How to Convert a Flux Core to Gas Welding

Metal inert gas welding can be used on thicker pieces of metal than flux welding.

Flux core arc welding (FCAW) uses a metal welding wire that is impregnated with a chemical compound called flux that emits an inert shielding gas when burned to protect the weld from contamination by the air. Most FCAW-capable welding machines can be converted to use a gas metal arc welding (GMAW) technique with a few minor modifications. The GMAW is a metal inert gas (MIG) welding process which uses a fluxless solid metal welding wire and requires that an inert shielding gas be sprayed onto the weld from an external air tank through the welding machine.

Things You'll Need

• FCAW and GMAW-capable welding machine
• MIG welding gun
• Tank of inert shielding gas
• MIG wire
• Wire cutters

Instructions

1. Open the side hatch to the welding machine to access the spool of flux wire. Raise the tensioning arm on the wire roller and wind any excess flux wire back onto the wire spool. Then take the spool of flux core wire off of the spindle.

2. Detach the FCAW welding gun and hose from the front of the welding machine by unplugging its power cable and unscrewing the hose coupling from the bracket.

3. Attach the MIG welding gun and hose by screwing its coupling onto the bracket and plugging in its power cable to the front of the welding machine.

4. Connect the air hose from the MIG welding gun to the regulator on top of the compressed air tank of inert shielding gas by screwing it onto the regulator coupling.

5. Place a roll of MIG wire onto the spindle inside of the welding machine and feed the wire through the tensioning arm and wire rollers until it enters the welding torch hose. Close the access hatch on the side of the welding machine.

6. Open the regulator valve on top of the air tank and turn on the welding machine.

7. Pull the trigger on the MIG welding torch to advance the MIG wire through the hose and out the tip of the welding gun.

8. Trim the MIG wire so that only 1/4 inch of the wire protrudes from the welding gun. The welding machine is now ready to perform gas metal arc welding.

Tips & Warnings

• Read and follow the manufacturer's instructions before using or modifying a welding machine.

References

• Advanced Welding Supply; GMAW (Solid Wire) vs. FCAW (Flux-Cored Wire); Chris Albanese
• Miller Electric; Millermatic 140 Owner's Manual; 2010
• Lincoln Electric; Pro-MIG 175 Operator's Manual; July 2005