Vulcan welders are manufactured by Canary Electrical PVT Limited. Unlike some of the other more popular welding brands, Canary Electrical is not based in the United States. Instead, this company comes from India, which is still one of the world’s top manufacturing centers.

Here is what you need to know about Vulcan welders.

Who Makes Vulcan Welders?

It takes some digging to find out more information about Vulcan welders. The Vulcan welding brand belongs to the parent company Vulcan Ltd. Vulcan Ltd. is part of an even bigger company. So, Canary Electrical PVT Limited is the company that is behind Vulcan welders.

Canary Electrical is a manufacturer based in Morbi, which is a town in the state of Gujarat, India. This company is a large manufacturer and exporter of welding machines, including the Vulcan line.

The History of Vulcan Welders

Vulcan welders don’t have as long and storied a history as some other brands you may be familiar with, such as Hobart, Miller Electric, and Lincoln Electric. However, there are still several decades of experience behind these products.

The company that produces Vulcan welders, Canary Electrical, was founded in 1980. It specializes in manufacturing welding machines such as TIG welding machines, AC/DC ARC welding machines, and inverter-based welding machines. Canary Electrical is not limited to the Indian market. It is a prominent exporter of welding machines, mostly to other South Asian markets but also to the United States.

Finding information about the history of the Vulcan brand specifically is a bit more difficult. However, we can assume that the Vulcan brand started around the same time as Canary Electrical was founded. Canary Electrical has several decades of experience making the latest cutting-edge welding machines using innovative technology, and the company input much of its knowledge into its Vulcan brand.

What Makes Vulcan Welders Different?

There are a few things that make Vulcan welders different from similar models made by other companies.

• The price point. Vulcan welders are a lot more affordable than similar welding machines from other companies, although they still cost several hundred dollars. This makes them more accessible to hobbyists, but some professionals are suspicious of the low prices.
• Inverter technology. Inverter technology in welding is a new technology that converts AC voltage to usable voltage. Previous machines used transformers, which are bulky and expensive to produce. Since many Vulcan models use inverter technology, the cost of production goes down, and the machines are easier to maneuver.
• Functionality under difficult conditions. Canary Electrical says that it wanted to make machines that people could use in all conditions, including dusty, dirty conditions. Many welding workshops are not exactly the most pristine places in the world, so this functionality is definitely necessary. Thanks to technology such as auto-sensing, low heat distortion, and more, Vulcan welders are great even for outdoor use.

Are Vulcan Welders Any Good?

Reviews are a bit mixed about whether or not Vulcan welders are any good. The machines have certain advantages, including their durability, strength, and resilience to conditions such as wind and debris. They are also lightweight and relatively affordable, making them more versatile than similar welders. People particularly praise their TIG welders, which are often used in professional settings.

However, other people are skeptical due to the lack of information available online about the company. There also isn’t a lot of transparency about parts replacement and warranty information. Tradesmen who rely on welders to make a living are understandably reluctant to invest in a machine they won’t be able to get fixed if something happens.

The final verdict is that Vulcan welders are good, especially for hobbyists, because:

1. They are lightweight.
2. They are easy to use and maintain.
3. The short warranty and lack of parts replacement don’t matter as much for people who use welders sporadically.

Are Vulcan Welders Made in the USA?

No, Vulcan welders are made in India.

This doesn’t mean the manufacturing is not high-quality. However, there are a few reasons why you might want to buy from US-based manufacturing besides supporting American jobs. US manufacturers are more responsive to customer service and are more likely to have replacement parts available near you. Reviewers indicate that servicing and replacing Vulcan welders in the U.S. is a bit tough at the moment.

Final Thoughts

Vulcan welders are made in India by Canary Electric. They are solid welders, but many people still prefer local companies such as Hobart.

The post Who Makes Vulcan Welders? appeared first on Beginner Welding Guide.

Hobart welders come from the Hobart Brothers company. Besides welders, they also manufacture filler metals and electrodes.

If you’ve ever wondered about the history behind the name on your welding machine, or you’re researching different companies to decide which ones to buy, here is what you need to know about Hobart welders.

Who Makes Hobart Welders?

Hobart welders are manufactured by Hobart Brothers LLC, a prominent manufacturing company. In 1996, Hobart was actually acquired by Illinois Tool Works, so technically, Illinois Tool Works is the company that manufactures these welders. However, ITW chose to keep the Hobart name, in part because of the quality associated with it for decades.

The History of Hobart Welders

Hobart welders have a long, illustrious history that actually predates modern welding. 

Hobart Brothers, the company that manufactures Hobart welders to this day despite its merger with Illinois Tool Works, was founded in 1917. That is over a century of history behind your welder! 

Hobart started out as a family company run by C.C. Hobart, his wife, and three sons. It didn’t start out as a welding company. Instead, C.C. Hobart made many different metal objects, including generators, air compressors, and even furniture. In 1925, Hobart Brothers made its first welder, and the rest, as they say, was history.

By the mid-20^th century, Hobart Brothers was a welding powerhouse. The company powered much of the World War II weapons production effort and was even rewarded for its efforts. It had contracts with prominent companies such as American Airlines. 

The company even started its own training academy, the Hobart Institute of Welding Technology, in 1930. In the decades since, thousands of welders have been educated thanks to this non-profit academy. The efforts were crucial in the early days when few people were trained in welding. They are just as important today when welding is a ticket toward a secure trade for many young people.

One other impressive fact about Hobart Brothers is that the company remained family-owned and operated until 1996 when it was purchased by Illinois Tool Works. That family reputation is part of why the Hobart brand survived for so long.

What Makes Hobart Welders Different?

There are a few features that make Hobart welders distinct from other welding machines. They include:

• Better wire feed speed control. Hobart welders offer infinite control over the feed wire speed, which is very valuable when you are using a system that automatically feeds filler wire.
• Simpler controls. The simpler controls mean Hobart welders are more accessible for beginner welders.
• More affordability. Hobart welders are known as some of the best welders for hobbyists. That’s because they’re easy to use and won’t cost a pretty penny to bring to your workshop without compromising on quality.

Are Hobart Welders Any Good?

Hobart welders are some of the best welders you can find on the market today, especially if you are an amateur welder looking to scratch your DIY itch. 

Here are some of the reasons why Hobart welders are excellent.

1. They are very durable. Hobart welders come with sturdy parts that hold up to any wear and tear, which makes them last for a long time.
2. They are accessible for DIYers. Many welding machines are too complicated, large, or expensive for a DIY workshop. Hobart machines are perfect for amateur welders to use without compromising on quality.
3. They are more versatile. For example, Hobart MIG welders come with two plug-in options.
4. You can trust the company. Hobart machines come with a pretty long warranty, usually about three years, which makes me trust that the company will cover any damage.
5. Plenty of industries trust it. Hobart welders are popular in shipbuilding, the automotive industry, and many other industries. That means they’re good enough for my garage.

These are enough reasons to realize that Hobart welders are pretty good.

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

Check Price on Amazon

Are Hobart Welders Made in the USA?

Hobart Brothers is an American company that prides itself on making all of its welders in the United States. Most production happens in Troy, Ohio. Some Hobart welders are manufactured in Appleton, Wisconsin. Many people were worried that ITW would move production abroad, but it didn’t do so for the Hobart line.

Final Thoughts

Hobart welders are made by the Hobart Brothers company, a historical family-owned company. Now, Illinois Tool Works owns Hobart Brothers but kept the name, manufacturing practices such as manufacturing domestically, and quality people associated with Hobart.

The post Who Makes Hobart Welders? appeared first on Beginner Welding Guide.

When you’re getting started with welding, you have a lot to learn about the intricacies of your welding machine. Besides learning how to set up your welding machine, you must also learn how to use your welding machine without damaging your equipment or endangering yourself. One important thing that can help you know how to weld safely is understanding the welding machine’s duty cycle.

A duty cycle describes the percentage of time within a specified duration that a welding machine can draw current before it overheats.

For example, a welding machine with a 50% duty cycle at 200 amps for 10 minutes, means that it can draw 200 amps for 5 minutes before it needs to cool down.

Understanding the duty cycle will help you get the most out of your welding machine. Here is what you need to know about this welding term.

Why Is the Duty Cycle Important?

The duty cycle will change depending on the amperage of the welding machine you are using. This makes sense because the higher the amperage, the hotter your machine will get, bringing it closer to overheating. If you run your welding machine at a lower amperage, you can use it longer.

You might be wondering what happens when you exceed the duty cycle. Most modern welding machines have built-in protection because they know welders will forget this calculation. The thermal overload protection senses when the internal components of a machine approach a high internal temperature. Then, it automatically turns the machine off to prevent damage.

If you don’t want your welding machine to turn off randomly while working, keep the duty cycle in mind and give your machine enough rest before turning it back on again.

What Is a Common Duty Cycle?

Duty cycles differ depending on the amperage and the type of welding machine you are working with. Your instruction manual and label will have the duty cycle.

