@mccunecp 12 лет назад

I never thought to weld with out the peice that covers the tip I can see it works pretty good in this video.

@SavageMedic 9 лет назад

Holy cow, I've been welding as a hobby on and off since I was in high school (about 4 years ago) and never new you were supposed to pull the weld with flux cored. I always ran mine like a conventional MIG welder. Thanks for the tips, time to go fabricate!

@drdremd 9 лет назад

If it's got slag you have got to drag.

@soldozer 9 лет назад

Slag = drag. Thats welding 101.

@bmspilot4345 12 лет назад

Great video! Thank you for posting. Made up my mind on the welder I want to learn on for outdoor use. Shows very good welds. Thanks again!

@strongfp 7 лет назад

Worked in a rail freight car manufacturing plant for three years. They had flux core, but it was also with combination with argon and CO2, the wire used was called XL-71, that stuff was amazing, so easy to weld in pretty much any position for thicknesses over 1/8 inch. If you get your hands on that stuff, go nuts on structural welding.

@leonardpearlman4017 3 года назад

Gas shielded flux-core is a slightly different and much nicer thing. I think the self-shielded action we see here is something you use when there's no choice (such as being outside or otherwise in a breeze). I'm just learning to do it now. It's nasty! I think it's really the thing for heavy structural which is not what I'm doing. Some applications are for six or eight hundred amps! I have some dual-shield stainless which I really like, and the ESAB dual shield also. As Jody said about something else: "They make you seem better than you are"! Innershield action is NOT like that. It makes you seem like you're making a big mess!

@mrlewish 12 лет назад

Thank you for being one of the few welding videos showing welding being done SAFELY.

@warriorcycles1569 10 лет назад

nice vid good job at exsplaining the wind outside and the gasyus sheild

@MillerWelders 12 лет назад

And regarding the gun angle, we use the old saying "if there's slag, you drag!" Because this process produces slag, we want to pull the gun instead of pushing to avoid creating slag inclusions.

@brianworley7705 3 года назад

I am doing the drag most of the time. Even then I am getting lots of slag inclusions and uneven metal deposits. Surface is ground clean, so what am I overlooking? Related question, my chipping hammer tip rounds over very easily on both the pointed and flat ends. Ground it a couple of times. Thought maybe the specific one I bought didn't get heat treated correctly so bought a replacement. Doing the same thing. Do all chipping hammers round over or did I just end up with a low quality hammer?

@zachshiray8998 3 года назад

@@brianworley7705 did you reverse the polarity of your machine like he said?

@brianworley7705 3 года назад

@@zachshiray8998 Yes, when I changed from mig wire to flux core wire, I changed the polarity according to the diagram on the inside of my welder cover. I double checked it later thinking maybe I had done something wrong, all appears good. I don't know if I need more practice. I have observed the gun/tip angle seems to change a decent weld to splattering. So maye that is how I am getting slag inclusions?

@giangmelinh 3 года назад

*Some industrial machines are just amaizing*

@Ibragallthetime 12 лет назад

One of the best vids online for welding tips!

@pcofranc 11 лет назад

I have been using a friends welder with flux core wire. I never used flux core so I didn't realized that knurled wheels are needed. I was getting ready to replace the liner because of the feed problems, now I know I need to get the correct wheels. Thanks.

@briandbeaudin9166 5 лет назад

Thanks. A concise but informative video.

@bassturkey 10 лет назад

Joel...thank you for a great video. An experienced welder at work named Al Howie recently explained to me that the gas shield nozzle my welder came with is not good for flux core wire. I'm going to remove it and try again. All I was getting was splatter and blobs of weld. I'm better with stick, so this has been frustrating for me. Thanks to for going into detail on angles, stitches, drags and positions. Deuce? I own a real Deuce. That would be an M35A2C. Peace.

@flash001USA 11 лет назад

Thanks for posting this information on youtube. Videos like this are a great help for people like me that want learn this skill.

@tradesman26 7 лет назад

Watched this last night, took notes. Today I dropped the cover thingy, held at about 1/2", cleaned shlag before second pass and when I stopped and started again, tuned back the pressure on my wire feed, and turned back my feed rate. It was almost like I remembered how to weld, I was like holy shit there's a decent puddle. Any way it helped me so thanks.

@MillerWelders 11 лет назад

When you're not using a shielding gas, all that nozzle does is collect spatter. You have a better view of the arc without it.

