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A beginner&#;s guide to buying a welder for light fabrication, maintenance, motorsports, home-hobby, farm/ranch, metal art, automotive and other DIY applications
Understanding your Needs
While all ESAB welders let you accomplish many welding projects, there is one series of welders that gives users more flexibility than any other welder on the market: the Rebel Family. This portable, integrated multi-process welding system lets you weld using the MIG, flux cored, Stick welding and TIG welding processes.
No other compact, lightweight welder offers more flexibility than the Rebel! Review the chart below for a quick snapshot of all the possibilities with its multi-process output.
MIG
Flux Cored
DC Stick
DC TIG
Popular uses
Fabrication
Automotive
Farm
Metal art
Maintenance
Home/DIY
Farm
Fabrication
Repair
Hardfacing
Outdoors
Home/DIY
Farm
Repair
Hardfacing
Outdoors
Home/DIY
Automotive
Aviation
Precision welds
Metal art
Metals this process can weld
Steel
Stainless
Chrome-moly
Aluminum
Steel
Stainless
Steel
Stainless
Cast iron
Aluminum*
* Very difficult
Steel
Stainless
Chrome-moly
Copper
Brass
Bronze
Titanium
Metal thickness
> .025&#; (24 ga.)
> 1/8&#;
> 1/8&#;
> .010&#;
Heat control
Excellent-Good
Moderate
Moderate
Excellent
Easy-to-learn
Very easy
Very easy
Some skill
Most skill
Bead aesthetics
Excellent-Good
Good
Good
Best
Welding Speed
Fast
Fast
Slower
Slowest
Portability
Somewhat
(requires gas)
Very
(gasless wire)
Very
Somewhat
(requires gas)
When buying a welder, consider the following factors:
Input Power Requirements
Before buying a welder, you need to determine if the primary power you have available (or can have an electrician install) is compatible with the unit. Consult the operating manual or spec sheet and look at requirements for primary voltage (range, phase, frequency), minimum primary circuit size and recommended circuit size (required to achieve maximum output).
For example, the Fabricator 181i has the following requirements:
As a general rule, consider the following:
Note that some power sources accept different types of primary power. For example, the Thermal Arc 161 and 201 Stick welding and TIG welding inverters accept both 115V and 208 &#; 230V primary power, as does the Thermal Dynamics Cutmaster 42 plasma cutter.
Portability, Size and Weight
In the days before inverter technology, getting the welder to the
work site used to be a challenge in many situations. Small MIG welders
weigh 70 lbs. or more, Stick welders typically weigh more than 100 lbs.
and TIG welders are even heavier. Even moving one of these welders
around a shop without a wheeled cart could lead to lower back strain.
Welding Output and Duty Cycle
The output or &#;size&#; of a welder is measured using amps, volts and rated duty cycle. Duty cycle is the amount of time a welder may be operated at a given output without exceeding the temperature limits of its component parts.
Duty cycle is always measured using a 10-minute cycle. For example, the Fabricator 181i has duty cycle of 20% when MIG welding at 180 amps/23 volts. This means the unit can weld continuously for two minutes at this output. It will then need to cool for the remaining eight minutes.
Duty cycle and welding output are inversely proportional. When welding at lower outputs, duty cycle increases. For example, the Fabricator 181i has a duty cycle of 60% when MIG welding at 113 amps/19.7 volts.
Note that duty cycle is evaluated at a specific ambient temperature. Thermal Arc uses 104o F. Some other industry leaders use this standard, while others use a lower temperature (e.g., 86o F); these other units will need to be &#;de-rated&#; when welding in hotter conditions.
Amperage and Metal Thickness
When someone asks, &#;What thickness of metal can that unit weld,&#; they are really referring to metal thickness that can be welded in a single pass while achieving full penetration.
When buying a welder, consider the following as general rules:
Broadly speaking, you need 1 amp of power for every .001&#; of steel thickness. Stainless steel and welding out-of-position require 10 to 15% less heat input, while aluminum requires about 25% more. Here are some common metal thicknesses in gauges/fractions, decimals and metric equivalents.
Gauge or
Fraction
24
22
20
18
16
1/16
14
1/8
10
3/16
1/4
5/16
Decimal (in.)
.
.
.
.
.
.
Contact us to discuss your requirements of mma 250 welding machine. Our experienced sales team can help you identify the options that best suit your needs.
.
.125
.
.
.250
.
Metric (mm)
.607
.759
.912
1.214
1.519
1.588
1.897
3.
