Compared flux core to stick on a 2 inch thick flange repair last week

I had to weld up a cracked flange on a boiler drum in St. Louis and decided to try flux core instead of my usual stick rods. The flux core laid down cleaner beads and I didn't have to chip slag as much between passes, which saved me about 30 minutes on a 4 hour job. Has anyone else made the switch for heavy plate work? What's your go-to process for thick repairs?

3 comments

3 Comments

the_piper6d ago

Honestly, flux core is the way to go for heavy plate in my book too. I had a similar job on a pressure vessel flange a few months back, and switching from stick saved me a ton of time on slag clean up between passes. The puddle control feels a lot smoother to me, especially when you're fighting wind or drafts in a boiler room. Plus the deposition rate is just better for filling in those thick joints without too many stops and starts. Tbh I don't see myself going back to stick for that kind of work unless there's no other option.

leo_black765d ago

Gotta say, @the_piper, I think you're mixing up flux core and dual shield a bit there. Flux core wire is gasless, right? It's designed for outdoor work where you can't shield with gas. What you're describing with smoother puddle control and better deposition on heavy plate sounds more like dual shield flux core, which uses gas. I've run both, and dual shield is way better for thick stuff like pressure vessel flanges. Gasless flux core is more for windy jobs where you can't keep a gas shield going. Just wanted to clear that up, no offense meant.

shane_clark17h ago

Good point @the_piper, I used to think stick was the only way for heavy stuff but this makes me reconsider.