Learn the ins and outs of Flux-Cored Arc Welding (FCAW), one of the most versatile and efficient welding methods for both indoor and outdoor projects. This category covers everything from choosing the right flux-cored wire and machine settings to mastering techniques for thick materials, structural work, and repairs. Whether you’re tackling heavy-duty fabrication or looking for a gasless welding solution, our guides and tips will help you get strong, reliable welds with FCAW.
Welding cast iron with flux core can be a real challenge, even for experienced welders. Cast iron doesn’t behave like mild steel — it’s brittle, loaded with carbon, and cracks easily if you don’t treat it right. Many welders crank…
Dialing in the right Flux Core MIG welding settings can be one of the biggest challenges in the shop. You tweak the wire feed speed, adjust the voltage, and still end up with too much spatter, weak penetration, or even…
Learning dual shield flux core welding was a game-changer in the shop. Unlike regular flux core, this process combines flux-cored wire with an external shielding gas, giving welds extra protection and strength. When I first tried it, I realized how…
Welding 22-gauge steel with flux core is one of those jobs that’ll test your patience and your skill. I’ve burned through more thin sheet metal than I care to admit when I first started working on car panels and light-gauge…
There’s nothing more frustrating than running a flux core weld and seeing those annoying little squiggles — the infamous worm tracks — appear across the bead. I used to blame the wire, then the metal, then my technique, until I…
Welding thin metal with flux core can be one of the trickiest jobs in the shop. It’s that moment when you’re trying to run a smooth bead, but the sheet starts to warp, or worse — you blow right through…
Flux core aluminum welding rods are one of those things that had me scratching my head the first time I came across them. Most of us learn early on that aluminum is best handled with TIG for precision or MIG…
Flux core welding can be a bit intimidating for beginners — spatter flying everywhere, uneven beads, and metal burning through when you least expect it. It’s a common struggle, especially when you’re just getting used to how flux core wire…
Welding aluminum with flux core was one of those challenges that caught me off guard in the shop. I was used to running clean beads on stainless with TIG or dialing in MIG for thicker steel, but aluminum is a…
Running flux core welds can sometimes leave behind those frustrating worm tracks — little surface trails that make a bead look messy and weak. Many welders confuse it with poor arc control, but the real issue often comes down to…