Users Guide

Flux Cored Wires

Q U A L I T Y

A N D

K N O W - H O W

I N

W E L D I N G

Flux cored wires

The use of flux cored wires started already in the
early sixties, so it is not a new process. Today it is
used in shipbuilding, offshoreconstruction and general fabrication.
The development of wires and its production has made the quality of flux cored wires very
high and stable. Since the wire diameters has become smaller, down to 0,8 mm, the field of use
has increased and flux cored wires comes into
more and more types of steel fabrication.
The flux cored wires covers a large variety
of weld metal qualities and boosts the productivity, especially in out of position welding.

Contents
What is a flux cored wire and how is it made .. 4
Different wire types ........................................... 5
How to use a flux cored wire ........................... 6
Classification according to EN 758:1997 E ...... 7
Shielding gas ..................................................... 8
Ceramic backing ............................................... 8
Storage recommendations for FCW .................. 8
The range of mild steel flux cored wires .......... 9
Examples of applications ................................ 10
The stainless flux cored wires ........................ 11
The range of stainless flux cored wires .......... 11
Examples of applications ................................ 12
Corrosion in stainless ..................................... 13
Trouble shooting guide ................................... 14

Photo on page 5 bottom, reproduced by courtesy of

Volvo Articulated Haulers AB.
Photographs on page 13 are reproduced by courtesy of
the Nickel Development Institute.

What is a flux cored wire and

how is it made?
Elga flux cored wire are made from a metal strip
that is first formed to a u shape, filled with a dry
powder mix and further formed into a tube. The
tube is then drawn down to the required wire size.
This production method ensures that the final product is of a constant high quality as well as eliminating the possibility of incomplete powder fill.
Flux cored wires manufactured from metal
strip have the additional benefit of high productivity when compared to wires that are made from
a seamless tube. This is due to the higher current
density of the wire.
Because the flux cored wire is a tube, there
will be physical differences compared to a solid
wire. The current has a much smaller cross section to pass so the current density in a flux cored
wire becomes higher at the same current. This
will result in a productivity advantage for the flux
cored wire, as shown in the diagram.
The penetration also becomes wider and this
gives less risk of getting slag inclusions and lack
of fusion defects. The slag producing wires also
provides good properties in out of position welding at high currents.

Deposition rate per hour

kg/h
7
6

rutile flux cored wire

5
4
3

solid wire

2
1
150

200

seamless type butt type

250

300
Ampere

overlap type

Different wire types

There are three main types of wires as outlined

below:
Rutile flux cored wires
The rutile flux system provides both good weldability and mechanical properties and, with some
wires, excellent impact values at 60C. All of the
Elga rutile flux cored wires are fully positional,
and produce weld metal with less than 5 ml of
hydrogen per 100 g of deposited weld metal.
The new and unique rutile offshore
grade flux cored wire, DWA 55 LSR, is capable of
producing consistently good mechanical properties at 60C, even after multi-cycle stress relieving.
Basic flux cored wires
The basic flux system gives very good weldmetal
quality and good crack resistance in restraint joints,
but the metal transfer in the arc is more globular
than spray and, consequently, the weldability is not
as good as the rutile wires.
The flux/slag system only allows these wires
to be used in the flat and horizontal positions, although it is possible to improve the positional characteristics of these wires by the use of a pulsed
power source.
Metal cored wires
The metal cored wires have no slag forming elements, only metal powder inside. This gives a higher
recovery. The arc is stable and gives very little spatter.
As there is no slag cover these wires have
limited positional applications. The metal cored
wires are very often used in mechanised and robotic applications.

How to use a flux cored wire

Why a parameter box
When using a flux cored wire, we recommend that
you work within a parameter box, this will ensure
the correct welding condition. It is important to
have the right relationship between current and
voltage to determine the right penetration and
minimise spatter.
The arc voltage influences the arc length. If
the arc length is excessive the weld metal will be
contaminated by nitrogen and oxygen picked up
from the surrounding atmosphere, affecting the
mechanical properties.

