Flux Core Welding: Getting to the Truth

Like most things in life, Flux Core Welding comes with a bit of a reputation. We see a lot of people hesitant to use this type of welding because of the idea that it’s in an inferior process. We wanted to take a moment today to clear up some of those misunderstandings and to illustrate how viable this technique is for a wide range of welding projects! Let’s dig into Flux Core Welding and learn about how this might just be the perfect type of welding for you!


First, we’d like to talk about splatter. If you’re new to welding and giving Flux Core a try, you may find your weld work creating a lot of undesirable splatter. But before you blame this process, stop and check to see: are you running your machine on DC Positive? There’s your problem. Flux Core welding needs to be run on DC Negative, which is different from most other wire welding processes. This will greatly reduce your splatter (if not completely eliminate it) and create a much smoother, stronger weld!


Before we get into the concerns regarding porosity related to Flux Core welding, it’s a good idea to make sure you store your electrodes properly. The biggest issue related to porosity is created from improper electrode storage, and not the process of welding. But if you’re concerned about porosity and you know your electrodes have been stored well, we urge you to think about the wire you’re using. Every wire thickness has its own recommended distance to weld. If you hold your contact tip too close to your weld, you’re almost guaranteed to get porosity. So how do you make sure you avoid this issue? Study up! Pay attention to the distance requirements with each electrode and make sure you’re following them as you weld!

Do you have more questions about Flux Core Welding? We can answer them! Visit a Sidney Lee Welding Supply location today and we’ll get you set up with all the information and welding supplies you need!