This paper is concerned with effects of Al, Mn and Si contents on spatter, fume, microstructure and mechanical property with 490MPa Grade Flux Core Wire(FCW). Ten kinds of FCW were fabricated by varying Mn, Si and Al contents and each FCW was weld for check the amount of spatter and fume generations, microstructures and mechanical property. Amount of spatter and fume generations was decreased with the increasing Si contents and decreasing by Al contents in FCW. And, their microstructure of weld metal were changed by Mn, Al and Si contents in FCW. With increasing of Al and Si, acicular ferrite was fine and volume fraction of acicula ferrite was increased. Thereby leading to improvement of Charpy impact property and strength.