The cycle is expressed as amperage and percentage. You’ll probably see a series of numbers that look like this:

• 200A @ 60%
• 175A @ 70%
• 150A @ 80%

The first number refers to the amps you run with the welding machine. The second number refers to the percentage of time that a welding machine can be active at that amperage. The percentage refers to a 10-minute interval, so 60% of ten minutes is six minutes.

This table shows my recommendations for welding machine duty cycle based on some common scenarios:

I have also put together a table of the most popular welding machines and their duty cycles so you can see some real world examples:

What Duty Cycle Do You Need as a Beginner?

When thinking about which welding machine to get or which amperage to set your machine, you now know that you have to think about the duty cycle. However, how will you know which cycle is best for your machine? 

The duty cycle is not so important when deciding which welding machine is better than another. This is more of a safety indicator than an indicator of quality or easy usage unless you are a MIG welder (more on that later).

So there is no duty cycle that is better than another when setting up your welding machine as a beginner. What matters is that you are aware of this duty cycle and are careful not to take your machine too close to the edge; otherwise, it can cut out on you.

Information about a duty cycle can help you determine whether a welding machine is a quality product. You can look at:

1. A machine’s efficiency – Some machines have a low-duty cycle because they only have a 240V input.
2. The input type
3. Manufacturing quality – Producers should offer information about their duty cycle tested against a standard such as the European Standard.

Duty Cycle for welding processes

How closely you need to pay attention to your duty cycle will also depend on the type of welding you are doing. 

MIG Welding

The duty cycle is the most important for MIG welders. MIG welding is a mostly automated process where the filler metal enters the fold automatically. This lessens the impact on the welding machine, which can work longer than machines engaging in other types of welding. MIG welders are prepared to weld continuously for longer because less coordination is involved. 

In production, where everything is designed for maximum efficiency and welders need to spend as much time running their machines, the duty cycle is essential. Producers will buy welding machines with as long a duty cycle as possible to avoid unnecessary shutdowns while waiting for the machine to cool down.

Stick Welding

Stick welding (or MMA) is more complex than MIG welding. Welders have to manually switch out electrodes, adjust tools, chip away slag, and do all sorts of things that help the welding process run more smoothly. No matter the duty cycle, stick welders spend most of their time with their welding machine turned off as they manually adjust everything else.

Duty cycles can be below 30% for stick welders without affecting the welding process.

TIG Welding

The answer for TIG welding is more complicated. The problem is that this welding process has a lot of applications. TIG welding for detailed work involves a lot of downtime and doesn’t need a high duty cycle.

However, some TIG welding applications, such as pipe joint welding, need a high duty cycle; otherwise, there will be an awkward break in the middle of the joint.

Final Thoughts

The duty cycle of your welding machine tells you how much you can use it continuously within a 10-minute period without it overheating and turning off. Duty cycles vary considerably depending on input, machine efficiency, and amperage. If you’re doing MIG welding and some types of TIG welding, duty cycle can be very important. 

The post Beginner’s Guide to Welding Machine’s Duty Cycle appeared first on Beginner Welding Guide.

Understanding all of the dials and digital readouts on the welding machine can be intimidating. The few controls on a stick welding machine are going to be simpler than on a TIG machine. A top end TIG machine could have as many as 20 control knobs for various settings.

Stick welders, MIG welders, and TIG welders all have various controls on the front of the machine. These are to adjust the level of current needed for a weld.

But how do you know what welding amperage or voltage setting to set the machine to?

Setting the amperage on a welding machine, whether Stick (SMAW), MIG (GMAW)(*typically uses voltage setting), or TIG (GTAW), depends on some key variables such as application and base material, welding process, and electrode.

Once you determine these three main variables, you can set your welding machine and start laying a weld bead. In this article, we will discuss these three variables in depth, and also provide some “pro tips” along the way!

Welding Application and Base Material

In this section, we will discuss the welding application, the base material, and specifically how this applies to the amperage selection on a welding machine.

Welding Application

Welding application has a direct correlation with the amperage used in a weld.

Micro TIG welding and laser beam welding have similar applications where in the case of TIG welding the amperage is quite low. However, in the case of laser welding, there is no amperage at all since there is no electrical current flow within the workpiece. In contrast, MIG welding and Stick welding (and sometimes TIG welding) can use very high amperage settings in order to achieve optimal penetration into the workpiece.

For example; A highly technical TIG weld on a helicopter exhaust manifold will have a drastically different amperage needed than for say, an oil pipeline.  The difference will be between welding thinner exotic metals and welding a three-foot diameter pipe to the next pipe in sequence.

In some applications, amperage is selected for convenience. For example, you might want to MIG weld a sheet of metal to another sheet of metal in your workshop, so you might be inclined to turn up your amperage to get the weld bead laid down as quickly as possible.

This is not to say rushing through a weld is a good practice but speeding up a weld bead in a non-critical application is very common.

PRO TIP:  If you are interested in seeing all sorts of welding applications in one place, you should either get a tour at a shipyard, a fabrication shop, or your local technical or vocational school. Chances are, you might see a specific welding application which interests you and you might want to explore that application further in a career-oriented sense. 

Base Material

The category of base material is quite broad. Therefore, we will focus on two main areas in the category of base material. And those are Type, and Thickness.

Both of these areas have a very strong correlation with what amperage setting needs to be used on the welding machine.

How type of material can affect amperage selection?

The type of material used in different welding applications can vary widely from weld to weld, jobsite to jobsite, or even from welding technology to welding technology.

Before even thinking of what amperage to set your welding machine to, you should ask yourself what type of metal you will be welding.

The main material types which standard welding methodologies can weld together are carbon steel, stainless steel, and aluminum. All three of these material types require different amperage selections on their respective welding machines. The most notable difference is between the ferrous and the non-ferrous materials, i.e. steel versus aluminum.

Certain materials require higher or lower amperage settings based on the raw material melting point. This is very apparent when looking at aluminum materials. Primarily since aluminum material melting point is typically around 1,200 degrees Fahrenheit.

Amperage selection when welding Aluminium

When welding aluminum materials together, the current usually has to be switched from DC (direct current) over to AC (alternating current). In addition, the amperage must be turned up to compensate for the higher melting temperature of aluminum.

TIG welding aluminum is unique in that the current utilized is AC due to its cleaning characteristics. This is achieved due to the weld current alternating from one direction to the other.

Once the arc is struck in an aluminum TIG weld bead and the weld puddle is formed, the operator must move the bead relatively quickly. This is due to the aluminum base material tending “soaking up” the high amperage heat and potentially warping the base metals.

Stick Welding amperage for different steel thicknesses

The adjustments to Stick welding amperage to compensate for steel material thickness are similar to the processes necessary to compensate for material thickness with a MIG welder.

Stick welders have a simple control knob on the front of the machine which adjusts the amperage level with the twist of your wrist. In the same way, MIG welders have that same simplistic functionality which comes in handy when you want to switch from a workpiece which is thick to one that is thin.

PRO TIP: If you are not sure what amperage to use with a certain piece of material, whether thick or thin, aluminum or steel, it is always a good idea to practice a weld bead on a scrap piece of material similar to the final metal workpiece you intend to weld. This small amount of time practicing will save your hours of time grinding out your weld after you find out that your weld does not have a correct amount of penetration for the thickness of material you are welding. 

Stick Welding: Switching from a thin workpiece to a thick workpiece

The welding technology which has the most noticeable changeovers when switching from a thin workpiece to a thick workpiece is stick welding.

Stick welding is different from MIG and TIG welding in that the welding operator must select a different electrode that best suits the workpiece thickness. The same electrode which works well for a thin piece of steel would not be as useful when welding a thicker piece of steel. This is because a thicker piece of steel requires more penetration and a wider root to the weld.

A thinner electrode would not be up to the task – it would simply be consumed too fast.

Welding Process and Amperage Selection

The welding processes which we will explore in the context of amperage selection are these three main processes: TIG (Gas Tungsten Arc Welding, or GTAW), MIG (Gas Metal Arc Welding, or GMAW), and Stick (Shielded Metal Arc Welding, or SMAW).

There are other welding technologies which can be discussed in the context of amperage selection. But these three welding technologies are the most commonly used for beginners.

TIG Welding

TIG welding in general is reserved for those welders who have the greatest hand eye coordination because most TIG welders require hand, eye, and foot coordination – almost like driving a car!

The unique characteristic of TIG welding when it comes to amperage is that the foot pedal on the TIG welding machine controls the amperage needed in the weld per the user’s input.

The foot pedal starts at 0 amps in the resting state and gradually increases in amperage as the welding operator pushes the foot pedal down to a certain limit. The limit of the amperage control on the foot pedal is limited by the TIG welding machine’s amperage capabilities and/or the setting on the machine.

Some TIG welding machines have this “Peak Amperage” feature on the control panel which should be set to approximately 40-50% above your desired amperage range to be used in the weld.

Some TIG welders have other amperage control features such as background amperage or fine adjustments to the amperage when using AC current. But those adjustments are outside of the scope of this article.