Recommended parameter range for DWA 50

Volt
40

Electrode stick-out
The stick-out is the distance from the end of the
contact tip to the baseplate, including the arc-length.
This distance should be 1525 mm. It is mainly
for ensuring a proper gas shield of the arc and
weld pool and also to ensure the desired penetration.
Forehand or backhand welding
(push or pull)
Backhand and forehand welding gives different
results. In general backhand welding gives a deeper
penetration and a more convex weld bead. Forehand welding gives a flatter bead but penetration
is decreased.
Too much angle in forehand welding will
result in excessive spatter and loss of penetration.
Too much angle in backhand welding will result
in very convex bead and can also result in snailtrails (trapped shielding gas, under the slagcover).

Stick-out (mm)

Forehand
welding (push)

36

1,4

32
28
24
20

mm

mm
1,6

m
1,2

150 200 250 300 350 400 450

Ampere

Influence of increased volt

Current 230 A
24 V
27 V
31 V

Influence of increased current

Volt 26 V
180 A
220 A
280 A

Influence of increased stick-out

Current 220 A / Volt 23 V
15 mm
25 mm
35 mm

Backhand
welding (pull)

Classification according to EN 758:1997 E

Symbol
M
C
N

Symbol

Shielding gas

Positions

1
2
3
4
5

M2, mix gas acc. to EN 439

C1, carbondioxide acc. to EN 439
No shielding gas

All positions
All positions, except vertical down
Flat butt weld, flat fillet weld, horizontal-vertical fillet weld
Flat butt weld, flat fillet weld
Vertical down and positions according to symbol 3

Symbol

Min. yield strength

N/mm2

Tensile strength
N/mm2

Min. elongation
%

35
38
42
46
50

355
380
420
460
500

440570
470600
500640
530680
560720

22
20
20
20
18

Symbol

Hydrogen content
ml/100 g deposited
metal (max.)

H5
H10
H15

5
10
15

EN 758 T 46 3 1Ni B M 4 H5
Standard number

Tubular cored
electrode

Symbol Temperature for min.

average impact
energy of 47 J
C
Z
A
0
2
3
4
5
6

Symbol
R
P
B
M
V
W
Y
Z

No requirements
+20
0
20
30
40
50
60

Symbol
No symbol
Mo
MnMo
1Ni
1,5Ni
2Ni
3Ni
Mn1Ni
1NiMo
Z

Chemical composition %
Mn
Ni
Mo
2,0

1,4

0,3-0,6
1,4-2,0

0,3-0,6
1,4
0,6-1,2

1,6
1,2-1,8

1,4
1,8-2,6

1,4
2,6-3,8

1,4-2,0
0,6-1,2

1,4
0,6-1,2 0,3-0,6
Any other agreed composition

Characteristics

Types of weld

Shielding gas

Rutile, slow freezing slag

Rutile, fast freezing slag
Basic
Metal powder
Rutile or basic/fluoride
Basic/fluoride, slow freezing slag
Basic/fluoride, fast freezing slag
Other types

Single/multiple pass
Single/multiple pass
Single/multiple pass
Single/multiple pass
Single pass
Single/multiple pass
Single/multiple pass

Required
Required
Required
Required
Not required
Not required
Not required

Shielding gas
The purpose of the shielding gas is to protect the
arc and the molten weldpool from the surrounding atmosphere. The type of shielding gas used
should be in accordance with that recommended
in the catalogue, as should the gasflow. Impact
values of the weld metal are dependent on low
Nitrogen levels, if the gas shield is incorrect then
the Nitrogen pick-up will increase and the values
will decrease.

Ceramic backing

Elga Optimator is a high

performance multi stage regulator.

In most joint types it is possible and even advantageous to use a ceramic backing. In one-sided
welding, both time and money are saved by the
use of backing. There are many different types of
ceramic backing each designed for its own particular joint. The most commonly used types are
shown in the sketches.

Storage recommendations
for FCW
The flux cored wires in the Elga program, DW,
DWA, MX and MXA do not contain any binding
agents or any hygroscopic ingredients, therefore,
the deposited weldmetal will always have a low
hydrogen level. But it is important to protect the
wire from rusting, because rust is hygroscopic.
As long as the wire is unpacked it is well protected, but an opened spool in the wirefeeder should
not be left for a longer time, to protect the surface
from rusting. Unpacked wire should be stored in
a dry place on a pallet, not directly on the floor.

