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A: I would like to answer your question as a general discussion of flux-cored welding. The American Welding Society (AWS) classifies all tubular electrodes having a flux on the inside as flux-cored wires, and calls it the Flux Cored Arc Welding (FCAW) process. All flux-cored wires have some similar characteristics. These include forming a protective slag over the weld, use a drag angle technique, have the ability to weld out-of-position or flat and horizontal only at higher deposition rates (depending on type of wire), ability to handle contaminants on the plate, etc.
Welding wire: Select an aluminum filler wire that has a melting temperature similar to the base material. The more the operator can narrow-down the melting range of the metal, the easier it will be to weld the alloy. Obtain wire that is 3/64- or 1/16- inch diameter. The larger the wire diameter, the easier it feeds. To weld thin-gage material, an 0.035-inch diameter wire combined with a pulsed-welding procedure at a low wire-feed speed - 100 to 300 in./min - works well. Convex-shaped welds: In aluminum welding, crater cracking causes most failures.