MIG Welding

For the purposes of this article, we will use the variable voltage settings in lieu of the amperage settings which other welding technologies use more commonly.

The voltage settings on a standard MIG welder determine the power used during the MIG welding operation. There is always a necessary balance between voltage and wire feed speed. Especially since the wire feed speed needs to increase as the voltage also increases or else the weld puddle will not be adequately fed with filler material.

For thin materials you would start at the lowest voltage setting, and for thicker materials you would increase the voltage accordingly. MIG welder machines are inherently consistent as long as the base materials do not change too much. A welding operator could have a MIG welder setting set for years if he or she does not change the type of material used.

PRO TIP: All MIG welders are different, and all welding applications are different. Once you find your optimal weld setting for your MIG welder (for your specific application, write this down on a paper and attach it to the side of your welder. This will save you from the headache which happens when another operator uses your machine, or the machine gets bumped and your settings are lost. 

Stick Welding

Stick welding, as mentioned earlier, has the most significant correlation between weld application and weld amperage.

A stick welding operator could use one amperage setting one day while he or she is welding a plate of steel for a structure, then use a different setting another day while he or she is surface welding a backhoe bucket.

The good news about stick welding is that there are charts that can be easily found online that are usually very good at predicting the amperage needed for a certain welding thickness and accompanying stick welding electrode.

If you follow the amperage levels shown on one of these charts, you should be in good shape. If you need to make minute adjustments to the heat of the weld while “under the hood” during your stick weld, the easiest way to achieve this is to pull the welding rod away from the weld puddle to “long-arc” slightly. This will achieve a wider and hotter puddle.

This table gives you a starting point of the correct stick welding parameters for your electrode type and size:

PRO TIP: A good rule of thumb for setting your stick welder (SMAW) to the approximate right setting to start off with is the amperage setting should be about the same as the decimal equivalent of the rod diameter. For example, 3/32” rod diameter would be (.094) 90 amps, 1/8” rod diameter would be (.125) 125 amps, 5/32” rod diameter would be (.157) 155 amps. This rule of thumb works for most electrode sizes, and once you get your arc started and your first weld bead on your part, you can adjust the settings from there. 

The Electrode

The only welding process that significantly correlates electrode and amperage is Stick welding or SMAW. This type of stick welding and amperage are so dependent on each other in this category, which is why this topic made it into the top three amperage selection factors.

TIG welding and MIG welding processes do use electrodes by definition, but TIG uses a semi-consumable tungsten rod and MIG welding uses a highly consumable wire, both of which have little significance when talking about amperage selection.

There are many types of electrodes available for stick welding, and each has their specific use. For example, electrodes differ due to the thickness of base material being welded.

They also differ due to horizontal, vertical, or overhead positions. These different properties are captured in the four to the six-digit number printed on every stick electrode for easy reference.

These numbers tell the user which power supply, weld position, tensile strength, and penetration that electrode was designed for.

The most common electrodes on the market are 6010, 6013, and 7018. These three electrodes are very common in the industry due to their incredible flexibility in applications.

How to choose the correct Electrode and Amperage?

The 6010 electrode is designed to penetrate deeply into the workpiece, whereas the 6013 electrode is designed to penetrate less. For the best appearance of a weld, a welding operator should select a 7018 weld electrode.

Once you have selected your stick welding electrode, you should read the side of the electrode container to see what the electrode manufacturer recommends for the welding amperage. The specific amperage to be used depends primarily on the diameter of the electrode.

For example, an eighth in diameter electrode welds great between 75 and 125 amps. Whereas a 5/32 diameter electrode can weld optimally at up to 220 amps.

The best way to know what the optimal amperage you should use is to test the welding electrode on a scrap piece of metal and observe the resulting weld. If it has an acceptable appearance and penetration rate, then run with it.

An important consideration when adjusting the amperage on your stick welding machine is the welding machine manufacturer’s recommended duty cycle for the machine.

Duty cycle is defined as the length of time the welding machine can be welding during a 10-minute period of time. Some machines are more heavy duty than others.

For example, a machine used at a construction site will most likely have heavier duty components and a longer duty cycle than a hobby welder in someone’s garage.

Duty cycle is inversely proportional to welding amperage. That is, as the amperage increases, the duty cycle length in minutes, decreases.

PRO TIP: Looking for a solution to resolve the scenario when you have an electrode with a bunch of the flux chipped off for whatever reason? If you are welding on the job where the weld needs to conform to certain requirements, using a chipped electrode is out of the question. Once way which experienced welders salvage chipped electrodes is by having a 6” x 6” steel plate nearby where they can quickly lay down a bead of weld, using up the area of electrode which is problematic, then resume their actual weld bead once the electrode is back to a section with good flux.

Conclusion

Amperage selection is not as confusing and intimidating as you might think.

There are certain key variables which determine the amperage which should be used in a certain welding application, such as Application and Base Material, Welding Process, and Electrode.

With these main variables in mind, finding the correct amperage necessary for your weld should be no problem. As always, if you are still unsure, there are numerous resources at your disposal, whether online, at a library or my favorite, in your local welding store.

Keep Reading

• 8 Tips for MIG Welding Beginners
• Gas or Flux Core when Mig Welding?
• Do I need a TIG welder?
• A Beginners Guide to Welding Chromoly
• Do you need a Metal Welding Table to Weld?
• How to Use a Plasma Cutter?

The post How to Select Welding Amperage Settings + Chart appeared first on Beginner Welding Guide.

Arc welding machines are the most commonly used types, but others are used for specific purposes like plastic welders, and others with a more generalized approach, like all-purpose welders.

If you want to learn more about the types of welding machines on the market, this guide will have you covered with brief overviews of each.

1. Shielded Metal Arc Welding (Stick) Machines

Let’s start with one of the most popular types of welding machines out there. The machine is commonly known as stick welders because they use consumable rods that look like sticks to create the weld pool.

These rods come in different gauges to suit different metal thicknesses, and they’re usually covered with a flux material.

As the rod melts under the high heat caused by the electric arc, the flux also melts to create a protective shield that prevents the weld pool from reacting with oxygen and nitrogen in the air.

Although this machine is relatively affordable with easy repairs and replacement parts, it produces a lot of slag waste and sputter, so the resultant weld usually requires further finishing and painting. However, it works very well with thick metals, even rusted ones.

Here are my recommendations for the best stick weldings.

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

Check Latest Price on Amazon

Best for Advanced Users

ESAB MiniArc Stick Package

• 115V or 230V Input Supply Input
• Extremely Lightweightt 18 lb with Adjustable Shoulder Strap
• Roll Cage Design
• Large TFT Screen

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Best Value for Money

YESWELDER Arc Welder 205 Amp Stick Welder

• Powerful Up to 205 Amps
• Automatic Compensation for Voltage Fluctuation
• Extremely Portable at 10 lb Weight
• Very Cheap Option to Test the Waters of Stick Welding

Check Latest Price on Amazon

2. Flux Core Arc Welding Machines

Flux core welding is another welding machine that relies on high voltage electric arcs to generate enough heat to melt metals instantly.

Unlike the stick welding machine, this one uses a tubular consumable electrode with an inner core of flux material. 

Another distinction from stick welders is that the wire here is automatically fed by the machine instead of being manually guided.

As the electrode wire melts, the flux creates a protective shield that either fully protects the weld pool (self shielding flux core) or partially with the help of insulating gas (gas shielded flux core) that is typically a blend of Argon and Carbon dioxide.

Flux core welders are slightly more expensive than stick welders but still affordable. They’re also great for working in windy conditions as well as thick rusty metals, although they produce a layer of slag that needs removal.

3. MIG (Metal Inert Gas) Welding Machines

MIG welders are officially known as Gas Metal Arc Welding. This one has a lot in common with flux core welding, as it also relies on electric arcs for welding and uses a consumable electrode wire that is continuously fed by the machine.

The main difference between the two is that in this type, the wires are solid with no flux material inside or outside. 

Instead, a mixture of inert gasses (mostly Argon and Helium) is fully responsible for shielding the weld pool for oxidation.

This machine is quite easy to use and yields decent results, although it’s fairly pricey and not suitable for outdoor use and rusted or thick metals.

This table shows my recommendation for the top MIG welding machines.

Best MIG Welder

Lincoln Electric 180 MIG Welder

• 180 Amps Can Weld 1/2" Thick Mild Steel
• Aluminum Ready Spool Gun
• 3 Year Warranty
• Extremely Reliable and Durable

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Best Value for Money

Hobart Handler 140 MIG Welder

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

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Best on a Budget

Forney Easy Weld MIG Welder

• Infinite Voltage and Wire Feed Speed Control
• Extremely Lightweight and Portable at 19 lb
• Can Weld up to 1/4" inch Mild Steel
• 30% Duty Cycle at 90 Amps

Check Latest Price on Amazon

4. Thyristor MIG Welding Machines

Thyristor MIG welders are a variation of regular MIG machines that are produced with high end parts, including a thyristor that is designed to better control the current and electric power of the arc produced.