Typical examples of ceramic

backing applications.

The range of mild steel flux cored wires

Product name

Wire type

Shielding gas

Impact value C

Elgacore DW 50

Rutile

C1

20

Elgacore DWA 50

Rutile

M21

20

Elgacore DWA 52F

Rutile

M21

20

Elgacore DW 55E

Rutile

C1

40

Elgacore DWA 55E

Rutile

M21

40

Elgacore DW 55L

Rutile

C1

60

Elgacore DWA 55L

Rutile

M21

60

Elgacore DWA 55LSR *

Rutile

M21

60

Elgacore DW 588

Rutile

C1

Elgacore DWA 51B

Basic

M21

20

Elgacore MXA 100

Metal

M21

20

Elgacore MXA 200

Metal

M21

20

Elgacore MX 200

Metal

C1

+/0

Elgacore MX 100T

Metal

C1+M21

20

Elgacore MXA 55T

Metal

M21

60

* The new rutile wire that can be stress relieved.

Stress relieving at 620C +/10, soak time 2 hrs
Impact energy J

130

DWA 55 LSR

110
90
70
50

As welded

Number of SR treatments on same testpiece

Examples of applications
Pipe 6, 20 mm wall thickness. Position H-L045
Stress relieved at 620C. for 3 h.
Bead

Consumable

Dia.

Amp

Volt

Elgatig 162

2,0

90

15

Elgatig 162

2,0

95

16

DWA 55LSR

1,2

175

23

47

DWA 55LSR

1,2

190

25

810

DWA 55LSR

1,2

175

23

Outer hull of a ship, plate thickness 16 mm,

position PF, single sided welding.
Bead

Consumable

Dia.

Amp

Volt

MX 100T

1,2

105

16

DWA 50

1,2

175

23,5

35

DWA 50

1,2

230

26

67

DWA 50

1,2

205

24,5

Highly restraint butt-joint, plate thickness 12 mm,

position PA, single sided welding with ceramic
backing.
Bead

10

Consumable

Dia.

Amp

Volt

DWA 51B

1,2

230

28

MXA 100

1,2

235

27

35

MXA 100

1,2

265

29

67

MXA 100

1,2

245

28

45

The stainless flux cored wires

Elga have a very comprehensive range of rutile flux
cored wires for the high alloyed materials. Within
each grade of stainless steel wire we have both a
L and a LP type.
The L type is for horisontal position and produce a smooth and well-contoured weld bead.
The LP wires have the same arc characteristics as the L wires but can be used in all positions
due to the fast freezing rutile slag system.

The range of stainless steel flux cored wires

Product name

Wire type

Shielding gas

AWS code

Cromacore DW 308L

Rutile

C1 / M21

E 308LT0-4 / -1

Cromacore DW 308LP

Rutile

C1 / M21

E 308LT1-4 / -1

Cromacore DW 308H

Rutile

C1

E 308HT0-1

Cromacore DW 308LT

Rutile

C1

E 308LT0-1

Cromacore DW 309L

Rutile

C1 / M21

E 309LT0-4 / -1

Cromacore DW 309LP

Rutile

C1 / M21

E 309LT1-4 / -1

Cromacore DW 309MoL

Rutile

C1 / M21

E 309LMoT0-4 / -1

Cromacore DW 316L

Rutile

C1 / M21

E 316LT0-4 / -1

Cromacore DW 316LP

Rutile

C1 / M21

E 316LT1-4 / -1

Cromacore DW 317L

Rutile

C1 / M21

E 317LT0-4 / -1

Cromacore DW 317LP

Rutile

C1 / M21

E 317LT1-4 / -1

Cromacore DW 329A

Rutile

C1 / M21

E 2209T0-4 / -1

Cromacore DW 329AP

Rutile

C1 / M21

E 2209T1-4 / -1

Cromacore DW 347

Rutile

C1 / M21

E 347T0-4 / -1

11

Examples of applications
Cargo tank in chemical carrier, base material
Uranus 45N (duplex), plate thickness 19 mm,
welding position PF.
Bead

Consumable

Dia.

