Jason Becker

By: Jason Becker on February 24th, 2020

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MIG vs. Flux Core vs. Metal Core

FCAW | Flux Core | GMAW | MIG

We had Jerry Matheson from Select Arc in again today to do some testing on the different types of wire. We wanted to know which wire would be best for production welding in the shop on thicker types of materials. We wanted to keep everything as fair as possible so once again we are removing the human element from the equation. We will be running each process on the same machine and utilizing the Abicore Binzel Welding Tractor to perform each weld. We will run each electrode at 20ipm of travel speed with the recommended contact tip to work distance and best possible gas. In addition, we will attempt to keep each wire at the same average amperage. We will monitor amperage using a clamp-on multimeter.  

To rate the performance, we are going to base the criteria off of the following outcomes. 

  • Heat Input (how much heat is being transferred to the part)
  • Deposition Rate (amount of weld metal being deposited into the weldment)
  • Melt-Off Rate (how much wire is being consumed and does not take into account the efficiency of the electrode.)
  • Efficiency Rate (how much of the original weight of electrode is being converted to weld metal)

We will be posting the formulas to calculate each of the variables in the video. The wire which has the best average will ultimately be the winner. Obviously your situation will dictate the best wire for your given application. I have always been a fan of solid wire for most applications in the shop, but you have to remember that short circuit cannot and should not be used on any materials thicker than 5/16". Check out the full video above, I am sure you will find the methods and outcomes entertaining as well as educational, If you have any questions, please drop them in the comments section below and we will do our best to get you some answers. Thanks for stopping by and until next time Make Every Weld Better Than Your Last!


About Jason Becker

Jason Becker is a welder/fabricator with 22 years of field experience in the welding industry and a Marine Corps Veteran. He is also an AWS Certified Welding Inspector and Certified Welding Educator (CWI/CWE). While teaching welding at his local college, Jason pursued his Bachelors Degree in Construction Management from Seminole State College and graduated with honors in 2016. He now works full-time as the co-host for Weld.com.