ABSTRACT A development project was undertaken to explore methods for increasing quality and productivity during lay barge welding of offshore submarine pipelines. Semiautomatic flux cored arc welding (FCAW) was identified as a process which is capable of achieving both these goals. Twenty different flux cored consumables were used to make test welds which were then mechanically and radiographically evaluated. The results of these welds trials indicate that the semiautomatic flux cord arc welding process is a fact, dependable and repeatable method for submarine pipelines girth welding. INTRODUCTION The primary method for girth welding offshore pipelines for the past thirty years has been shielded metal arc welding (SMAW), often referred to as stovepipe or vertical down stick welding. More recently semiautomatic and mechanized gas metal arc welding (GMAW short Arc Transfer) have been used to replace stick welding on some long, large diameter pipelines, especially overseas, but there has been a reluctance to use this process due to lack of fusion and hardness problems. Stick welding also has the advantage of being relatively inexpensive but the disadvantage of low productivity. Mechanized GMAW will provide a productivity increase over either of these but at a significant increase in cost. Obviously if a welding process could be identified which offered high productivity at a lower cost than mechanized GMAW, it would be the preferred method of welding submarine pipelines. Semiautomatic flux cored arc welding (FCAW) is such a low cost, high productivity process. This paper details results obtained with twenty different FCAW consumables. Completed welds were radiographed and interpreted to API 1104. The welds were then subjected to mechanical tests which included root and face bends, nick breaks, tensiles Charpy V - Notch impacts and microhardness traverse. These results were compiled and correlated to identify consumables for further development and procedure qualification. Two procedures were qualifies for API 5L X65 line pipe requiring charpy values of 20 ft-lbs at -50 C. FLUX CORED CONSUMABLES There are three of FCAW consumables currently on the market:self shields flux cord, where all weld pool shielding is provided by the flux,gas or duel shielded flux cored, where the weld pool shielding is provided by the gas. Some of these consumables are also available with small Nickel additions to increase their toughness. Recommended shielding gases range from 100% CO2 to 95% Ar/5% CO2 depending on the manufacture and intended welding position. Flux cored consumables are available in diameters ranging from 0.035? to 1/8?. The development work described by this report utilized 0.035?, 0.045? and 0.052? diameter FCAW wires. Manufacturer recommended parameters were used as starting points for parameter development. After brief trials, adequate operating parameters were established for each consumable. Metal cored consumables were found to perform well using either straight or pulsed power units. The self and gas shielded FCAW wires were easily tuned to smooth operation conditions using a constant voltage power supply. Flux cored consumables are known for their fume generation. During the trials, visual observations were made that the flux cored consumable produced a lower level of fumes than a cellulosic stick electrode.