Amp

Volt

DW 329AP

1,2

125

24

DW 329AP

1,2

145

26,5

DW 329AP

1,2

145

26,5

DW 329AP

1,2

130

25

DW 329AP

1,2

145

26,5

DW 329AP

1,2

150

27

Cargo tank in chemical carrier, base material

316 LN, plate thickness 16mm, welding position PF.
Bead

Consumable

Dia.

Amp

Volt

DW 317LP

1,2

145

24

DW 317LP

1,2

185

27

DW 317LP

1,2

185

27

DW 317LP

1,2

170

26,5

Mild steel to 316 LN, ballast tank,

plate thickness 16 mm, welding position PA.

12

Bead

Consumable

Dia.

Amp

Volt

DW 309MoL

1,2

150

25

DW 309MoL

1,2

190

27,5

35

DW 309MoL

1,2

200

28

317LN

Mild steel

Corrosion in stainless

Iron embedded by a carbon steel wire

brush and construction work in the same
area has initiated pitting corrosion on
stainless steel pipe.

Stainless steel is a metal that is resistant to corrosion but nevertheless, it can corrode. This corrosion can take place very quickly and it can cause
great damage. There are many different types of
corrosion that occur with stainless steels, e.g. pitting corrosion, crevice corrosion, deposit attack
corrosion, preferential attack corrosion, intergranular corrosion and stress corrosion.
To avoid these attacks on the steel and around
the welding area, it is important to choose the right
plate material and consumables. In general, the
analysis of the consumable should correspond to
the analyse of the plate. It is important to protect
the plate from welding spatter, grinding dust and
impurities in general.
The welding procedure itself must be carefully done in order to fulfill the mechanical and
metallurgical requirements. Extra considerations
has to be taken to the heat input, gasflow, jointpreparation and bead planning. At Elgas technical centre you can get all the help you need from
our highly qualified Welding Engineers.

Pitting corrosion occured where crayon

markings were made and not later
removed on a stainless steel vessel.

Weld spatter resulted in corrosion; weld

repairs were required after the affected
spots were ground out.

This vessel corroded due to heat

tint (top) and a contaminated
surface that was improperly
cleaned (bottom).

Corrosion initiated because slag

was not completely removed from
around a weld.

13

Trouble shooting guide

Defect
No wire is fed even
when the inching switch
is pushed.

When the torch switch is

ON, the wire is fed but
no arc is generated.

Blowholes are
generated on the
weldbead.

Too much spatter.

Unstable arc.

Undercut.

Overlap.

Fillet weld is
falling down.

Rootrun is cracking in
the middle.
(ceramic backing)

14

Cause

Correction

Motor fuse blow.

Replace with the specified fuse.

Breaking of the control cable or

improper contact.

Check the cable with an instrument.

The governor circuit is defective.

Replace the printed circuit card.

The electromagnetic switch is not ON.

Check coil voltage and if defective

replace it.

The earth cable is not connected.

Connect the earth cable.

The relay for the electromagnetic switch

is not operating.

Replace the relay.

No, or too little shielding gas is fed.

Check and correct the gasflow.

Air is mixed with the shieldinggas.

Check the gas hose and its connections

for leakage.

To large torch angle in backhand

welding.

Reduce the angle.

Welding parameters are incorrect.

Adjust voltage in comparison with the

current.

Too little shieldinggas.

Correct gasflow.

The contact tip is worn out.

Replace with a new tip.

To large innerdia. of the contact tip.

Replace with correct tip.

The liner is clogged with dirt.

Clean the liner or replace.

Wrong welding parameters.

Correct the parameters.

Voltage is too high.

Reduce the voltage.

Welding speed is too high.

Reduce welding speed.

Earth point is not correct.

Move earth point to the start of welding.

Travel speed is too low.

Increase welding speed.

Voltage is too low.

Increase voltage, or reduce current to

get less weldmetal.

Too high parameters.

Reduce voltage and current.

Wrong aiming point.

Move the aiming point.

Travel speed is too low.

Increase the travel speed.

Too high parameters.

Decrease current to below 200A.

Too high welding speed.

Reduce welding speed.

If this does not help change to a basic
wire in the root.

Notes

15