FCAW Course details

Purpose: Provides welder training in Flux-Cored Arc Welding (FCAW), delivered by a CWI, in 4-hour blocks (up to 8 hours/day) for industries like construction, shipbuilding, fabrication, repair shops, facility maintenance, etc.

Duration: Short courses (e.g., 1-4 days, ~8-32 hours) or part of welding programs.

Target Audience: Businesses or professionals seeking FCAW skills and/or certification for production welding, metal fabrication, and precision welding competencies.

Key Learning Objectives

1. Understanding FCAW:

   • Learn FCAW basics: semi-automatic/automatic process with flux-cored tubular electrode and constant-voltage/current power supply.

   • Differentiate self-shielded (FCAW-S) vs. gas-shielded (FCAW-G, e.g., 75% Argon/25% CO2) methods.

   • Explore applications for mild steel, stainless steel, and thick materials in outdoor settings.

2. Equipment and Setup:

   • Master FCAW equipment: power source, wire feeder, welding gun, ground clamp, and shielding gas systems.

   • Select wires (e.g., E71T-11, .030-.045-inch) and adjust voltage, wire feed speed, and travel speed.

3. Welding Techniques:

   • Perform fillet/groove welds in all positions (flat, horizontal, vertical, overhead).

   • Practice drag/pull techniques (15-45° angle, 3/4-inch stickout) for penetration and quality.

4. Safety and PPE:

   • Use PPE (helmets, gloves, leather jackets, steel-toe boots, glasses) to protect against UV, sparks, and burns.

   • Manage fume/smoke and fire hazards per safety protocols.

5. Weld Quality and Inspection:

   • Achieve welds meeting Structural Steel Codes, guided by CWI expertise.

   • Address defects (porosity, slag inclusion, incomplete fusion, melted contact tips).

   • Practice slag removal and surface cleaning for quality welds.

Course Structure

• Theory: FCAW principles, equipment, settings, and standards, taught by CWI.

• Hands-On: Lab-based welding with CWI feedback on technique and quality.

• Assessments: Weld tests and evaluations per criteria.

Prerequisites

• Basic welding knowledge or introductory safety training.

• Minimum age (e.g., 18) and physical ability to weld.

Outcomes

• Skills Gained: FCAW proficiency for production welding and quality welds.

• Certifications: Prepares for code certification testing.

• Career Paths: Roles in structural welding, fabrication, or repair.

Advantages

• CWI-led training ensures industry-standard FCAW skills.

• Suits outdoor/thick material welding with high deposition rates.

Challenges Covered

• Managing fume/smoke in welding environments.

• Ensuring proper slag removal and weld cleanup.

• Troubleshooting FCAW issues (e.g., wire feed, porosity).

Note: Contact Marc Conner for course scheduling.