3.416
4.763
6.350
7.938
When discussing amperage and metal thickness, be sure to consider these points:
1. Welding thicker metal can be accomplished by beveling the edges to create a V-groove and then making multiple pass welds (often called &#;running stringer beads&#;). The heaviest construction equipment and thickest pipe is often welded with a 1/8&#; diameter Stick electrode run between 110 and 165 amps.
2. An old trick for increasing penetration on thicker metal is to heat it with a torch until it reaches about 250o F (which you may want to do anyway to drive off moisture).
3. In many applications, using a smaller diameter electrode increases control over travel speed, the weld puddle, weld bead placement and heat input. When welding on thinner metal (auto body work is a good example), good arc characteristics at low outputs (e.g., good arc stability, positive arc starts, low spatter) are far more important than total power.
4. Consider the nature of the projects you plan to tackle. Long, continuous wire welds on thicker metal with larger diameter electrodes will call for a welder with a higher output and duty cycle. Conversely, a Stick welding electrode burns in about 1 minute, after which you need to stop and chip slag. During that time, the welder will cool.
5. The current carrying capacity of the electrode selected dictates maximum welding output. Here are a few common electrodes and typical operating ranges.
Stick Electrodes
3/32&#;
1/8&#;
5/32&#;
,
40-85A
75-125A
110-165A
40-90A
80-130A
105-180A
60-100A
110-165A
150-220A
Wire Electrodes*
.024&#;
.030&#;
.035&#;
Solid Steel
30-80A
40-145A
80-175A
Gasless flux cored (E71T-11)
Not made
30-140A
50-155A
Solid Aluminum
Not made
100-150A
110-170A
*Short circuit transfer process. Amperages are approximate and will vary depending on AWS wire classification and shielding gas selected.
Tungsten Electrodes
.040&#;
1/16&#;
3/32&#;
1/8&#;
2% type
30-60A
60-115A
100-165A
135-200A
Shielding Gas Selection
Different processes and base metals require different shielding gases:
Consult with your welding supply distributor if you have any questions about shielded gas choices.
Notes on Selecting a Stick Welder
Stick inverters make it much easier to learn to weld because they have a &#;hot start&#; function. During Stick arc initiation, the rod is prone to sticking because the voltage drops to zero when the rod touches the work piece. Hot start helps to free the rod and establish the arc by automatically boosting the welding current for a fraction of a second during arc starts. Once the arc is established, the hot start function shuts off.
Stick inverters also have the ability to adjust arc force or &#;dig&#; characteristics. Increasing dig creates a stiffer, more driving arc that helps prevent the rod from sticking when welding overhead or welding in tight fit-up situations. electrodes especially tend to run better with a little more arc force added, while and electrodes favor less or neutral arc force settings.
Note that some conventional Stick welders are built specifically to excel at welding with one type of electrode or in one particular application (it has to do with their volt/amp curve, which is an advanced topic). Because Stick inverters with arc force adjustment enable you to adjust the arc characteristics from soft to stiff, you always get the best performance in any situation.
People who grew up welding with a classic Stick buzz box and its AC output might be concerned about switching to a DC output. However, if you imagine an electric current flowing only in one direction, it&#;s easy to picture how a DC output creates more positive arc starts, helps keep the arc established and makes the rod less prone to sticking. These benefits make Stick welding a lot easier to learn! Other benefits of a DC output include reduced spatter, easier out-of-position welding and better weld bead aesthetics.
Notes on Buying a MIG/Flux Cored Welder
Inverted-based MIG welders create extremely positive arc starts (little or no popping) and a very stable welding arc with minimal spatter. They can react to changing welding conditions (typically arc length and electrode stick out) extremely quickly and adjust their output to maintain consistent performance.
Inverted technology also makes it affordable to incorporate features found on industrial MIG welders, such as inductance control. Without going into too much technical detail, adding inductance decreases the number of short circuits per second while increasing the amount of arc-on time per short circuit. This creates a more fluid weld puddle (better &#;wet out&#;), which in turn produces smoother beads and a flatter crown.
Inductance noticeably improves results on stainless steel. The properties of stainless keep the heat of the welding arc very localized. The puddle does not like to wet out, resulting in a ropey looking bead with a high crown. Adding inductance&#;more arc on time&#;helps solve these problems.
Some features to look for that aren&#;t related to inverter technology:
Notes on Selecting a TIG Welder
Choose the TIG weldingprocess when you want the
best weld bead appearance possible&#;that classic &#;stack of dimes&#; look&#;or
need more precision and control, such as for chrome-moly tubing in
motorsports applications.
As with MIG and Stick, TIG inverters provide positive arc starts and a
smooth, steady welding arc. Industrial-grade TIG inverters may also
have pulsing controls, which help increase travel speed and reduce
warping in thin stainless steel applications.
