What is dual shield welding? Setting, Setup, Tips & Advantages

Welding has become an integral part of every little manufacturing business, including metal, nuts, and bolts. Electric arc welding is similar to the dual shield welding as it is the basic phenomenon in double shield welding.

Why do we call it the dual shield welding?

This name knows the dual shield welding in the general public, but it is the flux core arc welding for a welder. The reason to name it the dual shield welding is the double layers of shielding are provided during the welding process.

The dual shielding uses two types of also to protect the arc from the environment. It is important to protect the electric arc from the environment to conduct a smooth welding process; the outer gases can cause serious distractions in the welding process.

In shielding welding, two things are involved in the building up the slag; the first one is the metal of the wedding wire, it works as slag for the metal and adds the needed amount of alloy element for the metal.

The second main thing in the dual shield metal welding is the gases; these gases are responsible for covering the metal from the external atmospheric disturbances.  

The best place to perform dual shield welding

Many welders think that dual shield welding is a tough welding activity, and it should only be performed at some factory.

They are wrong!

The dual shield welding is for indoor purposes, and doing it outdoor can be a bit tricky as the wind blowing in outdoor areas can disturb the flow of the shielding gases.

The setup of the dual shielded welding

Here is what you need for dual shielded welding.

  • The right tips and gas nozzles.
  • Contact types, especially the ESAB M8.
  • Liners, spiral steel liners.
  • The welding torch with water and gases.
  • The wire feeding unit.
  • The shielding gas stock. Polarity, voltage, and inductance checker.     

Dual shield welding settings

You need to train yourself for the dual shield welding; you cannot follow the same traditional welding process. Here are a few things that you may follow to get the best results through the dual shield welding processes.

1. Wire diameter selection

So, the first thing a welder must do and understand before he put his hand up for the dual shield welding is the welding wire’s diameter. 

While selecting the wire diameter, you must keep in mind that the wire deposition depends on the current levels but not on the wire’s diameter. Many welders believe that if they select a wider diameter, the feeding will increase, and there will be more deposition, which is entirely wrong.

The larger diameters will only increase the disturbance unless you have some big articles to weld. If you feel that you can operate at a higher current level, then and only then you must opt for a larger diameter.

If, for example, you have a wire with a 0.056 diameter that has a relatively higher current value, you can easily weld 11 or more lbs. an hour with it, instead of using a wire with a higher diameter.

2. Check the wire stick out.

The wired stick out is a very general term used in traditional welding; it is also very popular in dual shield welding. All the welders are supposed to maintain it throughout the welding process for a smart finish.

The wire sticks out refer to the metal wire, which is not welded, so it ultimately shows that this sort of welding wire can resist the current output during the welding sessions.

You need a small stick out of almost a half-inch for a smaller diameter, so the current deposition rate may not be affected throughout the process.

The management of the current flux and the maintenance of the electric arc during the welding process depends a lot on the welders’ skill. This can be done through voltage regulator machines. For a proper gas shielding effect, you must consider the minimum stick out; moreover, to maintain the fast vaporization and puddle formation, the least possible stick out is necessary. 

3. FCAW wire

FCAW wire storage plays a crucial role in wire feeding and welding. Usually, it is better to use the wires with the minimum moisture in their core. 

For a better experience, you must get it prepared and seamed wires. This way, there will be less moisture and

 it will help in a smooth welding process.

4. Torch angle

FCAW will create a fluid like a puddle during the welding process, and to maintain the slag system produce as the result of the puddle creation, we can use various types of torch angle for the welding.

You can start with experimentation to check the most suitable torch angle; it will also depend upon the type of metals you are welding; the two most common types of torch angle are the drag method and the backhand method. 

If you want more coverage, the backhand method is the best, helping you maintain the slag system. Similarly, it will also allow more penetration resulting in a finer welding output; the ideal welding torch angle in dual shield welding is 10 degrees to 20degrees. 

