PREPARED BY Eng.UPUL EKANAYAKE-Certified Welding Inspector-AWS-CWI, CSWIP 3.1
Copyright Reserved
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Theory Plan for FCAW Programme-Prepared by Eng.Upul Ekanayake
Certified Welding Inspector CWI-AWS, CSWIP 3.1
Serial Period
No
hrs
1
2
3
4
2
2
2
2
Total
no of
hrs
Lesson topic
2
Electrical Principles FCAW welding machines,
Welding power source - wire feeder - protective gas supply / welding torch - mains connection - maintenance of the devices
4
Setting the parameters on the machine for FCAW both Gas and
flux cored, types of arc- setting gas flow rate
Influence of voltage, current – DCEP/DCEN, wire feed speed,
torch holder — contact tip spacing — arc types (Mode); Gas flow
rate
6
Avoiding dis-continuities caused by welding techniques, errors
and faults - Causes of pores, lack of fusion, wagon tracks, weld
craters, over lapping, cracks, etc. and faults around the wire feed
device, gas and other flux cored welding torch
8
wire electrodes, protective gases
Properties of the steels, influence of the welding heat —
suitability of the steels for welding — wire electrodes AWS 5.20,
(AWS EXXT-1 ....) — shielding gases specified CO2 or not—
shielding gas supply flow.
Accidents, safety and Loss Prevention
Personal protective equipment ~ Handling techniques of gases
— Dangers from electricity, radiation, splashes, gases, vapours,
smoke ~ Fire and explosion prevention — First aid
5
2
10
6
2
12
AWS – WPS ,Drawings interpretation and measurements.
Weld joints symbols, joint preparation
fixtures and positioners
PREPARED BY Eng.UPUL EKANAYAKE-Certified Welding Inspector-AWS-CWI, CSWIP 3.1
Copyright Reserved
pre heating and post heating.
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FCAW Practical plan
*** Note:- this practical plan is scheduled to non-experienced in MIG/MAG
personnel
Se
no
1
Period Total
hrs
hrs
2
2
Exercise task
2
12
16
Setting exercises for build-up
welding with different types of
arc systems constant –
voltage/current
3
4
20
Flame cutting
Work piece preparation.
(Removal of all Dirt, oil, grease,
corrosion around Joint area)
40
60
Wire
Electrode
diameter
In mm
Introduction to the handling of
the devices for Gas Shielded Flux
cored electrode, and SelfShielded Flux Cored Electrode.
Work piece preparation.
(Removal of all Dirt, oil, grease,
corrosion around Joint area)
4
Welding
Position
Workpiec
e
thickness
In mm
Flat,
up,
8 to12
Vertical
up
10…12
Metal production tasks
I-profile and base plate
FCAW spot welding)
Selected
tasks
Select
specialist knowledge
Selected
tasks
Tack weld back plate
0.8 to 2.4
0.8 to 1.2
Welding of V-Groove on Sheet
metal with back
5
6
12
8
72
80
Weld checked for continuity,
evenness, quality and
completeness.
Select
Select
Select
PREPARED BY Eng.UPUL EKANAYAKE-Certified Welding Inspector-AWS-CWI, CSWIP 3.1
Copyright Reserved
Visual and NDT test, no lack of
fusion, undercuts, pores and
cracks, slag inclusions, end crater
etc.
(Root pass, hot pass, capping
Defects and causes)
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