As a result, the thyristor MIG welders reduce the sparking significantly, making them highly precise and easier to use.

Durability and toughness are also noticeable advantages of these welders because they have high dimensional accuracy and work with various types of steel.

5. TIG (Tungsten Inert Gas) Welding Machines

TIG welders are similar in principle to MIG welders (use electric arcs and similar shielding gasses). However, the main difference here is that this one uses a tungsten rod for welding.

Since tungsten has a very high melting point, the tungsten electrode here is non-consumable, saving you the extra costs of buying electrode wires.

Another advantage of the TIG welder is the aesthetically pleasing finish and the ability to work on extremely thin non-ferrous workpieces, such as aluminum, nickel, lead, and copper. 

The only drawback of the TIG welder is that it’s trickier than other types of arc welders and the welding unit can be quite expensive .

You can see my recommendations for TIG welding machines in this table below.

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

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Best Value for Money

Everlast PowerTIG Welder

• AC/DC TIG Welder
• Can Weld Up to 1/2 Inch Steel
• 12 ft Torch
• Complicated User Interface

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Best Premium Option

Lincoln Electric 200 Amp TIG Welder

• Powerful 200 Amp TIG Welder
• Well Suited for Aluminum
• 115 or 230V Supply Voltage
• Premium TIG Welding Machine

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6. Plasma Arc Welding Machines

Plasma Arc Welders are fairly similar to TIG welders, but they’re usually larger in size with more industrialized properties.

While they also use a tungsten electrode, the anode also doubles as the shielding material and surrounds the tungsten rod to create the arc in such a small gap, giving it pinpoint accuracy.

Plasma Arc welders are very expensive and are often used in advanced applications where higher welding temperatures are necessary, especially in aerospace and marine industries.

7. Spot Welding Machines

Spot welders are mainly used to join two or more overlapping metal sheets through heat and pressure generated through electric current between two cylindrical electrodes.

Spot welders are among the most cost-effective welding machines when it comes to power consumption and welding speed. 

For that reason, it’s commonly used in industries that don’t involve thick metals, such as the automotive industry.

Spot welding machines have a high initial cost, but they’re easily automated and optimized for large scale production with little maintenance. 

8. Multi-Purpose Welding Machines

Since a wide range of welding machines rely on generating a high voltage electric arc to weld metals at seams, choosing the right one for every application can be a little tedious, and that’s where multi-purpose welding machines come in handy.

These welding machines are designed so you can use them to perform various arc welding processes. 

For example, these machines are usually compatible with flux core, MIG, as well as TIG welding, and you can switch between these modes easily by adjusting the settings and electrodes.

Of course, the main advantage of these welding machines is the massive versatility that lets you work on various projects with the same machine, but they’re usually very expensive (but more cost efficient than buying each machine and its accessories separately)

9. Energy Beam Welding Machines

This process is a high energy welding technique that utilizes a highly focused magnetic field to weld specific points on metals.

Energy beam welding is also known as “electron beam welding” because it uses high velocity electrons to join two metals together. 

The advantage of this method is that it is highly versatile and can work with just about any type of metal regardless of its thickness. It can also bond two different types of metals together while achieving a beautiful weld.

The main drawback of this fusion technique is that it requires vacuum instead of gas shielding because it can’t work in the presence of any gasses, so it’s only used industrially.

10. Oxy Acetylene Gas Welding Machines

Oxy acetylene gas welders are machines that use a special fuel made of acetylene and oxygen to generate heat. 

This combination burns at temperatures that can reach as high as 5,800 °F to 6,300 °F, which is hot enough to melt and fuse metals together.

Since this welding technique uses the torch flame to weld, it’s fairly easy to use in comparison to arc welding. 

An oxy acetylene setup usually includes a few parts too, so it’s quite portable and suitable for outdoor use.

Another big advantage to oxy acetylene welding is affordability, as the initial cost of an oxy acetylene setup is usually much cheaper than MIG and TIG welders while achieving decent results on thin materials.

Not only that, but you can also use oxy acetylene flame to cut large sheets of metal, which adds to its versatility and cost effectiveness. 

Despite these merits, oxy acetylene flame is quite dangerous and requires utmost care while handling the torch.

11. Submerged Arc Welding (SAW) Machines

Submerged welding is a type of arc welding that involves using a consumable electrode that is automatically fed into the welding gun and melts upon contact with the workpiece. 

The main difference here is that a special granular flux material is specifically used for this type of welding, so the electric arc is usually “submerged” under that layer, hence the name.

Since this type of welding doesn’t involve a high pressure gaseous shield and cools down slowly, the resultant weld is usually much cleaner and of higher quality than other arc welders.

Another advantage of submerged arc welding is that you can use it while working on various materials, such as

• Carbon steel
• Alloy steel
• Stainless steel
• Nickel alloys
• Copper alloys

Submerged arc welding machines have a higher penetrating power than TIG welders, so they’re commonly used while welding thicker materials (such as plumbing), although they’re quite bulky and not as portable as other arc welding machines.

12. Transformer (AC) Welding Machines

A transformer welder, also known as “AC welder”, is a type of welding machine that uses alternating current for welding.

The main component of this welding machine is the step-down transformer, which covers the low amperage (around 15 amp), high voltage (around 600 volts) input from the wall into high amperage (around 55 amp), low voltage (around 208 volts) output with enough energy to weld metals.

The main advantage of using AC welders is that they are compatible with a wide variety of electrode wires and a relatively simple design, so they’re also easy to maintain.

Transformer welding machines can weld a wide variety of common metals, but they can be used with special metals like tin, copper, gold, and silver. 

13. Rectifier Welding Machines

The rectifier welding machine is a subtype of the transformer welding machine. Similar to the original one, this one also operates using AC power input.

However, the main difference here is that this unit’s rectifier can convert this input into alternating and direct current (DC) output.

There are several types of rectifier welding machines out there, but they’re all similar in terms of construction, as they are usually composed of the rectifier cell as well as a moving coil reactor and a transformer.

14. Converter Welding Machines

Converter welding machine, also known as “Inverter welding machine”, is similar to transformer welders but features a solid-state electronic converter.

The presence of a single phase converter comes with several advantages, such as minimized energy loss, cleaner seam aesthetics, and a higher level of adjustability. 

But as you might’ve expected, these units are more expensive than regular transformer welding machines.

15. Plastic Welding Machines

As the name suggests, plastic welding machines are designed to join and stabilize the bond between plastic workpieces.

There are various designs of plastic welding machines, but they mainly depend on radio frequency waves to weld the plastic together. 

These high frequency electromagnetic waves will heat the layers of material from within, and then pressurize them to fuse together and create a permanent bond.

High end plastic welding machines will work with a wide variety of plastics and polymers, including PVC (chlorinated and non-chlorinated), polyethylene (low and high density), Acrylonitrile butadiene styrene (ABS), polycarbonates, and more.

16. Atomic Hydrogen Arc Welding Machines

The atomic hydrogen welder is a special type of arc welder that passes a high voltage current between two electrodes made of tungsten with a shield of hydrogen gas. 

As the electric arc passes, hydrogen is converted to its atomic form along with an extremely high temperature that allows for a relatively high welding rate.

The main drawback here is that the atomic hydrogen welder has limited applications (only used on flat surfaces) and is fairly difficult to use with high initial and operational costs.

As a result, these types of welders are gradually phased out and replaced with more affordable alternatives and faster alternatives, such as shielded metal arc and MIG welders. 

Wrap Up

As you can see, several types of welding machines are on the market. The most common ones for beginners are arc welding machines because they’re relatively easy to use and work for various purposes, such as stick, MIG, and TIG welders.

Luckily, many versatile models can be used for different welding applications, making them a great bang for the buck.

The post 16 Essential Types of Welding Machines To Know About appeared first on Beginner Welding Guide.

MIG welding, TIG welding, and stick welding machines use different settings. Here’s what you should know. There are more than a dozen different types of welding machines depending on your requirements, so make sure you understand what metal type and thickness you are going to be working on most frequently.

Setup for Different Types of Metal

Many settings for a welding machine depend on the type of metal you plan to bond. Commonly welded metals include copper, carbon steel, stainless steel, and aluminum. 

The type of metal determines the best settings and options, such as: 

1. Metal thickness
2. Shielding gas
3. Electrode/filler wire
4. Polarity
5. Voltage
6. Wire feed speed
7. Gas flow rate

Each metal has different melting points and levels of thermal conductivity. The different properties impact the effectiveness of different welding techniques and settings.

Best Value for Money MIG

Hobart Handler 140

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

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Best Value for Money Stick

ESAB MiniArc Stick Package

• 115V or 230V Input Supply Input
• Extremely Lightweightt 18 lb with Adjustable Shoulder Strap
• Roll Cage Design
• Large TFT Screen

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Best Value for Money Multi-Process

Weldpro 200 Amp Multi Process Welder

• 3 Year Warranty
• MIG, Stick, and TIG from One Unit
• Simple Digital Display
• Lightweight at only 30 lbs

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Setup for Metal Thickness

The thickness of the metal is an important consideration when setting up different welding machines. 

