Course Title: Welding
Session Title: Fluxed Cored Arc Welding (FCAW)
Lesson Duration:
1- week
[Lesson length is subjective and will vary from instructor to instructor]
Performance Objective:
To demonstrate Fluxed Cored Arc Welding.
Specific Objectives:
Upon completion of this lesson, the learner will be able to:
1. Upon completion of this lesson, the learner will be able to:
2. Demonstrate proper safety procedures for FCAW.
3. Identify the proper tools and equipment necessary.
4. Set up and troubleshoot equipment
5. Select the proper filler, type of gas, wire, and voltage needed.
6. Weld a pad in at least four positions.
7. Weld a T-joint and Butt-joint with a single-pass.
8. Layout, cut and prepare coupons.
9. Test the coupons.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the activities may result in the elimination of any or all of the TEKS listed .
Welding:

130.323(c)(2)(F)
…demonstrate skills related to health and safety in the workplace, as specified by appropriate government regulations.

130.323(c)(3)(A)(B)(C)(D)(E)(F)(G)(H)(I)(J)(K)(L)(M)(N)(O)(P)(Q)
…demonstrate effective communication skills with individuals from varied cultures such as fellow workers, management, and customers;
…demonstrate mathematical skills to estimate costs;
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…demonstrate technical writing skills related to work orders;
…apply accurate readings of measuring devices, both U.S. customary and metric;
…accurately use an appropriate tool to make measurements;
…compute measurements such as area, surface area, volume, and perimeter;
…determine how changes in dimension affect geometric figures;
…calculate problems using whole numbers, fractions, mixed numbers, and decimals;
…use a calculator to perform computations;
…perform conversions between fractions and decimals;
…understand the functions of angles;
…apply right triangle relationships using the Pythagorean Theorem;
…understand the parts of a circle;
…identify the most reasonable mathematical solution using estimation;
…use cross-sections of three-dimensional figures to relate to plane figures;
…describe orthographic views of three-dimensional figures; and
…describe isometric views of three-dimensional figures.

130.323(c)(4)(A)(B)(C)
…use welding equipment according to safety standards;
…properly dispose of environmentally hazardous materials used in welding; and
…use appropriate personal protective equipment as needed to follow safety measures.

130.323(c)(5)(A)(B)(C)(D)(E)(F)
…demonstrate knowledge of a welding blueprint;
…interpret blueprints, drawings, charts, and diagrams;
…analyze components of the welding symbol;
…analyze types of welding joints;
…analyze positions of welding; and
…identify types of welds such as fillet, groove, spot, plug, and flanged.

130.323(c)(6)(A)(B)(C)(D)
…explore careers in welding;
…work independently to fabricate a welded project with minimal assistance;
…work collaboratively with other students to complete a relevant project; and
…troubleshoot equipment.

130.323(c)(A)(B)
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…evaluate weld inspection processes; and
…analyze welding codes.
Interdisciplinary Correlations:
English:

110.42(6) – Vocabulary Development

110.42(6)(A)(B)
…expand vocabulary through…listening and discussing
…rely on context to determine meanings of words
Instructor/Trainer
References:
American Welding Society (AWS)
Modern Welding (2004)
Welding Principles and Applications (1999)
Instructional Aids:
1. FCAW PowerPoint Presentation
2. FCAW Rubric Handout
Materials Needed:
Sample pieces of flat metal
Sample pieces of various shaped metals
Types of Metals Chart
Standard Metal Shapes Chart
Metal Shapes Test
Metal Types Test
Spark Test record sheet (optional)
Equipment Needed:
Computer & monitor to support PowerPoint
Safety equipment
FCAW Equipment (min. amperage of 200-400 constant voltage).
Continuous electrode wire
Electrode feed unit
Learner
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The student should provide writing instrument and paper for note-taking.
Introduction
Introduction (LSI Quadrant I):
In the industry of welding, there are many different types of materials joined together. The school welding shop is far more limited in the types of materials, but it is necessary to know the most commonly used metals in the field of welding. Knowledge of the materials will help you make better choices concerning filler metals and uses of the fabrication.
One of the types of welding that you should know it FCAW.
Outline
Outline (LSI Quadrant II):
Introduction
T
Introduction
List the objectives on the board.
Show the PowerPoint.
I. Safety Terms i. NEMA- National Electrical
Manufacturer’s Association ii. Contaminants- Impurities formed from chemical reactions. iii. Toxic hazards- Fumes, vapors, and poisonous gases produced in the welding process. iv. Oxygen displacement- Welding often reduces the amount of oxygen around the area being welded. v. Duty cycle- 10 minute break to avoid
overheating the welding machine. vi. Safety lens-
1. Nonferrous
Instructor Notes:
The PowerPoint presentation should be shown after
Introduction
This lesson may be prefaced by the lesson on basic metals.
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2. Ferrous
II. FCAW Terms i. FCAW- The weld is completed by the
feed of the electrode through the weld joint, at a controlled rate. ii. Automatic- Process where mechanical devices control the welding iii. Semiautomatic- The welder controls the process. iv. WFS- Wire Feed Speed. v. ESO- Electrode stickout. vi. Dual-shielded- A shielding gas is
used with the flux-core electrode for
double protection. vii. Self-shielded- When the arc is made, the electrode is released that protects the weld zone from contaminants.
III. Why use FCAW?
IV. Pass out and explain rubric.
V. Preparing to weld i. Preparations ii. Guidelines iii. Safety iv. Set up wire feeder v. Semiautomatic/automatic
VI. Students practice FCAW welding with instructor guidance.
VII. Independent practice.
VIII. Review and check for mastery.
IX. Students perform layout, cut, and prepare coupons and are tested on them (see rubric).
X. Breakdown and Cleanup.
The instructor should use
Whichever process fits in to their lab.
This is a sample rubric and the individual instructor may wish to emphasize other skills for higher points
Students should understand that this is still part of the process.
Application
Guided Practice (LSI Quadrant III):
The teacher will demonstrate safety, set up, and weld. A student may or may not
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be used to demonstrate if they are advanced.
Independent Practice (LSI Quadrant III):
1. Safety setup (students must be checked off on safety)
2. Equipment setup.
3. Students practice weld. Instructor goes around and checks for understanding and safety.
Summary
Review (LSI Quadrants I and IV):
Check for mastery/understanding by orally reviewing the students on the information. Answer any questions the class may have. Ask individual students identify stages of the process.
Evaluation
Informal Assessment (LSI Quadrant III):
Instructor should monitor student understanding throughout the lesson. If further explanation is needed on a given topic, instructor should elaborate or re-teach that portion of the lesson. Check for general mastery level of each student during review time.
Formal Assessment (LSI Quadrant III, IV):
Mastery of at least 70% on the rubric.
Extension/Enrichment (LSI Quadrant IV):
For those students who need remediation, a re-teach and review session will reinforce the topics of concern. The remediation will need to be tailored to the individual needs of the student.
Students can use this lesson to prepare for SkillsUSA competition.
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Name:__________________________
1. True or False In FCAW the weld is completed by the feed of the electrode through the weld joint, at a controlled rate.
2. True or False The ESO is a Wire Feed Speed.
3. True or False One of our goals for this lesson was to weld a pad in at least 3 positions
4. True or False Testing coupons was not part of this lesson.
5. True or False Safety is not important in FCAW because you don’t use a welding instrument.
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Key
Name:__________________________
1. True or False In FCAW the weld is completed by the feed of the electrode through the weld joint, at a controlled rate.
2. True or The ESO is a Wire Feed Speed.
3. True or One of our goals for this lesson was to weld a pad in at least 3 positions
4. True or Testing coupons was not part of this lesson.
5. True or Safety is not important in FCAW because you don’t use a welding instrument.
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