@MillerWelders 11 лет назад

Michael - It really depends upon the wire you use. Some dual shield wire is electrode positive (DCEP) and some is electrode negative (DCEN). Be sure to look at the spec on the wire that you’re using

@valveman12 12 лет назад

GR8 Video. Very Clear. Thank you

@lihuacen9673 5 лет назад

Good explanation Thank you for sharing

@gaminawulfsdottir3253 6 лет назад

Excellent video.

@MillerWelders 11 лет назад

Way to pick up on that detail -- glad we could help. Any Miller distributor will have those drive wheels in stock.

@pitbullhi 12 лет назад

Very informative, thanks!

@JohnSmith-ox7xc 4 года назад

Great video, but something I feel that needs clarifying is whether the wire should be touching the work piece before you press the trigger or should you hover it a few mm's away.

@chispajaguar 12 лет назад

Muy bueno , y aun no he usado una maquina que trabaje sin gas y como resalta la seguridad es aun mas resaltable yvalido su video gracias y saludos desde Mexico.

@ARKSYN 5 лет назад

Nothing like recording a mono input as stereo. Big ups recording engineer ;)

@2404Pepe 3 года назад

excellent video!!! thanks so much!!1

@torcan1978 12 лет назад

very helpful and much appreciated

@MillerWelders 11 лет назад

Some flux-core wires do require a shielding gas, but most don't. In most cases we turn to flux core because it's an outdoor or breezy environment where shielding gas simply won't work. Depends on your specific wire and application, though.

@g.pelayo9266 10 лет назад

very helpful clip, thumbs up

@frankmmiii 11 лет назад

Thanks for the informative vid Joel. Hey RotSeele I saw your post and wanted to comment. I saw some other instructional vids and they recommend pulling the bead but don't necessarily say you can't push it. If you watch Joel's video here, when he talks about the vertical weld he says if you "push up" you will get more penetration as opposed to pulling down. Probably the reason your teacher said to push the bead. I'm just starting out in welding myself. I'm a little older than you but just wanted

@eliseocortes0228 8 лет назад

excellent explaination

@juan14964 7 лет назад

very good info

@buenavista814 9 лет назад

Excellent.

@spartikus3 12 лет назад

Great video. Simple explanations for beginners. All the important info was there for me to improve my basic mig skills. I'm trying to weld floor pans in my muscle car and let me tell you, every little tip helps when your lying on your back trying to figure out how to get the weld to puddle properly upside down :) Thanks much for the tutorial.

@homebuiltindoorplane 9 лет назад

Very good thanks

@zac123h 12 лет назад

thank you for the vid

@hlyautey 10 лет назад

You had my interest when I saw the 9N.

@InTheFleshInc 5 лет назад

Good tutorial

@surendrayadav-bu1ug 7 лет назад

very nice

@strongme80 8 лет назад

I wish 'Miller Welders' re-shoots all their welding videos with a proper camera filter so we can see the puddle and the bead being formed not just the ultra violet rays! The explanation does not suffice and it sounds theoretical without practice. So that being said, will stay neutral, no thumbs up or down.

@FixAllFixer62 6 лет назад

Michael Strong that called someone show how 2 but need to thats how u lean not all videos u watch.

@Geeksmithing 5 лет назад

@@FixAllFixer62 lol, what?

@stevefromlondon9175 3 года назад

Hi thank you for a great video & easy to follow I just bought one my welder has a shroud over it is that for the gas I see you have taken yours off thank you for any info Regards Steve UK London

@MillerWelders 3 года назад

Hi Steve, you can leave them on when flux core welding, but they are not needed and will allow you to see the weld better without it.

@OneSquidOneBike 11 лет назад

Going to use my dad's welding machine since he's not at home. Hope this video is enough for me to start welding lol

@MillerWelders 11 лет назад

Also, the use of the appropriate Personal Protective Equipment is required to prevent contact with live electrical parts. As always, to protect yourself and others from injury, you must read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing welding equipment.

@fx451Jockey 12 лет назад

Good vid and info, but that little look at 4:36 LOL. He's thinking, I wonder if they noticed that...

@noonce 4 года назад

LMAO yeah that was hilarious... 8 years later

@jackrichards1863 9 лет назад

About the fastest welding method I've ever used.Low current use compared MAW and about 3 times the travel speed. While not the most attractive result certainly tough and pinpoint positioning of heat.