Knowing the thickness of the metal helps determine the best electrode for stick welding and TIG welding. Certain electrodes offer deeper penetration, which helps ensure a stronger weld with thicker materials.

For MIG welding, the thickness of the metal determines the required amperage. You need about 1 amp of power for every 0.001 inches of thickness:

• 1/16 inch: 65 amps
• 1/8 inch: 125 amps
• 1/4 inch: 250 amps

The maximum amperage of the typical welding machine is about 250 amps. The rule of 1 amp per 0.001 inches of metal tapers off at around 1/4 inches. A 250-to-300-amp MIG welder should be able to weld 1/2-inch to 3/4-inch steel without difficulty. 

Choose the Right Gas

MIG welding and TIG welding require a shielding gas for high-quality welds. The shielding gas prevents exposure of the weld pool to the surrounding atmosphere.

The gas shields the weld from oxygen and hydrogen, which can lead to porosity and excess spatter. Common shielding gas options include:

• Argon
• Helium
• Carbon dioxide (CO₂)
• Oxygen
• Nitrogen
• Hydrogen

Argon is the most used shielding gas. Argon is a colorless, odorless, non-flammable gas. It’s often used as the base gas for creating a blend of shielding gasses for different welding situations.

Helium has high thermal conductivity, which helps maintain a hotter arc for producing a wider, deeper bead. Using helium as a shielding gas is useful when working on metals with high thermal conductivity, such as copper, aluminum, and magnesium. 

Helium costs more compared to argon and needs a higher flow rate. Adding 5% to 10% argon can help make the gas more cost-effective.

Carbon dioxide (CO₂) is the most affordable shielding gas and offers deep penetration, but it lowers the stability of the arc. It’s often used to dilute argon or helium.

Oxygen, nitrogen, and hydrogen are semi-inert or active gasses. Shielding gasses typically protect the weld from these elements. However, adding a small amount of oxygen can improve arc stability.

An argon-oxygen blend may be used for welding carbon steel and stainless steel. Yet, adding too much oxygen can create a more brittle weld.

Hydrogen improves the fluidity of the weld pool. Adding hydrogen may produce cleaner welds when working with stainless steel and nickel. It also narrows the electrical arc and helps maintain a higher temperature, resulting in better penetration. 

High concentrations of hydrogen shouldn’t be used on cast iron, carbon steel, magnesium, or aluminum, as it may make the base material more brittle. Nitrogen can stabilize the electrical arc when welding stainless steel or aluminum. 

If you’re unsure which shielding gas is right for your setup, start with 100% argon or a blend of argon with a small amount of carbon dioxide. If the weld appears porous, use less carbon dioxide. 

Choose the Right Electrode

MIG welding uses a filler wire/electrode, stick welding uses a filler rod, and TIG welding uses a filler rod/electrode. 

Companies make different types of stick electrodes for working with different metals. A classification system helps you understand the properties of each electrode, such as EXXXX.

The letter “E” indicates that the product is an electrode. The two subsequent numbers indicate the tensile strength. The third number indicates the position that you can use the electrode in, such as:

• 1 = flat, horizontal, vertical, or overhead
• 2 = flat and horizontal positions only

The fourth number refers to the type of coating and current. A “0” digit stands for a high cellulose sodium coating, which is only used with DC+ current.

The E6010 electrode is the most common electrode for stick welding but only with DC+ power. The E7018 electrode works in all positions and AC or DC power. 

The filler wire/rod type is also important when using MIG or TIG welding. You may need a nickel-based filler metal when welding steel or another metal with a high melting point to a metal with a lower melting point. 

Setting the Polarity

The polarity is necessary on stick welding machines and TIG welding machines. You need to choose between:

• Direct current electrode positive (DCEP) 
• Direct current electrode negative (DCEN)
• Alternating current (AC)

DCEP and DCEN are often used when welding steel. DC welding offers smoother, more stable arcs. AC welding is recommended for thick workpieces, as the alternating current can generate higher temperatures.

Setting the Voltage

The voltage is set based on the information provided on the chart or manual that comes with your MIG welder. The voltage determines the width and height of the bead.

A TIG welding machine allows you to adjust the voltage and frequency. Refer to the manufacturer’s instructions for these details.

Setting the Wire Feed Speed

The wire feed speed is another important setting when using a MIG welder. Most MIG welding machines include a chart. You look up the wire thickness and voltage to determine the ideal wire feed speed, which is often 240 to 290 inches per minute (IPM).

Setting the Gas Flow Rate

The gas flow rate is necessary for TIG welders and MIG welders. You need to adjust the gas tanks’ regulator valves to release the shielding gas.

The typical flow rate is about 10 to 35 cubic feet per hour (CFH). You may need a gas flow rate of at least 25 CFH in a typical shop setting.

Along with these suggestions, remember to read the instruction manual with your welding machine. Pay attention to the manufacturer’s instructions to find the ideal voltage setting, wire feed speed, and other essential details.

The post How to Set Up a Welding Machine for Beginners appeared first on Beginner Welding Guide.

An arc welding machine, or welder, is designed to create an electrical arc. The power source sends electricity through the electrode. The metal that you intend to work on is grounded. When the electrode touches the metal, it completes a circuit. 

The flow of electricity through the circuit generates heat. The heat turns the metal or alloys into a molten state. The materials bond as they cool and turn from a molten state to a solid state. 

The exact process will vary depending on the type of welding machine that you use.

1. Setting Up the Machine

Most MIG welders include at least three settings. You need to adjust the amperage, wire feed speed, and gas flow rate. 

The gas flow rate is set on the regulators on the shielding gas tank. You need to turn the valve to adjust the flow of shielding gas. 

The typical gas flow rate is between 20 and 25 cubic feet per hour (CFH). If the weld pool appears porous, you need to increase the flow.

The amperage and wire feed speed are set on the machine. The amperage is set based on the thickness of the filler wire that you use:

• 0.023 inches – 30 to 130 amps
• 0.030 inches – 40 to 145 amps
• 0.035 inches – 50 to 180 amps
• 0.045 inches – 75 to 250 amps 

TIG welders include different settings. You need to set the polarity and the amperage. The polarity options include alternating current (AC) and direct current (DC). 

DC power is used for TIG welding stainless steel, steel, and iron alloys. AC power is needed when TIG welding aluminum.

The alternating current helps remove aluminum oxide on the surface of the aluminum. Removing the oxide ensures a cleaner joint with less porosity, making it less likely to crack under stress. 

TIG welding machines also include settings for adjusting the frequency and pulse of the arc. The wavelength settings allow you to narrow or widen the shape of the arc cone or increase or decrease its force.

2. Grounding the Metal

Arc welding requires you to ground the metal. A ground clamp is attached to the base material you’re working with. 

The clamp includes a wire connecting to the welding machine, making it part of the circuit created by arc welding. Without a complete circuit, you’ll fail to generate an arc.

3. Using an Electrode

An electrode is essential to the welding process when utilizing arc welding machines. This welding tool is a conduit for the electric current to melt and fuse the metal pieces. To start the process, you position the electrode to touch the surface of the metal you want to melt. Ensuring that the electrode is clean and appropriately aligned with the workpiece for precise welding is crucial.

Usually, the electrode is made of a material that easily conducts electricity, such as copper or aluminum. It’s often covered with a flux material which, when exposed to the welding heat, produces a gas to shield the weld area from the oxygen and nitrogen in the air. This shielding gas helps stabilize the electric arc and protects the molten metal from oxidation and other atmospheric contamination.

4. Forming an Arc

Once the electrode touches the metal, the next step in the arc welding process is to pull the electrode slightly away from the metal workpiece. This distance should ideally be between two to four millimeters. This is a crucial step, as it is during this movement that the electric arc is created.

The electric arc formation happens when the electrode is pulled back and the electrical circuit opens. At this point, the voltage across the gap is high enough to ionize the atoms in the air, which generates an electric spark that crosses the gap. This electric arc is incredibly hot, reaching up to 36,000 degrees Fahrenheit. This heat is sufficient to melt the electrode and the workpiece, forming a molten pool where the weld is desired.

As soon as the arc forms, the temperature increases instantaneously, melting the flux coating of the electrode and generating the shielding gas. The combination of heat, ionized gas, and shielding gas makes it possible to melt and join metal pieces, which upon cooling, forms a solid bond known as the weld bead. Maintaining a stable arc and steady hand throughout this process is crucial for consistent and high-quality welds.

5. Melting the Metal

The metal starts melting almost immediately after you start the electrical arc. The filler metal or electrode also starts to melt. The two materials create a weld pool, which is a puddle of molten material.

Most metals start fusing with the filler metal at around 3,000 degrees Fahrenheit. However, some metals have a much higher or lower melting point.

