Table of Contents
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Functions of Welding Flux
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Use of Flux in Welding Processes
a. SAW – Submerged Arc Welding
b. SMAW – Shielded Metal Arc Welding
c. FCAW – Flux Cored Arc Welding -
Choosing the Right Welding Process
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Conclusion & Call to Action
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Key Takeaways
In welding, flux plays a vital role in protecting the weld zone and enhancing weld quality. But what is flux in welding? In simple terms, flux denotes a mixture of materials, typically carbonate and silicate, used during welding to shield the molten weld pool from atmospheric contamination. The term flux, in the English language, means a continuous flow, and in the context of welding, it refers to a shielding agent that prevents impurities and gases from interfering with the weld.
The key use of flux in welding is to protect the weld metal from contamination by atmospheric gases. This is achieved through the combination of various flux ingredients such as calcium, calcium carbonate, calcium fluoride, magnesium, potassium and manganese oxides, sodium, silica, and aluminium oxide. These components are not just for shielding; they also help in arc stabilisation and enable better control over the mechanical properties of the weld. The use of flux in welding ensures a cleaner, stronger, and more reliable weld joint.
Functions of Welding Flux
Why flux is used in welding goes beyond just shielding. It contributes to both the physical and chemical stability of the weld. Here are its key functions:
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A shielding agent: The welding flux has a lower density than the weld metal. Therefore, while welding, the welding flux melts and floats around the weld and deposits itself. This creates a protective layer that shields the molten pool from atmospheric contamination.
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Prevents oxidation: Upon heating, flux in welding produces gases that push back the atmospheric gases and prevent oxidation as well as any potential reactions that could occur with nitrogen. These gases ensure the weld does not react with harmful elements like oxygen or nitrogen.
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Creates slag for further shielding: The remains of welding flux solidify to create slag, which adds to the protection of the welded area. This slag layer also helps control cooling and improves the weld’s mechanical properties.
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Used as a coating in electrodes: Welding flux is commonly used as a coating in various arc welding processes such as SMAW, SAW, and FCAW. It not only provides shielding but also stabilises the arc, improves weld bead appearance, and simplifies slag removal, making it essential in both manual and automated welding operations.
Each of these functions highlights the importance of flux in welding and reinforces its role in achieving cleaner, stronger, and more reliable welds.
Use of Flux in Welding Processes
Different welding techniques employ flux in welding in unique ways, each tailored for performance and efficiency.
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SAW - Submerged Arc Welding
Submerged Arc Welding (SAW) uses granular SAW flux for shielding. Benefits include:
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Higher deposition rates for faster welding
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Improved mechanical properties of the weld
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Better heat control and deeper penetration
The SAW flux also controls the heat while welding, helping concentrate the heat and enabling deeper weld penetration.
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SMAW - Shielded Metal Arc Welding
SMAW uses solid core wires for its electrode. The welding flux is coated to the bare electrode by a process called extrusion. This flux coating aids in arc striking, arc stability, and slag removal, and ensures:
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Stable arc ignition and control
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Effective slag removal
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Reliable shielding during welding
The welding flux is coated to the bare electrode by a process called extrusion.
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FCAW - Flux Cored Arc Welding
As the name suggests, Flux Cored Arc Welding uses welding flux as a core part of its process. The flux-cored wire contains flux within and is available in two variants:
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Gas-shielded (requires external shielding gas)
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Self-shielded (no external gas needed)
Other variants include low-alloy steel flux wires. FCAW advantages:
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High deposition rates
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Effective in all welding positions
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Stronger and cleaner welds compared to other welding methods
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Ideal for outdoor, windy, or contaminated environments, including materials with scale and rust
The flux-cored wires are further divided into gas-shielded and self-shielded... welding contaminated materials with scale and rust too!
Choosing the Right Welding Process
Selecting the most suitable welding process is crucial for achieving optimal results in terms of strength, efficiency, and weld quality. The decision depends on several key factors:
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Project Scale and Nature: Large-scale industrial projects like pipelines or structural beams may benefit from high-deposition processes such as SAW, while smaller, precision tasks may require SMAW or FCAW.
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Desired Outcomes: If the goal is speed and high productivity, flux-cored welding offers excellent deposition rates. For projects needing an aesthetic finish and minimal spatter, SMAW or TIG may be preferable.
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Welding Positions: Some processes, like FCAW, are versatile and can be used in all positions, flat, vertical, and overhead, making them ideal for complex site work.
Choosing the right welding method requires a balanced consideration of performance expectations and operational conditions. Whether working indoors or outdoors, on clean or contaminated surfaces, there's always a suitable welding technique to meet the challenge.
Welding flux plays a vital role in achieving clean, strong, and reliable welds, whether used in SAW, SMAW, or FCAW processes. From shielding against atmospheric contamination to stabilising the arc and improving mechanical properties, the use of flux in welding is indispensable for professionals across industries.
Never let the materials available be a deciding factor. With the right consumables and process selection, welders can tackle diverse challenges with confidence and consistency.
At D&H Sécheron, we offer a premium selection of welding flux and flux-cored arc welding products tailored for diverse applications. Explore our MAXFLUX range and discover how the right flux can transform your weld qu
ality.
Key Takeaways
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Welding flux shields the molten pool, controls oxidation, and forms slag.
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What is flux in welding? It’s a blend of compounds that improves weld quality.
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Why flux is used in welding: Ensures stronger welds, arc stability, and defect prevention.
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Flux in welding varies by process: SAW, SMAW, and FCAW each apply it differently.
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Choose D&H Sécheron for reliable, high-performance welding flux solutions.
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