Here are other considerations when selecting a TIG welder:
Welding is an essential part of most Industries or organizations. When metals are to be formed or worked on, a welding machine is needed to join two or more pieces of metal together. Are you a brand new technician in welding? Are you buying a welding machine for the first time in Nigeria? This buying guide will help you. The technical team for welding solutions at GZ Industrial supplies, in partnership with Tikweld welding, has made it so simple to understand the basics of welding. Even for those who want to own a small welding machine at home for handling small jobs at home, we will support your buying decision-making from this article. Read on and get better at knowing what you need to know before your first investment in welding machines.
Kaierda Electric Welding machine WN-315N
There are four types of welding machines, as below;
MIG: inert metal gas&#;welding is the most straightforward form of welding. It&#;s generally best used for large and thick materials. It employs a consumable wire that acts as both the electrode and the filler material. Compared to TIG welding, it is much faster, resulting in shorter lead times and lower production costs. The availability of semi-inert gasses like carbon dioxide, which used to be tougher to find, has made its usage with steel products far more common. Mig welding machines can weld various materials like Alloys, Steel, Aluminum, Copper, etc.
Kaierda Gas-Shielded Welding Machine CO2/MAG KE-500
TIG welding also uses an electric arc like MIG. When working with TIG welding, you use an electrode made of tungsten. Tungsten is one of the most rigid metal materials. It will not dissolve or burn off. Welding can be done through a process known as fusion which is using or not using a filler metal. TIG also uses an external gas supply, such as argon or helium.
Aerospace and auto also use TIG welding as well as other industrial markets. Tig welding also a great type of welding as it can be advantageous for farmers to use welding wagon frames, fenders, and other essential equipment.
You may also like: Understanding TIG vs MIG welding machines: A comprehensive guide
Maxmech Inverter Welding Machine MIG/MMA-250
One of the positives about Stick welding is that it&#;s portable. Stick welding is used in construction, maintenance and repair, underwater pipelines, and industrial fabrication.
You will use a shielded metal arc welding or more commonly known as Stick welding, for this type of welding. You will use a consumable and protected electrode or stick. The stick softens and combines metals by heating with an arc between a covered metal electrode and the base metal workpiece. As the stick melts, its protective cover also melts and shields the weld area from oxygen and other gases that may be in the air.
Flux-cored arc welding is similar to MIG welding because both use continuous wire and power supplies. It combines a continuous electrode with a base metal. When welding outdoors, a flux shield offers protection against weather elements. This type of welding supplies welding is used for welding thick metals. It&#;s commonly used because of its high welding speed and can yield clean welds on aluminum and steel.
Ingco Diesel Welder Generator GDW
A suitable welding machine is dependent on the location of the welding. It&#;s essential to know the place of the welding to decide which welder to use. If you are welding indoors, you could operate your machine to a 115 Volt AC machine or a 220-240 volts AC supply. 220 Volt supply is a standard supply that any commercial or domestic location receives in Nigeria (Single phase), and generally, welding machines operate at this voltage.
Being aware of the thickness and the components of a material that a job will require is also imperative as not all welders are appropriate for all metals.
Welding is generally done on three elements, carbon steel, stainless steel, and aluminum. Carbon steel is the most commonly used as it is compatible with a majority of the welding machines and can handle any excess heat that might be applied to the metal.
Using stainless steel, it is compatible with TIG or MIG welding machines and does not need much strength to operate as carbon steel. If you are using aluminum, it requires more complex welding machines, like the MIG machine. You can also use a high-end TIG machine for the aluminum weld. As all the elements have a different nature of work, it would be best to examine the metal that you wish to conjoin before selecting a welding machine.
Askaynak Welding Machine Welding Inverter 405 Ultra
Various welding procedures require different compressed gases. Gasses like Argon, Oxygen, and carbon dioxide are some of the most widely used compressed gases. Therefore, you must know the exact compressed gas required for the welding machine in mind.
The essence of a manual is to assist the user further on the standard usage of any machine. The Manual points out key things to look out for and do while using the machine. You can measure how much continuous welding a machine can execute in a period. If you exceed the required limit, then it may heat the machine and cause damage to the internal control.
Maxmech Inverter Welding Machine TIG/MMA-400
It is essential to pay attention to the thickness of the metals you would be working on. If your metal is thick, you need more current to be appropriately welded, unlike thin metals. Welding aluminum is similar to welding a relatively lighter metal. It requires welders that provide the proper amount of heat for the weld. The guidelines mentioned earlier could be beneficial in buying a good welding machine. Tikweld welding supplies offers a wide range of quality and portable welding machines that are best suited for all your welding needs, like TIG and MIG welding machines, welding accessories, etc., at the best price.
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