Attempting to bond metals with vastly different melting points can be challenging. You risk overheating the material with a lower melting point. The melting points for different metals include:

• Stainless steel – 2,500 to 2,785 degrees Fahrenheit
• Nickel – 2647 degrees Fahrenheit 
• Cast iron – 2,200 degrees Fahrenheit
• Copper – 1980 degrees Fahrenheit
• Lead – 622 degrees Fahrenheit

The filler metal selection is incredibly important when working with metals of varying melting points. For example, a nickel-based filler material is often used when fusing carbon steel with copper or other materials with much lower melting points.

The molten material eventually cools and hardens, creating the weld joint that bonds to the two metals.

6. Using a Shielding Gas

A shielding gas protects the work materials from exposure to the atmosphere. Oxygen and other types of gases can negatively impact the quality of the weld. Environmental exposure can weaken the joints and make them more likely to crack. 

Common shielding gases include:

• Oxygen
• Carbon dioxide (CO₂)
• Argon
• Helium

Argon is the most used shielding gas. It’s an inert, odorless, colorless gas. Carbon dioxide offers deeper penetration but creates a rougher weld. 

A combination of argon and carbon dioxide is a common choice as it helps create more visually appealing joints with less spatter than pure CO₂. 

Gas tanks containing the shielding gas are set up near the work area when using MIG welding or TIG welding. Stick welding uses a consumable electrode coated in flux, which acts as the shielding gas.

You must ensure the work area has proper ventilation due to potentially flammable and combustible gases. 

Types of Welding

The two most common forms of welding include arc welding and torch welding. Torch welding uses a handheld torch to melt the work materials and filler rods.

Arc Welding

Arc welding involves using an electrode to create an electrical arc that achieves extremely high temperatures. There are also different types of arc welding, including:

• Gas metal arc welding (GMAW)
• Gas tungsten arc welding (GTAW)
• Shielded metal arc welding (SMAW)

Gas metal arc welding (GMAW) is called metal inert gas (MIG) welding. MIG welding is considered one of the easiest, especially tack welding methods. 

GMAW uses a consumable electrode. The electrode is typically made of a solid metal wire. The wire melts, acting as a filler for the welding process. The machine continuously feeds the wire through the welding gun. 

GMAW also involves the use of shielding gas. This may include a mixture of oxygen, argon, helium, and other gases. 

The shielding gas shields the work materials from oxygen and the surrounding environment. Without shielding gas, the weld becomes exposed to oxygen, which leads to oxidation and increased porosity.

Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, is another common type of arc welding. The welding gun includes a non-consumable tungsten electrode instead of a consumable wire.

A separate filler rod is held with your other hand. Holding the electrode with one hand and the filler rod with the other increases the challenge of learning to use TIG welding compared to MIG welding.

Shielded metal arc welding (SMAW) is also commonly called stick welding. It includes a consumable electrode rod instead of a wire. 

The rod is coated in flux, which is a welding agent. It aids the flow of molten metal during the welding process and shields the weld pool. It eliminates the need for a shielding gas, as the flux protects the weld from the atmosphere. 

Best Value for Money MIG

Hobart Handler 140

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

Check Latest Price on Amazon

Best Value for Money Stick

ESAB MiniArc Stick Package

• 115V or 230V Input Supply Input
• Extremely Lightweightt 18 lb with Adjustable Shoulder Strap
• Roll Cage Design
• Large TFT Screen

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Best Value for Money Multi-Process

Weldpro 200 Amp Multi Process Welder

• 3 Year Warranty
• MIG, Stick, and TIG from One Unit
• Simple Digital Display
• Lightweight at only 30 lbs

Check Latest Price on Amazon

Torch Welding 

Torch welding involves the use of a flame instead of an electrical arc. It’s also called oxy-acetylene welding, as it requires oxygen and acetylene. 

Oxy-acetylene torches don’t reach the same temperatures as arc welding machines. The maximum temperature of the flame is typically around 6,000 degrees Fahrenheit.

Torch welding also requires the use of a filler rod. You hold the filler rod with one hand and the torch with the other. As with TIG welding, the filler rod and the base materials fuse as the temperatures rise and cool.

Components of a Welding Machine

The components of a welding machine vary depending on the welding process. However, most arc welders include at least the following parts:

• Power supply
• Handle or gun
• Electrode
• Filler metal

A power supply is needed to provide electricity to the electrode. The electrode may be consumable or non-consumable. Consumable electrodes act as filler metal.

Consumable electrode wires are used in MIG welding, while stick welding uses electrode rods. TIG welding has a non-consumable electrode and a separate filler metal. 

A welding torch includes different components, including the torch itself and a power supply. 

A welding torch often includes a handle and a long metal tube that bends near the tip. The handle may also include an oxygen valve and an acetylene valve. Otherwise, gas flow is controlled via regulators on the gas cylinders. 

Conclusion

Welding machines are not overly complicated. Arc welding machines include a power supply, an electrode, and a grounding clamp.

The grounding clamp clamps to your workpiece. The power supply charges the electrode. When you touch the electrode to your workpiece, you complete the circuit. Pull away the electrode a few millimeters to start the welding process.

You’ll also need to learn to maintain your welding machine if you intend to keep using it. Always take the time to clean your machine when you’re done using it. You should also review the instruction manual for any additional maintenance tasks.

The post How Does a Welding Machine Work? appeared first on Beginner Welding Guide.

If you have just purchased a new welding machine or are thinking about buying one, one of your biggest concerns may be about how difficult the welding machine actually is to operate.

Some machines can be very complicated, especially, for the beginner. But, some machines are quite simple to use. Some basic welding knowledge will go a long way in understanding the machine’s settings.

Several factors can affect how difficult a particular machine is to use. For example, an AC electrode welding machine will have the fewest adjustment settings.

What Makes Welding Machines Hard to Use?

Since there are three mainstream welding processes we will begin by discussing the one adjustment that is common to all three.

But first, lets identify the three main types of welding:

• Electrode or “Stick” Welding
• MIG or “Wire” Welding
• TIG Welding

The one setting that is common to all three is the “Amperage,” setting. This setting determines the amount of heat that will be generated during the welding process.

The amount of heat needed is primarily determined by how thick the metals being welded are. In order for the weld to do its job, it must fuse the metals together completely. From the top side all the way through to the backside.

If the heat, or amperage, is too low the metals will not completely liquify from top to bottom. This lack of “Penetration,” will reduce the strength of the weld.

Conversely, if the heat, or amperage, is too high the metals will liquify too much. Consequently, the molten metal will fall away like melted wax dripping from a candle. This will leave a hole that must then be filled back up.

For more detail on how to find the proper amperage setting, please read a previous Beginner Welding Guide article on that subject, here.

Which are the Easiest Welding Machines to Use?

If we are looking at just the machine itself the electrode machines are the simplest to get set up properly.

If the electrode machine is an AC current machine only, there is only an on/off switch and an amperage adjustment dial.

On an AC/DC electrode machine, there will be one additional knob that switches from AC current to DC current.

Most machines will have a plate or decal on them to guide you in choosing which rod to use when welding certain thicknesses of metals and where to set the amperage. For the beginner, this is all one needs to get started.

MIG machines require more adjusting as do TIG machines. Ironically, a MIG machine that is set up properly may be easier for some beginners to learn on. Having said that, I believe a beginner would be well served to learn electrode welding first as opposed to MIG and TIG.

Differences Between the Welding Processes

The welding processes are these three main processes:

• Stick Welding (Shielded Metal Arc Welding, or SMAW)
• MIG Welding (Gas Metal Arc Welding, or GMAW)
• TIG Welding (Gas Tungsten Arc Welding, or GTAW)

There are other welding technologies which can be discussed but these three welding processes are the most commonly used.

TIG Welding

TIG welding, in general, is reserved for welders with the greatest hand-eye coordination. In addition most TIG welders require hand, eye, and foot coordination – almost like driving a car! 

The unique characteristic of TIG welding when it comes to amperage is that the foot pedal on the TIG welding machine controls the amperage.

The foot pedal starts at 0 amps in the resting state and will gradually increase in amperage as the welding operator pushes the foot pedal down.

A tungsten rod is used to create the arc with one hand while the off hand holds and feeds the filler rod into the puddle.

MIG Welding

The typical heat setting adjustment on a MIG welder uses voltage in lieu of amperage settings which other welding technologies use more commonly. 

The voltage settings on a standard MIG welder determine the power used during the MIG welding operation. A balance between voltage and wire feed speed must be found for a good MIG weld.

Especially since the wire feed speed needs to increase as the voltage increases or else the weld puddle will not be adequately fed with filler material. 

MIG welder machines are inherently consistent as long as the base materials do not change too much. For instance, a welding operator could have a MIG welder setting set for years if he or she does not change the type of material used.

Stick Welding

The good news about stick welding is that there are charts which can be easily found online or in a welding store. Many times there is one attached to the machine.

If you follow the amperage levels shown on these charts, you should be in good shape.

