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Flux-cored Arc Welding (FCAW) Services

When your fabrication project requires strong, durable, and reliable welds delivered on a tight timeline, Fitchburg Welding Company can achieve outstanding results with flux-cored arc welding.

FCAW is a versatile method commonly used in industrial applications from shipbuilding to bridge construction, and it is suitable for a wide range of materials including carbon steel, stainless steel, cast iron, and high-strength alloys.

Because of its high metal deposition rate, FCAW allows for faster weld speeds and increased productivity—ensuring that we can meet your project’s deadline without sacrificing quality.

The Flux-Cored Arc Welding Process

FCAW uses a consumable electrode in the form of a tubular wire. Rather than a solid wire, it has a hollow center filled with flux. During the welding process, this flux core melts, creating a shielding gas which helps to protect the molten metal against atmospheric contaminants.

In some cases—particularly when welding thin, flat metals—the electrode’s self-shielding is adequate protection, with no external shielding gas needed for further protection. On large projects, this capability can help save time and money.

When an external shielding gas is needed, the source is typically carbon dioxide or a blend of argon and carbon dioxide from a high-pressure gas cylinder, used in conjunction with the flux. This dual shielding can provide a higher-quality weld, especially on thicker metals.

Whether self-shielded or dual-shielded, the flux-cored arc welding process will produce a layer of slag, which also helps protect the weld from oxidation and contaminants. The slag is later removed during the finishing process, leaving the surface smooth.

Our FCAW Welding Equipment

To maximize efficiency and ensure the highest standards of quality are met, we continually invest in cutting-edge FCAW welding equipment. With a lineup of heavy-duty welding machines from Lincoln Electric, Miller, Cobramatic, and Hobart, Fitchburg Welding is capable of handling demanding workloads as well as thick materials.

  • Weld positioners with adjustable height, 135° tilt, 360° rotation, and capacity up to 350,000 lbs.
  • 60,000 lb. turning roll
  • 40,000 lb. turntables
  • Fully automatic 3-axis manipulator / welding cell
  • 60″ x 60″ welding manipulator

A One-Stop Shop for FCAW Welding Services

At Fitchburg Welding, flux-cored arc welding is only one of our comprehensive capabilities. Before welding, we cut and bevel your material and assemble all parts. After welding, we perform stress relief treatments to produce stronger joints, and magnetic particle testing and other nondestructive testing methods are used to ensure welds are free of internal voids. Shotblasting is used to remove rust and prep the surface for painting, and finally, we apply paint or coatings to your specifications. Fitchburg Welding is ISO 9001 certified for welding and fabrication services.