Some types of welding need the extra punch you get at start-up. That enables a crisper arc to start as the welder scratches the rod against the metal to begin the weld. A frequent problem for students is the inability to strike an arc, so a low OCV on a small welding machine may aggravate the situation. You should take note of the OCV in the specs if you are a rookie learning how to weld.
An OCV of about 80 volts is considered normal in a stick welder. This feature automatically cuts output power to your torch or gun if the circuit inside starts overheating.
The fan or other cooling mechanism will continue running to help disperse the heat assuming you leave the machine turned on. In some specs, this feature is clearly stated. But with other products, you may need to check the equipment manual or ask a sales rep. Various gases CO2, argon, oxygen, etc. For MIG welds, the type of gas you need depends on the process, the base metal, welding position, and environmental conditions.
The gases used include argon, CO2, helium, oxygen, and nitrogen, or blends of these gases. For example, a blend of argon and CO2 is common.
A TIG machine typically uses pure argon. But in certain special applications, it may require helium. TIG shielding gas may come as a special blend of gases designed for specific applications like MIG welding gases. Choosing the right welder comes down to finding what machine fits your needs.
The five key points just covered will aid you in that process and include:. These steps not only help you walk through the process of selecting a welder. You will learn about the various units and what works best in certain situations. Knowledge of the various welding processes and machines commonly used makes you a better welder and more valuable to a potential employer.
Jeff Grill hails from Long Island, a mile stretch of land that starts just off the coast of Manhattan and stretches deep into the Atlantic ocean. He has always been interested in welding from an early age and has the cuts and bruises to prove it as he set out to work with a variety of metals.
Save my name, email, and website in this browser for the next time I comment. We've been mentioned on. If the materials you intend to weld together include ferrous materials which might not be that clean to weld on, such as pipes, angle iron, and fences, then this category is for you.
The materials in this category might be found outdoors and might not be fully clean prior to welding on them. Materials could also include moderately thick steel plates which need to be welded together.
Additionally, the weld material could be your desired material itself if you are surface welding. If the materials you intend to weld together include sheet metal, steel tubes, or thin plates, among other various materials, then this category is for you.
You might be planning on welding sheet metal on a vehicle, welding steel tubes for a race car, or welding thin ferrous plates for an agricultural tool. If you intend on welding specialty steels such as chromoly, any kind of aluminum, or sheet metals both steel and stainless steel , then this is your category.
If you find yourself not knowing which materials you will ultimately end up welding together, then this is your category. This last question is intended to help determine what kind of welder you would prefer based on how important ease of use is to you. Some welders are quite simple and easy to use, while others are quite complicated and require lots of complex equipment and high level of welding skill to master. One reason why ease of use of a welder is highly important to you might be that you equate ease of use with simplicity.
A simple outfit of welding equipment might be all that you need for the jobs which you intend to complete. Your intended uses for this welder should not be complicated since complications with equipment nullify the usefulness of the machine for you.
If you are okay with sacrificing some simplicity for some all-around utility of a welder, then this category is for you. The best welder in your eyes is easy to use but at the same time you are okay with some complexity in order to improve production speeds and improve all-around utility of your equipment. This category is for you if you are eager to advance your skills and become proficient in advanced welding techniques. Whether to achieve weld penetration, cosmetics, weld quality, or just to show off, you prefer to use a welder which is reserved for those with advanced skillsets.
If you simply are not sure yet how you will be using your welding equipment, this category is for you. Perhaps you are still exploring the welding process and need to keep your options option to different types of welders. After you tally your answers, this section will help guide you to the welding equipment which you need the most. Your answers have directed you toward purchasing a stick welder SMAW: Shielded Metal Arc Welding due to the basic welding applications, economical budget, basic material selections, and best ease of use.
There are several types of welders available, each with their own pros and cons. Deciding between a gas welder and an arc welder, may be the first decision. Even then, arc welders are not all the same, stick welders, TIG, and MIG welders, all use an electric arc to fuse metal. Even seasoned metalworkers can have a tough time choosing the best welder or combo for their needs.
This article is going to provide a complete guide to buying the best welder, along with important facts about welders and welding. What welding equipment do you need? Before commencing this discussion on welders, it would be advisable to familiarize yourself with the common terms used when comparing welders and welding techniques.