If you need to make minute adjustments to the heat of the weld while “under the hood”, the easiest way to achieve this is to pull the welding rod away from the weld puddle to “long-arc” slightly. This will achieve a wider and hotter puddle.

What is the Best Welding Machine for Beginners?

The most basic welding method is electrode welding. The machine is simple, the choice of rods to use is not all that complicated and the base metals do not always have to be all that clean. Of course, the cleaner the base metal, the higher quality the weld will be.

In addition to proper rod selection and amperage setting, other parts of the actual welding process that will quickly improve your welds are steadiness, welding speed, arc length, and rod angle.

TIP: If you are looking for a welding machine for beginners, read through our buying guide.

To break it down further, steadiness refers to how much control you are able to impart to the rod tip. Erratic movements will take away from the quality of your weld.

Welding speed is defined as how fast you pull the electrode along while you are welding. Too fast and there will not be enough heat generated to properly fuse the base metals together.

Welding too slow may build too much heat causing a burn through.

Arc length is the distance the rod tip is being held from the base metal. Too much arc length will create more heat and cause excess spatter. Too little and the rod may tend to weld itself, “Stick,” to the base metal making it necessary to pull it loose and start the arc again.

Rod angle is fairly self-explanatory. The rod, or electrode, should always be held in a straight line along the path to be welded. However, it should lean slightly in the direction the weld is to go. Picture a straw in a glass of tea an approximate the angle as the straw leans to the side of the rim.

Get yourself a machine and start welding today! Just about everything you will need to know to get started can be found inside the articles of this website.

Read More

• What are the causes of welding spatter?
• MIG vs TIG Welding
• Best Welding Machine for Beginners

The post Are Welding Machines Hard to Use? [TIG, MIG, Stick] appeared first on Beginner Welding Guide.

You are not alone. The welding equipment market is typically geared towards experienced welders since that is where most sales originate. Therefore, it can be challenging to decide on which welder you should buy as your first one.

Should you spend a lot of money? Should you buy a TIG welder or a MIG welder? This article will step you through the decision process in order to guide you through to your first welder purchase.

Let’s first start by defining the different welding technologies which we will be discussing, Stick, MIG, and TIG welding technologies:

Stick Welding, also known as Shielded Metal Arc Welding (SMAW)

Stick welding is a type of welding which involves a simple welding machine set up with the electrode negative and the workpiece positive polarities.

The electrode consists of a handle, a spring-loaded clamp holding onto a welding rod. The welding rod is consumable and consists of a metal core with a dry casing, which when melted becomes the shielding for the weld puddle.

The shielding stays on top of the puddle, and once the weld is complete the same shielding is called “slag” and must be removed manually, typically by chipping it away using a special hammer designed for this purpose.

The resulting weld is very strong and is often used to join together heavy duty industrial items such as pipes, plates and I-beams.

MIG Welding (Metal Inert Gas), also known as Gas Metal Arc Welding (GMAW)

MIG Welding is a type of welding process in which the welding arc occurs between a consumable wire and the work piece. The welding arc melts the consumable wire, which is continually fed through the handle which the user controls with a trigger.

The consumable wire is fed into the weld pool and can build up the weld to the required specification based on the machine setting and the user’s technique.

In order to achieve a clean weld, a shielding gas is used. The most common shielding gas for MIG welding is carbon dioxide, mainly due to its lower cost when compared with argon or helium.

TIG Welding (Tungsten Inert Gas), also known as Gas Tungsten Arc Welding (GTAW)

TIG welding is a type of welding process in which the welding arc occurs between a tungsten electrode and the work piece. The tungsten electrode is held in a collet inside of the welding torch.

The user holds the tungsten electrode approximately an eighth of an inch away from the work piece to keep the arc constantly forming the weld puddle. The user can weld with or without a consumable filler rod manually dipped into the weld puddle.

Skill and technique are key to a cosmetically appealing TIG weld bead since the process is manually controlled.

Whereas fusion TIG welding does not require any filler and just a technique of waving the torch back and forth across work pieces being joined, producing a weld with filler rod requires pulsing of the foot pedal and dipping the filler rod into the weld puddle with one hand and holding the torch with the other hand – a technique requiring serious coordination of the operator’s foot, both hands, and eyes.

(For the following 4 questions select A, B, C, or D and remember your answer.)

Question 1: What is Your Welding Application?

This is the first exploratory step to deciding which welder you need to ultimately purchase. This step involves thinking about what you will be using your welder for most of the time.

If you are going to be using your welder most of the time for one application in particular, you should not get a welder which is suited for a different application all together.

Below are three general applications categories which beginner welders frequently decide on. Don’t worry if your application does not fit in one of these areas, you can simply choose the one which fits your application the best.

A) Welder Used to Repair Items on Your Property

If you have a property which has farm implements, tractors, trailers, or fencing, then this category would most likely fit your application the best.

This application category suits repairing items which are typically outside, in less than optimal conditions. Perhaps you need to repair a steel fence which one of your livestock broke – and you can’t wait for a repairman to come to your property.

It would be convenient to have a welder in your arsenal which you can use to quickly make a repair with. The welder needed for this category needs to be durable and easy to use.

B) Welder Used for a Small Business

If your intentions for this welder are to use it for you small business or hobby, then this application is quite different from the previous category.

Perhaps you will weld tubing together for some off-road bumpers or roll cages, or perhaps you will weld pieces of metal together for an art sculpture you are designing.

The welder for this application needs to be easy to use and able to create high quality welds.

C) Welder Used for Tight-Tolerance or Aluminum Items

If you plan on welding aluminum items together, or if you need to fusion weld small intricate pieces together for an assembly, this is your category.

Sometimes small components such as a small bracket or a port to an aluminum tank need to be welded together with precision.

This application category describes a welder which can also be used for a small business or hobby but goes beyond that to more advanced group of parts.

D) Not Yet Sure of the Application

It is quite alright to not know your final application for the welder yet. If you are not sure how you will be using your welder yet – maybe you are still new to the idea of welding items on your own – select this category for your application.

Question 2: What is Your Budget?

This second question in this easy quiz asks you to determine your budget since this is a deciding factor in the selection of a type of welder.

More expensive welders and more economical welders have different characteristics unique to their different price ranges.

A) Budget is a Strong Factor in the Decision-Making Process

If budget is a real concern in your process of deciding on a welder, then this is the category you should select.

There is nothing wrong with being budget conscious, and there is definitely a sector of the welding equipment market which caters to this category.

The type of welding equipment which fits into this category is typically more economical and built for durability and simplicity – without any of the more advanced features which come with high-end welders.

B) Budget is Important but can be Flexible

If budget is important to you but flexible since you want to optimize your balance between good quality equipment and cost, then this category is for you.

In this category you might consider spending a little more than you originally expected if you see some features which you deem worthy of a bit more cash outlay.

C) Budget is Not Much of a Concern

If budget is not that much of a concern to you (and perhaps you have a very good credit limit) then this category is for you.

You probably hold a decent amount of welding knowledge already and wouldn’t consider yourself as starting from zero as far as welding skills.

You might have already taken some courses to learn welding skills, and you are ready to buy welding equipment which you can grow into.

D) Not Sure of Your Budget

If you are undecided on which budget to select since you are not sure what you can afford yet, then this category is for you.

Question 3: What Materials Do You Intend to Weld?

The third question is very important and gets straight to the heart of the welding process, determining what materials you will be welding with your welder.

Don’t worry if you will be welding many different types of materials, simply select the category which best fits your intended material group.

A) Angle Iron, Steel Pipe, Steel Fences, or Thick Ferrous Plates

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.

B) Sheet Metal, Steel Tubes, or Thin Ferrous Plates

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.

C) Specialty Steel, Aluminum, or Sheet Metal

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.

D) Not Sure on the Materials

If you do not know which materials you will ultimately end up welding together, this is your category.

You probably won’t be welding aluminum, but you will probably be welding an assortment of metals.

Question 4: How Important is Ease of Use to You?

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.

A) Ease of Use is Highly Important

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 you need for the jobs you intend to complete.

Your intended uses for this welder should not be complicated since equipment complications nullify the machine’s usefulness for you.

B) Ease of Use is Somewhat Important

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.

C) Ease of Use is Not That Important

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.

D) No Preference to Ease of Use

If you are not sure yet how you will use 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.

Results

Please tally your total number of answers from each of the 4 questions.

The results below are based on how many of each answer you counted (A, B, C, or D).

After you tally your answers, this section will help guide you to the welding equipment which you need the most.

If you Answered Most of the Questions “A”

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.

A stick welder machine is a great repair tool for items on your property since the machine is simple, portable, and the technology is such that you can weld on less-than-clean base materials. Budget conscious people will enjoy the fact that since stick welders are simple machines, their price tag is typically more affordable.