5. The power source and feeder

The ideal current level for a minimum wire diameter is 120amp and not more than 300 amp. For FCAW, you need a constant voltage machine with a direct current electrode positive.

While buying the feeder, you need to consider the wire structure, ask yourself do you want it coiled or in spools. Moreover, you must always use the right sized drive rolls; you can also use some other U-shaped diver rolls for a smoothened experience.

6. Shielding gas

There are many types of gases and mixtures of gases available in the market for dual shield welding, but the most common ones are the carbon dioxide and the mixture of argon and carbon dioxide.

Carbon dioxide is the conventional one as it is then broken down into oxygen and carbon monoxide, making it even smothered to weld. Both oxygen, argon, and carbon monoxide are active gases, so they immediately react with the molten metals and their alloys.

The only way to get the best result is to read the shielding gas manufacturers’ instructions and capability. They will guide you about the working and the significance of the gas combinations.

7. The heat input

The heat input in a welding process depends upon the three factors. We can control the heat input in the dual shielding welding process by controlling all these three factors. 

  • Arc
  • Welding current
  • Travel speed

The improper heat input can cause several damages to the product, and thus you will not get what you want.

Difference between the dual shield and flux core welding

There is a very major difference between the dual shielded and flux-cored welding. The flux-cored welding is also known as self-shielded welding. Here we do not need any external shielding gas, as we do for the dual shield welding. 

The flux automatically creates the shielding gases, unlike we do not ne don’t buy the gasses for the dual shielding process.

Suppose you are thinking of a more portable welding process. In that case, the flux core welding process is easier to conduct than the dual shielded ones, as you do not need to carry a gas cylinder with you. In some cases, the dual shield welding is also referred to as the flux core welding when the welding wire uses both the flux and the external gases. 

Advantages of dual shield welding

Dual shield welding is best for indoor welding activities; here are a few advantages of the dual shield welding.

Higher productivity

You can produce a lot through dual shield welding, at a very affordable cost. The dual shield comes with higher current and deeper penetration, which will decrease work time, and ultimately, they can produce more.

High deposition

In dual shielding, we use higher current levels, which will result in more structured welding. This way, welders can fix the difficult looking metal articles with great ease.

Deep penetration

In dual shielding, we use the small cross-sectional current paths to make the filling and wire penetration more column-like than spreading it over the welded area.

Very little skills

You do not need to go for an extra course for dual shielding welding, like dry and wet welding. You can still perform the dual shield welding without getting into any trouble.

Tips for dual shield welding

  • Welders think that they need dual shield welding’s positive electrodes, just like the MIG welding. Still, it will not be technically possible to do dual shield welding with a positive electrode, and you are supposed to change it to negative for the dual shield welding.
  • You need to clean the slug off after every welding session, no matter the duration of the process.
  • You must always follow the side to side motion during welding, reducing the risk of cuts during welding.
  • For horizontal working angles, the ideal angle is 10 degrees.
  • Do not do the dual shield welding in open space, as it will disrupt the shielding gases’ flow.
  • Only a 1/2 or ¾ inches of wire is suitable for stick out.

Frequently asked questions

1.  What is a dual shield wire?

 It is an electrode, currently thought of as the best for the dual shield welding. The unique features of this wire are the high penetration, with high flux. These electrodes are bets to use with a 100% carbon dioxide gas.

Now, as the manufacturers have worked a lot on this wire to be used for mild metals and alloys, these are easy to use and operate, and the results are more structured than the regular welding processes.

2. What types of shielding gases are used for dual shield welding?

Generally, we use two types of shielding gases for double shield welding; these are the 

  • 100 percent carbon dioxide.
  • 75 percent argon dioxide and 25 percent carbon dioxide     

Conclusion

   Dual shield welding is a modern type of welding, and people are quite fascinated with it; according to surveys, the companies that practice dual shield welding can save 60% of their expenses.

 Dual shield welding gives all the new welders who have only learned the basics of welding an opportunity to maneuver their skills. So far, it is the most secure and best welding type, as the outputs are structured and satisfactory.  

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