The Main Differences Between FCAW (flux-cored arc welding) and GMAW (Gas metal arc welding) (MIG/MAG)
FCAW (Flux-cored arc welding)
The FCAW process is favoured for ferrous metals as it requires little-to-no pre-cleaning. In some cases, FCAW can use shielding gas on top of the primary shielding flux to further protect the weld pool from oxidation. Dual-shielded FCAW offers more consistent mechanical properties and higher deposition rates than solid wire or stick electrodes.
FCAW welding uses a flux-cored electrode that emits a protective shielding layer as it is deposited into the weld pool. FCAW emits toxic fumes from the flux which blocks the weld area from contaminants. As a result, the FCAW process is an efficient way to weld metals while protecting the weld area from oxidation and other contaminants.
GMAW (Gas metal arc welding)
GMAW (MIG/MAG welding) uses a solid wire electrode along with external shielding gas to prevent contamination of the weld metal. This gas also protects the weld pool from atmospheric contamination. In terms of advantages, GMAW leaves less weld spatter than FCAW and offers more versatility to weld a wide variety of metals. It is also cleaner and can be used in confined spaces. However, GMAW does have some disadvantages. One is that it offers less penetration than FCAW. In addition, it has a bigger electrode wire (2 – 5 mm) which can be difficult to handle, compared to the smaller FCAW wire (0.9 – 3.2 mm). Despite these drawbacks, GMAW is still a popular welding method due to its many advantages.