Welding refers to a process whereby materials are fused, or joined, using heat. This usually applies to metals and thermoplastics. Though, generally, welding mostly refers to joining metals and this is going t be the focus of the article.
Our first step is going to be defining the terms used when discussing metal welding. Most modern welders use an electric spark, or arc, to generate the heat needed to join metals. A high amp electric current generates an arc, this melts the metal, thereby fusing two pieces using the molten metal.
When talking about gas welding, a clear distinction has to made between a gas flame oxyacetylene welders , and gas shielding. A gas, or oxyacetylene welder uses a combination of gasses to produce a high temperature flame. This flame can be used to fuse or cut metal. While electric arc welders have become the preferred method of welding, oxyacetylene welders are preferred by some, especially for repairs to engines and transmission systems.
Oil and other debris on a metal surface will disrupt the electric conductivity and need to be thoroughly cleaned before using any type of electric welder.
A gas flame will simply burn away any contaminants. However, oxyacetylene welders tend to produce a less attractive weld and can warp the metal. The gas is used to prevent airborne contaminants from affecting the quality of the weld.
Stick welders use consumable rods with varying length and diameter. The length of the rod determines how long you can weld for, continuously, before replacing it. A large diameter welding rod is used for thicker material, or harder metals, at a higher amperage.
Thin welding rods are used at low amperage for mild, thin, steel. Welding rods can differ in their composition for welding different types of metals. A roll of wire replaces the welding rod for MIG welders. This wire is fed continuously into the welding gun, allowing the operator to weld, uninterrupted, for longer periods of time.
You have more precise control over the weld when using wire. Like welding rods, wire can will have varying diameters for thinner or thicker metals.
Likewise, different types of wire are used depending on the metal that is being welded. Welding wire can be used with a shielding gas supplied via a nozzle supplied by a gas bottle, or by means of flux within the core of the wire. Welding rods or flux core welding wire contain flux, eliminating the need for shielding gas.
Flux-coated welding rods are coated with a chemical compound that produces a shielding gas when heated. Welding wire can have a flux in the core, which acts in the same way.
Welders will usually overheat when used continuously at high amps. When the welder reaches its critical temperature, you will have to stop working and allow the welder to cool sufficiently before continuing. Duty cycle refers to the length of time that a welder can be used at maximum output, before it needs to cool down. This is expressed as a percentage over a minute cycle.
It will take 3-minutes for the welder to cool sufficiently, completing the minute duty cycle. This represents the voltage and amperage produced for a given duty cycle. Higher amps and voltage allow for welding thicker pieces. Slag is to be removed after cooling. Spatter Metal particles thrown from the weld, often cooling and hardening on the work surface. A spatter-resistant spray applied to the workpiece can minimize spatter.
Torch A device in the TIG process to control the position of the electrode, to transfer current to the arc and to direct the flow of shielding gas.
Tungsten A rare metallic element with extremely high melting point used for manufacturing TIG electrodes. The higher the wire feed speed, the higher the amperage. Both require a transformer to convert incoming current to suitable welding current, but an inverter welder does it more efficiently.
They are also much smaller in size, a lot lighter and uses less power. The modern electronics in inverter welders make it possible to maintain an ARC where a conventional transformer welder would allow the electrode stick to the work.
When running on domestic single-phase power most inverter welder machines do need a 15 amp power outlet. Welding consumables such as electrodes, welding wire and shielding gas typically last longer than when using a traditional welding power supply. Adjustments to current and voltage can be made for different materials and thicknesses, giving the operator tighter control over the job in hand.
The small size and low weight of inverter welders make them very popular with many trades so are ideal in general fabrication shops and construction sites making on-site repairs an easy task.
The heat produced by the arc between positive and negative electrical charge melts the parent metal which mixes with the molten deposits of the coated electrode, or the wire and gas shield. The electrodes the sticks are avaialble in different lengths and diameters and look like bits of wire that have been dipped in cement.
Arc welding works better than most other methods on dirty or rusty materials and in less than perfect conditions. For big welding jobs, stick welding is comparatively slow, since the consumable electrodes must be replaced every couple of minutes and because slag the residue from the flux must be chipped away after the weld is complete.
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