AWS Flux-Cored Arc Welding (FCAW) 2

Question 1

What is the primary difference between FCAW-G and FCAW-S?

Accepted Answer

FCAW-G uses external shielding gas; FCAW-S is self-shielded via flux in the core

Answer

FCAW-G (gas-shielded) requires an external shielding gas like CO2 or Ar/CO2 mix, while FCAW-S (self-shielded) generates its own shielding from the flux core — no external gas needed.

Question 2

Which AWS electrode classification is used for a flux-cored wire suitable for all-position welding with CO2 shielding gas?

Accepted Answer

E71T-1C

Answer

E71T-1C: E=electrode, 7=70 ksi tensile, 1=all-position, T=tubular (flux-cored), 1=usability designation, C=CO2 shielding gas.

Question 3

Excessive wire extension (stick-out) in FCAW will typically cause:

Accepted Answer

Reduced current, lower heat input, and incomplete fusion

Answer

Excessive CTWD (Contact Tip to Work Distance / stick-out) increases resistance in the wire, which reduces current, lowers heat input, and can lead to incomplete fusion or cold lap.

Question 4

Porosity in FCAW welds is most commonly caused by:

Accepted Answer

Contamination (moisture, rust, oil) or shielding gas disruption

Answer

Porosity results from gas trapped in the weld pool. Sources include moisture on the base metal or wire, oil/rust contamination, insufficient gas coverage, or wind disturbing the gas shield.

Question 5

In FCAW, the work angle for a horizontal fillet weld is typically:

Accepted Answer

45 degrees (bisecting the joint angle)

Answer

For a horizontal fillet weld, the electrode is typically held at 45 degrees (bisecting the angle between horizontal and vertical members), directing the arc into the root of the joint.

AWS Practice Test

AWS Practice Test

AWS Flux-Cored Arc Welding (FCAW) 2