Factors should to consider

Solid Welding wire

 (GMAW wire)

Gas shielded Flux cored welding wire    (FCAW wire)

External shielded Gas

It is necessary. Usually, 100% CO2 or Co2/Ar2 blended

It is necessary. Usually, 100% CO2 or Co2/Ar2 blended.

Thickness of the base metal

Very good for thin plate. That is why the dia. of the wire start from 0.8MM

Can weld thicker plate. So, the flux cored welding wire usually start from 1.2MM

Condition of the base metal

Can only weld clean metal.

Can weld the base metal has some scales. As the flux inside the wire has deoxidizer.

Deposition rate

By short-circuit transfer, the deposition rate is low

Has higher deposition rate.

Mechanical properties

Generally, the strength of a weld deposit made with a solid GMAW wire is limited to the strength of the electrode.

Because slagging agents and other components are added to their cores, FCAW Wire can achieve good mechanical properties

Post-weld treatment:

Silicon islands can be deposited during GMAW that might need to be removed before painting or coating. However, GMAW with solid wire generally is a clean process that requires minimal postweld operations..

FCAW wire requires the most labor-intensive cleanup because of the slag it leaves on the weld. You will need to remove slag between passes in multiple-pass applications and before painting or coating.

Easiness of welding

Required skilled and well trained operator

It does not need skilled and well trainer operator compared with Solid wire.

Price

It is economic compared with FCAW

It is little costly compared with solid