14 Welding Technology and Design

Narrow gap welding in thick plates will reduce the weld metal deposit and
welding time. NGW can be successfully carried out by SAW (as well as the MIG/
CO2) process. With the SAW process good shape welds without spatter can be
obtained. However, slag removal between passes, visual inspection of each
individual pass may become problems. In MIG/CO2 process of NGW, arc stability,
effective gas shielding and the effect of magnetic fields on the arc may cause
problems. Narrow gap welding is best suited for circumferential joints of pressure
vessels. The gap width can range from 15 mm to 22 mm, and suitable electrodes
for 3.2 mm to 5 mm dia are to be used. Wall preparation and joint fit-up require
high level of accuracy.
Flux cored arc welding (FCAW)
It is somewhat like submerged arc and shielded metal arc welding, except that the
flux is encased in a metal sheath instead of being laid over the wire. The weld
metal is shielded by the metal flux and by a gaseous medium, either being externally
supplied or evolved from flux. Some cored wires have been designed for all position
welding, but the weld puddle is still somewhat difficult to control, specially in the
overhead position. Carbon steel and stainless steel flux cored wires are available.
A schematic diagram of flux cored wire welding process is shown in Fig. 1.8.

Fig. 1.8 Flux cored wire welding (Courtesy: The procedure Hand Book of Arc Welding @
The Lincoln Electric Co., Cleveland, USA, 1973).

Since the flux is in the core of the electrode wire itself, it helps in mechanisation
of the welding process by introducing continuous wire feed. The flux coated
electrode on the other hand fails in a situation where reeling or coiling of the wire
is done. This is the major constraint in using covered electrodes in shapes of stick
form.
The functions of the flux are the same as in MMA welding, i.e., it provides the
shielding gas through chemical decomposition, acts as deoxidiser or scavenger to
produce sound weld metal, forms a slag which will float on the molten weld metal