The Best Kept Secret in the Welding Industry: Flux Cored Arc Welding (FCAW)

When most people think about welding, they picture traditional stick welding or MIG welding in a workshop. But behind some of Australia’s biggest infrastructure projects, defence programs, shipbuilding yards, and heavy fabrication facilities, another process quietly dominates the industry:

Flux Cored Arc Welding (FCAW)

For many outside the industry, FCAW remains one of welding’s best kept secrets.

Yet for employers working on large-scale industrial projects, it’s one of the most valuable and highly sought-after welding skills in Australia today.

Why FCAW Matters More Than Ever

Australia is facing a serious welding workforce shortage.

Industry projections suggest the nation could face a shortfall of up to 70,000 skilled welders by 2030. That shortage threatens major national projects including:

• Defence shipbuilding programs
• AUKUS submarine construction
• Infrastructure development
• Mining and energy projects
• Heavy manufacturing and fabrication

At the same time, demand for advanced welding processes continues to grow.

And that’s where FCAW stands out.

What Is Flux Cored Arc Welding?

Flux Cored Arc Welding (FCAW) is a semi-automatic welding process similar to MIG welding, but instead of using a solid wire, FCAW uses a tubular wire filled with flux.

That flux provides shielding and helps produce strong, reliable welds in demanding environments.

The process is widely used in:

• Structural steel fabrication
• Shipbuilding
• Defence manufacturing
• Heavy infrastructure
• Mining equipment
• Pressure equipment fabrication

In many heavy industrial applications, FCAW is preferred because it offers:

• High productivity
• Deep weld penetration
• Excellent weld quality
• Faster deposition rates
• Strong performance outdoors and on site

For industries working to tight schedules and large production volumes, those advantages are critical.

The Welding Process Behind Major Projects

Many people entering the welding industry train primarily on basic processes without realising how heavily FCAW is used across large industrial sectors.

In reality, FCAW is a cornerstone process for:

Why FCAW Welders Are in High Demand

The industry doesn’t just need “more welders.” It needs welders with skills relevant to modern industrial fabrication.

That means processes like:

• Flux Cored Arc Welding (FCAW)
• Advanced MIG welding
• Heavy fabrication techniques
• Structural welding applications

Employers are increasingly searching for people who can contribute to:

• Shutdown projects
• Fabrication workshops
• Defence supply chains
• Infrastructure construction

FCAW capability is rapidly becoming a major advantage for welders wanting stronger career opportunities and higher-value work.

A Smarter Way to Learn Welding Skills

Traditional trade training can be difficult for people balancing work, family, or location constraints.

That’s why blended learning is becoming increasingly important in the welding industry.

AWS CE offers the Job Ready Basic Flux Cored Arc Welding (FCAW) Course, designed to make industry-relevant welding education more accessible.

The course combines:

• Flexible online learning
• Industry-focused theory
• Self-paced study
• Practical welding knowledge

This approach allows students to study in their own time and at their own pace while building understanding of one of the industry’s most valuable welding processes.

Online Learning in Welding? Yes — When It’s Done Properly

There’s still a misconception that welding education must happen entirely in a classroom or workshop.

But modern welding careers require far more than just manual skill.

Today’s welders need to understand:

• Welding processes
• Safety and compliance
• Materials and metallurgy
• Weld quality and defects
• Industrial applications

These knowledge areas are highly suited to structured online learning.

Blended training models allow students to build theoretical understanding first, making practical training more effective and job-focused.

The Future of Welding in Australia

Australia’s future infrastructure pipeline is enormous.

Defence projects, energy developments, transport infrastructure, and industrial expansion will all depend on skilled welding professionals.

Processes like FCAW will continue to play a major role in delivering those projects safely, efficiently, and at scale.

For people looking to enter the industry—or experienced tradespeople wanting to upgrade their capability—learning Flux Cored Arc Welding could become one of the smartest career moves available.

Final Thoughts

Flux Cored Arc Welding may not receive the same public attention as some traditional welding methods, but within heavy industry, it’s anything but niche.

It’s one of the core processes powering modern infrastructure, shipbuilding, defence, and fabrication projects across Australia.

And with the nation facing a critical shortage of skilled welders, FCAW capability is becoming more valuable every year.

For many people, it could be the best-kept secret in the welding industry — at least for now.