Analysis of fumes emitted during hard facing of FCAW wires

Flux Cored Arc Welding (FCAW) wires are widely used for hard facing as they provide high deposition efficiency, wear resistance and faster speed rates than the solid wire used in Gas Metal Arc Welding process. Flux Cored Arc Welding process employs cored electrodes which contain the fluxing agents, metal powder, deoxidizers and Ferro alloys which contribute the fume emissions during the welding operation. The flux ingredients used vary based on the applications. An open-arc FCAW wire developed for high temperature wear resistance applications comprise borides, carbides of iron based alloy system. A high level of smoke is generated during welding with this wire which reduces the weld pool visibility. The research work is carried out to reduce the emission of fumes up to 70-80% (from present fume emission level) without affecting composition and wear behaviour of the alloy thereby making the wire environmental friendly.