Ease of use is high for the stick welding technology. There are no moving parts at all, and the only tricky part is starting the arc – which can be learned relatively quickly. Here are my top 3 recommended stick welders:

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

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Best for Advanced Users

ESAB MiniArc Stick Package

• 115V or 230V Input Supply Input
• Extremely Lightweightt 18 lb with Adjustable Shoulder Strap
• Roll Cage Design
• Large TFT Screen

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Best Value for Money

YESWELDER Arc Welder 205 Amp Stick Welder

• Powerful Up to 205 Amps
• Automatic Compensation for Voltage Fluctuation
• Extremely Portable at 10 lb Weight
• Very Cheap Option to Test the Waters of Stick Welding

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If you Answered Most of the Questions “B”

Your answers have directed you toward purchasing a MIG welder (GMAW: Gas Metal Arc Welding) due to the more focused welding applications, flexible budget, slightly expanded material selections, and moderate ease of use level.

A MIG welder is great for your small business or hobby application since you can consistently produce welds which have a nice cosmetic appearance and which are high quality without too much advanced welding skills.

Budget can come into play in the MIG welder category of machines since there are options for higher performance components on MIG welding machines – whether those are user-interface components such as a better MIG handle, or internal components such as upgraded MIG wire pusher wheels.

Here are my best MIG welders for beginners:

Best MIG Welder

Lincoln Electric 180 MIG Welder

• 180 Amps Can Weld 1/2" Thick Mild Steel
• Aluminum Ready Spool Gun
• 3 Year Warranty
• Extremely Reliable and Durable

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Best Value for Money

Hobart Handler 140 MIG Welder

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

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Best on a Budget

Forney Easy Weld MIG Welder

• Infinite Voltage and Wire Feed Speed Control
• Extremely Lightweight and Portable at 19 lb
• Can Weld up to 1/4" inch Mild Steel
• 30% Duty Cycle at 90 Amps

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If you Answered Most of the Questions “C”

Your answers have directed you toward purchasing a TIG welder (GTAW: Gas Tungsten Arc Welding) due to the highly focused welding applications, larger budget, specialized material selection, and the lack of need for ease of use characteristics.

Your applications include welding aluminum and exotic allow materials, all of which are achievable with the TIG welding process.

Since TIG welders can be quite expensive with all of the required accessories, budget is not too much of a concern for you and your objective is to purchase welding equipment which will last a long time for you.

You don’t need the process to be easy to use since you are already familiar with the challenges inherent with the process. I have put together this list of the top TIG welders for beginners:

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

Check Latest Price on Amazon

Best Value for Money

Everlast PowerTIG Welder

• AC/DC TIG Welder
• Can Weld Up to 1/2 Inch Steel
• 12 ft Torch
• Complicated User Interface

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Best Premium Option

Lincoln Electric 200 Amp TIG Welder

• Powerful 200 Amp TIG Welder
• Well Suited for Aluminum
• 115 or 230V Supply Voltage
• Premium TIG Welding Machine

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If you Answered Most of the Questions “D”

Your answers have directed you toward purchasing a MIG welder (GMAW: Gas Metal Arc Welding) due to the versatility of the MIG welder – it fulfills multiple applications, it is affordable, welds on many different ferrous metals, and it is relatively east to use.

Purchasing a MIG welder as your first welder is a good option which makes sense. MIG welders will meet most of your requirements for most of your projects.

Additionally, the affordability, ease of use factor, and the great all-around utility of the technology make it a good choice for the beginner who is not sure about the intricacies the welding processes yet.

Conclusion

This article is only a guide and cannot exceed the advice from a trained welding professional.

If you have reached the end of this article and you are still undecided on which type of welder you should purchase then perhaps you should consider taking a welding course at a local vocational school or community college.

Welding classes vary by the region you are in but typically they will teach you everything you want to know about the different types of welders and allow you to try your hand at the different technologies.

The post Buying a Welder: 4 Easy Questions for Deciding What Welder to Buy appeared first on Beginner Welding Guide.

That article will walk you through the decision-making processes of deciding which type of machine is best suited to what you would like to accomplish.

Name-brand welding machines like Lincoln, Miller, and Hobart are typically very ruggedly built. If not abused they should provide years of great service.

However, like most, I am always cautious when buying used equipment. Especially, when buying used electrical equipment. And since welding machines are electrical equipment on steroids, one should take an extra dose of precaution when considering the purchase of a used one.

If you are a beginner, locate someone with experience if you can. Someone experienced in using the very type of welding machine you are looking for. This could keep you from making a mistake right off the bat. And you will probably pick up some pointers in the process.

Cosmetics

The external appearance of a used machine may or may not be a clue to its working condition. It may look brand new on the outside but may have a hidden issue internally.  On the other hand, the exterior might be scratched, faded, dented, paint-splattered or otherwise appear to be worn out and yet be almost new with very few welding hours on the more important components.

One item that needs to be in good condition on the box is the faceplate. The faceplate will have the labels indicating amperage settings. It will also have all other instructions necessary to set the machine up properly for each job. If the lettering on the plate are not legible or missing completely, it is going to be very difficult to change settings with any accuracy.

However, you may be able to purchase a new faceplate, if damaged, depending on the age and model. Note: Be sure to snap a picture of a well-worn faceplate before it becomes impossible to read.

Power cord and welding leads

Next, check the power cord and welding leads for damage. Welders are constantly working with sharp, heavy pieces of hot metal that occasionally fall onto these vulnerable parts. If the outer insulation is damaged, crushed, missing, crumbling or hardened due to age, be prepared to replace them. Preferably, prior to using the machine for the first time.

Look closely at the welding handle for damage. A broken welding handle could expose you to electrical shock depending on the type and the damage. Replacing a stick welding handle is relatively cheap compared to MIG and TIG welding handles.

For more information relating to shock hazards while welding, please refer to my article, “Can I get shocked while Welding?”

Amperage and other control dials

Missing or broken control knobs and handles will make adjusting the settings very difficult if not impossible. While not always a deal killer it would be wise to check with the manufacturer in advance to see if new knobs or handles are still available for that particular model before purchasing.

Another thing, check to see if the dials will actually turn through the whole range they were designed to. The amperage setting control mechanism is typically not made to be adjusted while welding is in progress. Doing so can cause an arc in the dial mechanism itself causing severe damage. If you feel rough spots or find the amperage control hard to move at any point when turning it from it’s highest to lowest setting, you may want to pass on purchasing it.

Cooling fans

Used welding machines with lots of hours on them may have cooling fans with worn bushings or weak motors. After determining the fan motor works, listen closely to determine if there are any unusual noises emanating from the fan. Worn bearings and bushings will not sound as quiet or be as smooth running as newer ones.

Pay close attention when the fan is winding up when first turned on and when winding down after powering it off. If it makes unusual noises, the cooling fan may not have much life left. In the event, the fan was to quit working in the middle of a long welding session, overheating the main components could easily damage the machine beyond repair.

Engine driven machines

A used engine-driven welding machine needs a bit more scrutiny applied during the shakedown. If it will start, was it difficult to get started? Blue, black or white smoke from the exhaust should be a red flag. Blue smoke indicates oil is getting into the combustion chamber.

Black smoke indicates the fuel mixture is too rich. White smoke only applies if the engine is water-cooled. White smoke emanating from the exhaust could signal a blown head gasket or a crack in the engine allowing water to enter a cylinder.

If the engine is difficult to start, the cause could be something as simple as well used spark plugs. Or, as complex as worn out piston rings. One thing to look for is, of course, fuel in the tank. Then, ensure the fuel lines are in good shape and not cracked or split. An opening in the fuel line will cause the pump to suck air and no fuel will get to the carburetor.

A worn cylinder or rings may not provide enough compression to allow the engine to start and run well. If you think the engine may be worn out, ask to do a cylinder compression check. You will need to know the correct engine specifications to check against in order to determine if the compression is within its correct range. If the compression is good on all cylinders, a slow starting or rough running engine could just need a tune-up, filter change or carburetor kit.

The gauges should be in good working order. You will be unable to determine if the engine is in good condition if the gauges are not working or, are giving faulty feedback.

Is the battery strong? A weak battery will soon need to be replaced.

Deal killer

If the engine knocks, that typically indicates an issue that is rarely cheap or easy to repair. Keep looking until you find a used welding machine worth the money to be on the safe side.

All potential costs to get the engine back in good running condition should be weighed against the asking price.

Will it weld with no issues?

Any seller who is not agreeable to allowing you to test the machine may be hiding something. On the other hand, there could be circumstances where you will not be able to check the machine out closely before buying.

Some auctions or estate sales may not be set up properly to allow the machine to be tested on site. Under these circumstances do the best you can and be prepared to lose money if you end up buying a dud. You could end up scoring a very reliable machine for a decent price but never spend more than you are prepared to lose.

If you are allowed to weld with the machine, and I hope that you are, look for consistency in the arc voltage. Weld for a few minutes on a range of settings. Again, look for a smooth, consistent arc over time. Any strange voltage fluctuations, noises or smells should be a reason for caution.

It never hurts to ask for a trial period if the machine cannot be tested on site. A trial period of 48 hours should not be asking too much. And of course, the answer will always be no if you don’t ask.

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