Instructions for Flux Core Welding

Put on proper safety gear and remove fire hazards from the area. Safety is an important consideration before beginning any welding project. It is important to protect your skin and eyes during the welding process. Be sure you have safety glasses, flame-resistant clothing, welding gloves, helmet and steel-toe leather boots. You can purchase leather clothing and safety gear from a welding supplier.

Prepare the metal. Use a steel brush or grinder to clean the rust and grime from the base metal. Flux core welding is known for being tolerant of contaminated surfaces, but too much contamination could compromise the weld.

Prepare your equipment. Make sure your cables are in good condition and attached tightly to the welder. Set your electrode to straight polarity, or DC electrode negative. Set the drive rolls, double-check the wire tension, and inspect the tips, liners, and any rusty wires.

Determine the proper voltage and amperage based on metal thickness, joint configuration, wire diameter and position. There should be a reference chart available on the power source. Fine-tune the settings based on test welds.

Draw approximately three-quarters of an inch of wire from the tip.

Drag or pull the welding gun away from the completed weld. Maintain a perpendicular position with the weld joint.

Remove the slag with a steel wire brush, slag hammer or angle grinder.