Our fourth-year sheet metal apprentices are advancing their fabrication skills through an I-beam project using gas-shielded flux-cored arc welding (FCAW-G), commonly known as Dual Shield welding. Welding in the flat, vertical, and overhead positions challenges students to maintain control and consistency across different working conditions.

FCAW-G combines flux-cored wire with an external shielding gas. Throughout this project, apprentices are developing their ability to manage gun angle, travel speed, electrode extension, and weld puddle control—key factors in achieving consistent fusion and weld quality.

Each welding position presents unique demands. Flat-position welding reinforces bead placement and consistency, while vertical and overhead welding require additional attention to heat input and puddle control. Practicing all three positions helps students adapt their technique to the challenges they may encounter in the field.

This hands-on project connects welding theory with practical fabrication experience. Through FCAW-G training, our apprentices are strengthening the technical skills, precision, and confidence needed for demanding work in the sheet metal industry.