Welding Reference Card
One page. MIG, TIG, stick and flux core settings by thickness.
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FCAW voltage, wire speed, amperage range, and polarity starting points
Get accurate flux core welding settings with our FCAW calculator. Covers self-shielded and gas-shielded flux core on mild steel from thin sheet to heavy plate—voltage, wire feed speed, suggested amperage range, and polarity. Whether you're running inner shield or dual-shield flux core, use these parameters as a baseline before you strike an arc.
Need other processes? Try our MIG Welding Calculator, TIG Welding Calculator, or Stick Welding Calculator.
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⚙️ Essential Flux Core Welding Equipment
Five picks for machines, PPE, and slag cleanup matched to FCAW workflow
Editor's choice
ARCCAPTAIN 7-in-1 Multi-Process
- MIG + flux core + TIG + stick + plasma
- Runs common .030"–.045" flux wire
- Dual voltage 110V / 220V
- Digital controls
- Strong versatility per dollar
Professional
Everlast Cyclone 250 MIG
- Industrial MIG & flux core output
- 250A for heavy steel
- Synergic & manual modes
- Reliable wire drive
- Built for production
Best value
ARCCAPTAIN Welding Helmet
- True-color auto-dark lens
- Fast arc response for hot FCAW arc
- Wide viewing area
- Multiple sensors
- Great value under $100
Premium Leather Welding Gloves
- Grain leather dexterity
- Suited to flux core heat & spatter
- Reinforced wear zones
- Comfortable for long runs
- Pairs with heavy FCAW beads
DEWALT 4.5" Angle Grinder
- Slag & weld cleanup after flux core
- Strong motor for grinding discs
- Common 4.5" platform
- Rugged jobsite build
- Keep flapper discs on hand
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Complete Guide to Flux Core Welding Settings
Flux-cored arc welding (FCAW) is one of the most versatile and productive welding processes available to fabricators. Unlike solid wire MIG welding, flux core wire has a tubular design with flux compounds inside that create shielding gas and slag protection during the weld.
FCAW Stick-out & Polarity by Process
Self-shielded flux core (FCAW-S) typically runs DCEN with a longer stick-out; gas-shielded (FCAW-G) runs DCEP with a shorter stick-out and external CO₂ or C25. Use Advanced options to set classification, stick-out, gas, and travel speed — polarity still follows the self/gas toggle above.
| Process | Polarity | Stick-out | Gas | Notes |
|---|---|---|---|---|
| FCAW-S | DCEN | 1/2"–1" | None | Outdoor / windy; more slag |
| FCAW-G | DCEP | 3/8"–3/4" | CO₂ or C25 | Indoor; smoother bead |
Self-Shielded vs. Gas-Shielded Flux Core: Key Differences
Self-Shielded Flux Core (FCAW-S): Uses DCEN polarity (electrode negative). No external gas bottle required—suited to outdoor work, field repairs, and windy conditions. Expect more spatter, rougher bead appearance, and heavier slag versus dual-shield.
Gas-Shielded Flux Core (FCAW-G): Uses DCEP polarity (electrode positive) and external shielding gas—typically 100% CO₂ or 75/25 argon/CO₂. Smoother arc and bead profile with less spatter; primarily indoor or screened use.
Wire Size Selection for Different Thicknesses
.030" Wire: Thin flux core option for lighter gauge material and smaller machines.
.035" Wire: Common general-fabrication size for a wide thickness band.
.045" & up: Heavier sections and structural work—typically on higher-duty machines.
Polarity: Why It Matters
DCEN (Electrode Negative): Used for self-shielded flux core. Work clamp to positive (+), gun to negative (−).
DCEP (Electrode Positive): Used for gas-shielded flux core. Gun to positive (+), work clamp to negative (−).
💡 Pro Tip: Keep a chipping hammer and wire brush at your station. Flux core slag must be removed between passes—leftover slag drives slag inclusions on multi-pass welds. Self-shielded typically yields more slag than gas-shielded; budget cleanup time accordingly.
Related Welding Calculators & Guides
FCAW-S vs FCAW-G — Which Wire Are You Running?
Self-shielded flux core (FCAW-S) generates its own shielding from the flux inside the wire — no gas bottle, no wind screens, and no regulator to babysit. That makes it the default for outdoor structural work, field repairs, and farm fabrication where MIG gas would blow away. Gas-shielded flux core (FCAW-G) uses external CO₂ or mixed gas and typically produces cleaner beads, less spatter, and easier slag removal — but it needs indoor or sheltered conditions.
Wire feed speed, voltage, and polarity settings differ significantly between FCAW-S and FCAW-G. Running gas-shielded parameters on self-shielded wire (or the reverse) is one of the fastest ways to get an ugly arc and weak welds. Always match the calculator mode to your spool label and verify against the manufacturer’s spec sheet before production welding.
Flux Core Wire Polarity
Most self-shielded flux core wire runs on DCEN (electrode negative) — gun to negative (−), work clamp to positive (+). That is the opposite of typical solid-wire MIG, which uses DCEP. Gas-shielded flux core normally uses DCEP (electrode positive). Wrong polarity causes excessive spatter, poor penetration, an erratic arc, and slag that is hard to remove.
Before you dial in wire speed and voltage, confirm polarity at the machine terminals or digital menu. A quick test on scrap takes less time than grinding bad beads off a production joint. If you switch between MIG and flux core on the same welder, polarity is the first setting to double-check — not the last.
Flux Core vs MIG for Outdoor Work
Flux core is the go-to process when you cannot control wind or weather. Self-shielded wire eliminates the gas bottle entirely, which simplifies mobile rigs for construction sites, pipeline tie-ins, and equipment repair in the field. You trade some bead cosmetics and slag cleanup time compared to solid-wire MIG indoors, but you gain reliability when the environment fights you.
For shop work on clean mild steel with good fit-up, solid MIG often wins on appearance and speed. For outdoor stick-and-move jobs, flux core’s tolerance for wind and lack of gas logistics usually wins overall. Keep a chipping hammer and wire brush in the cart either way — flux core always owes you slag removal before paint or multi-pass work.