@joeybell2088 10 лет назад

amazi ng thank you

@MillerWelders 11 лет назад

Certainly, on our our website, go to the Careers section under About Us, there you'll find a list of current openings. Not sure how many of those positions are abroad.

@carterhuston5843 7 лет назад

Nice video thank you for the comment

@jaminova_1969 5 лет назад

Argh! I'm blind! Good video, but perhaps you could use a shaded lens filter for close ups of the arc?

@karlx-1 6 лет назад

Those are some sweet welds. I always seem to have a hard time following the gap/joint to be welded. My welds meander around. Maybe my shade is set too high? I'm paranoid about messing up my eyesight.

@Bob-Sacamano 6 лет назад

I'm in the same position. I set my lens to maximum sensitivity and shading but I can barely see the weld pool.

@joshcormier1 10 лет назад

Yes the same diameter as the filler material. Also used in multi pass grooves with bevels and such

@clydecox2108 5 лет назад

Thanks

@kestrelblue 7 лет назад

thanks from a beginner..

@MillerWelders 12 лет назад

For the self-shielded flux-cored process shown here, it is not necessary to have a nozzle. The arc generates an atmosphere that protects the weld puddle from the outside air, which is why the process is used so widely on outdoor construction applications and is not affected by the air from the fan. You can add an insulator to the front end of the gun, however, if you wish to protect the contact tip.

@exploitmankind 11 лет назад

I am an experienced MIG welder and, in my application, have very little use for TIG and have never attempted flux core. However, I'm trying to get into another steel shop where they do a lot of on-site work and they do mostly flux core. How hard is it going to be for me to learn flux core?

@joshcormier1 10 лет назад

No problem I am a student currently enrolled in a welding program if you have other questions I'll aid you to the best of my knowledge.

@Toerme 12 лет назад

People always say it's completely impossible to weld with flux core and that the welds will look terrible, but I'm amazed of how well they are turning out :O Also, how thin metal is it possible to weld with this method?

@ejavlas1 12 лет назад

what is the difference of self shielded and co2 welding anyways when both of them produce flux or slags to protect the welding pool? and even slight air passes to the area of the welding job produces porosity anyways?

@levi501ish 11 лет назад

Just use the grinder with a steel brush, comes off easily and leaves everything nice and clean.

@lennybaldacchino 4 года назад

i just do a little job now and then on my vehicle, rust panel change, but when i use flux core, the volts changes up and dawn, somehow, i do not understand it, it's a CIG model 155 amps, what tip can i get please here, should i take it to warantee shop, unless u might give us an idea thanks, great work u did i love that work there, thanks many,regards lenny

@MillerWelders 4 года назад

Thank you for reaching out. We recommend giving our service line a call to talk this through with a tech. The number is 920-734-9821. If there’s anything else we can help with, just let us know.

@derpherpp 10 лет назад

Thanks for answering my previous question. Another newbie question is how safe is electric flux corded welder? Let's say I accidentally exposed and touched the piece of metal while welding, would I get electrocuted and die on the spot? Example 100 amp welder. I'm in fl with 90+ degree everyday, so by the time I'm done wearing full protection suit, I'd sweats a lot and it's create moisture which I heard it's not good for welding.

@MillerWelders 10 лет назад

Thanks for the question, t dub. Please consult your owner's manual for a list of safety precautions, including personal protective gear, environmental considerations and best practices for installation and operation. In your manual you will find specific instructions for grounding your equipment, proper handling of electrical components, maintenance and more. Thanks!

@kyletupper7391 9 лет назад

i've held parts with one hand and welded with the other many times and never been shocked.

@uncletim6 8 лет назад

They're great for patching up smaller gauge it's 100 dollars so don't be surprised when you have a few issues

@courtneyculbeck9307 4 года назад

Thank you for the great video. Is it possible to fill small gaps when using flux core wire? Can i spot weld along the gap and then fill in afterwards?

@MillerWelders 4 года назад

Hi Courtney! Thanks for reaching out. We recommend giving our service line a call to talk this through with a tech. The number is 920-734-9821. If there’s anything else we can help with, just let us know.

@RickM1953 12 лет назад

If I convert my AC welder to a DC welder can I still use the Flux Core wire?

@joshcormier1 10 лет назад

also wire contacts the leading edge of the puddle and droplets of metal are added to the weld pool.

@rusky1971 12 лет назад

thank's

@boilersteamengineeringltd9154 11 лет назад

does the wire polarity go back to positive if you are welding gas shielded flux core or do you always recommend wire on negative

@ejavlas1 12 лет назад

right now i'm using a miller mig machine suitcase and i'm doing welding jobs on G.A. metal sheet. but I can't get the proper amperes and voltage to it,is it in the gas flow? before i'm use to using direct co2 for my machine and now i'm only using cylinders or tank. and my wire now is 0.8 mm and before it's 1.4 for shipbuilding. what kind of adjustments should i do?

@userchemical 12 лет назад

@mccunecp the nozzle is for gas, it directs the gas over the weld shielding it from the atmosphere. There is no gas being used in this video.

@mikejames1860 2 года назад

Looking to weld bike frames for my charity I run...tig is so expensive :(. What's my best bet affordably?

@genefoster9114 10 лет назад

Hi Joel, I've noticed that some people take off the gas shield when using flux cored wire. I can see why this is possible because you aren't using a gas. My question is ,'Would this be OK do you think for 'any' torch as I can see how much better you can see your work. Great Vids for green people like me .Thanks a lot.

@MillerWelders 10 лет назад

Gene - Quite often the nozzle is taken off so people don't ruin the nozzle and plug it up with spatter. This way the nozzle is clean if the operator would switch back to solid wire. Also, it is much easier to see.

@genefoster9114 10 лет назад

Thanks for that. I hadn't thought about the amount of flux spatter that would build up in the nozzle.Thanks again..good vids. Gene

@MillerWelders 11 лет назад

The International Electrotechnical Commission (IEC) defines a SELV system and SELV Voltage as an “ electric system in which the voltage cannot exceed the value of extra-low voltage: - under normal conditions and - under single fault conditions, including earth faults in other electric circuits” and; (cont.)

@davidtlatelpa1788 8 лет назад

Recently bought the Millermatic 125 and am having trouble with it. I have installed the flux core and adjusted the polarity as it specifies in the manual. Also I have tried to ground it on varies metals i had available. Everything appears to be in order but when i go to weld, nothing happens. Only the wire feeds but nothing else. What could i be missing? I've looked over the manual several times with no luck.

@MillerWelders 8 лет назад

+David Tlatelpa We recommend that you give our service number a call so that a tech can help you troubleshoot. The number is: 920-734-9821. Let us know if you have any trouble getting through. Thank you.

@kurtminges647 3 года назад

it would be good if you would video your welding thru a welding helmet glass we all could watch the technique...

@foreverwood1963 10 лет назад

I want to learn to weld badly my coworker let me practice with his stick welder, but that is not the simplest thing for a beginner although I did weld what i need to. It was ugly but it held. This flux core welding looks better to me because there's morse control with the hands.

@danymous 11 лет назад

hi, what type of welding machine would you recommend for welding 18-14 gauge of galvanized sheet and pipe? thanks in advance for your advised.

@WILPOLLOCK 8 лет назад

Hi! Thanks for video! Why are only flux core machines set DC positive when everything I've read says you need DC Neg to do flux core properly?

@MillerWelders 8 лет назад

+WIL POLLOCK, thanks for reaching out. Yes, you are correct in saying that you need DC negative to do flux core properly. For flux-cored welding, one would want to change their polarity to electrode negative. This is mentioned at 1:14. Please let us know if you have any further questions. Thank you.

@Joebunkyss1 8 лет назад

+WIL POLLOCK cool flag mix

@TracTech 7 лет назад

Do you still have this welder? Or it died? What is the weak spot of this welder (nozzles,...)?

@ThunderDivine 10 лет назад

It's not that the flux core dont need a shield gas, but the gas is being released within the core of the wire(flux core), so you might want a welder tip for shielding aswell.

@977david 11 лет назад

hello sir, I have a question I want to replace welding electrode welding 70/18 by the flux core 0.45 and my big question is has sufficient strength and penetration I create bridges Quick and steel scaffolding ..... . greetings from mexico thanks

@Follow.Jesus.Christ 10 лет назад

This guy was so nervous

@Thomasuki267 8 лет назад

It looked like the tip was much shorter for the 90 degree weld; is that the case? Other videos suggest 1/4"- 3/8". other than extreme lengths does it really matter? Thanks!

@MillerWelders 8 лет назад

Thanks for your question! The stick out will largely depend on the type of FCAW self-shielded wire and the diameter. This video is using an E71T-11 type wire. The second page of the following document has a parameter table that gives stick out or contact tip to work distance recommendations for each diameter: www.hobartbrothers.com/uploads/pdf/datasheets/Fabshield21B.pdf We hope this helps! Let us know if you have any further questions. Thank you!

@Thomasuki267 8 лет назад

Thanks. I had my first experience with wire feed welding today; had two old lawnmower blades to practice on (likely not ideal since the grass crud prevented arcing at times). Ugly but managed to weld them together solidly.

@wansolve2036 9 лет назад

What was that blue plastic/mylar sheet on the back of the bench? is that purely a light shield or does it also prevent shots of sparks and metal? Where is it avail?

@MillerWelders 9 лет назад

WanSolve, the blue plastic sheet is a weld curtain - it is used for shielding the light from welding and also shields the sparks from flying around your garage or shop. It is available on www.millerwelds.com under accessories. Or, you can visit your local welding distributor for larger pieces to custom make your own. Please let us know if you have any further questions.

@fixt100 12 лет назад

i realize that the shielding cup isnt necessarily needed but why would you expose gun internals to the splatter?

@derpherpp 10 лет назад

How come I don't see ground clip on the metals you were welding

@MillerWelders 10 лет назад

The ground clamp is attached to the ArcStation itself, not the metal. Let us know if you have any other questions.

@MillerWelders 11 лет назад

“AC voltage the r.m.s. value of which does not exceed 50 V or ripple-free DC voltage the value of which does not exceed 120 V, between conductors, or between any conductor and reference earth, in an electric circuit which has galvanic separation from the supplying electric power system by such means as a separate-winding transformer Note 1- Max voltage lower than 50 V AC or 120 V ripple-free DC may be specified in particular requirements, especially when direct contact w/ live parts is allowed.

@FrustratedBaboon 7 лет назад

After reading comments I had my headphones on backwards.

@3358g 7 лет назад

Whaaat no arc shots? What is this 2010?

@ramonjavierdamasdavalos1816 8 лет назад

Porque No USAN La Boquilla en La Antorcha,. ? ,. unque el video es bueno ,.

@zenteno5p 5 лет назад

porque es alambre tubular que trae su propio fundente y no nesecita gas la boquilla se utiliza solo cuando usas alambre solido se llama innershield

@everythingknife8763 8 лет назад

Do you need to clean the slag off at the finish? Will it affect the weld over time or even act as a barrier to the elements? The only reason I can think of to deslag is to inspect the weld.

@MillerWelders 8 лет назад

+Robert Marks You do not need to remove the slag on the final pass or if you are performing a single pass. You would only want to remove the slag for the following: if the weld is to be inspected, if you want to review your weld or if the part you’re welding is to be painted, power coated, etc. If you are just trying to stick 2 pieces of material together and do not care what the weld looks like, and the pieces will not be finished in any way, then no, the slag does not have to be removed. Please let us know if you have any further questions. Thank you.

@everythingknife8763 8 лет назад

Miller Welders Thank you. I was thinking of making a trestle for my wife's garden and I don't care too much about the welds since it's not load bearing except for climbing plants.

@daryld1961 8 лет назад

+Robert Marks always remove the slag and clean your weld. its what a professional would do

@MillerWelders 11 лет назад

Note 2 - The voltage limit should not be exceeded at any load between full load and no-load when the source is a safety isolating transformer. Note 3 - Ripple-free qualifies conventionally an r.m.s. ripple voltage not more than 10 % of the DC component; the maximum peak value does not exceed 140 V for a nominal 120 V ripple-free DC system and 70 V for a nominal 60 V ripple-free DC system. [SOURCE: IEC 61558-1:2005, 3.7.16 MOD]”

@olivierroubieu 7 лет назад

how do you create perfect beads like these? mine look like brail! is it because I'm using the wrong wire, not enough heat, not enough wire, what is it?

@MillerWelders 7 лет назад

Hi, Olivier. We recommend checking out this article for additional tips that you might find helpful: www.millerwelds.com/resources/article-library/flux-cored-welding-the-basics-for-mild-steel

@olivierroubieu 7 лет назад

Thank you

@brendangrumpyweir1905 5 лет назад

I noticed the shroud was taken off the mig torch for the gasless wire. Any particular reason for this ?

@MillerWelders 5 лет назад

Hi Brendan, thank you for the question. The reason people remove the nozzle from the gun when running flux core wire is for better visibility of the weld zone. Thank you.