Buying your First Welder

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A beginner&#;s guide to buying a welder for light fabrication, maintenance, motorsports, home-hobby, farm/ranch, metal art, automotive and other DIY applications

 

Understanding your Needs

While all ESAB welders let you accomplish many welding projects, there is one series of welders that gives users more flexibility than any other welder on the market: the Rebel Family. This portable, integrated multi-process welding system lets you weld using the MIG, flux cored, Stick welding and TIG welding processes. 

 

No other compact, lightweight welder offers more flexibility than the Rebel! Review the chart below for a quick snapshot of all the possibilities with its multi-process output.

 

MIG

Flux Cored

DC Stick

DC TIG

Popular uses

Fabrication

Automotive

Farm

Metal art

Maintenance

Home/DIY

Farm

Fabrication

Repair

Hardfacing

Outdoors

Home/DIY

Farm

Repair

Hardfacing

Outdoors

Home/DIY

Automotive

Aviation

Precision welds

Metal art

Metals this process can weld

Steel

Stainless

Chrome-moly

Aluminum

Steel

Stainless

 

Steel

Stainless

Cast iron

Aluminum*

 

* Very difficult

Steel

Stainless

Chrome-moly

Copper

Brass

Bronze

Titanium

Metal thickness

> .025&#; (24 ga.)

> 1/8&#;

> 1/8&#;

> .010&#;

Heat control

Excellent-Good

Moderate

Moderate

Excellent

Easy-to-learn

Very easy

Very easy

Some skill

Most skill

Bead aesthetics

Excellent-Good

Good

Good

Best

Welding Speed

Fast

Fast

Slower

Slowest

Portability

Somewhat

(requires gas)

Very

(gasless wire)

Very

Somewhat

(requires gas)

 

When buying a welder, consider the following factors:

• Primary power requirements
• Portability, size and weight
• Welding output and duty cycle
• Electrode selection
• Shielding gas requirements

Input Power Requirements

Before buying a welder, you need to determine if the primary power you have available (or can have an electrician install) is compatible with the unit. Consult the operating manual or spec sheet and look at requirements for primary voltage (range, phase, frequency), minimum primary circuit size and recommended circuit size (required to achieve maximum output).

For example, the Fabricator 181i has the following requirements:

• Primary voltage: 208 &#; 265V AC, single-phase, 50/60 Hz
• Minimum circuit size: 208 &#; 230V/25A
• Recommend circuit size: 208 &#; 230V/40A (or 230V/50A)

As a general rule, consider the following:

 

• A welder running on 115V primary requires a minimum breaker size of 20A with 30A recommend (this would be for welding at up to 140 amps). 
• A welder running on 208 &#; 230V primary requires a minimum breaker size of 30A with 50A recommend (this would be for welding at up to 180 amps). 
• Welding at an output of 200 amps or more requires at least a 50A breaker.

Note that some power sources accept different types of primary power. For example, the Thermal Arc 161 and 201 Stick welding and TIG welding inverters accept both 115V and 208 &#; 230V primary power, as does the Thermal Dynamics Cutmaster 42 plasma cutter.

 

Portability, Size and Weight

In the days before inverter technology, getting the welder to the work site used to be a challenge in many situations. Small MIG welders weigh 70 lbs. or more, Stick welders typically weigh more than 100 lbs. and TIG welders are even heavier. Even moving one of these welders around a shop without a wheeled cart could lead to lower back strain.

 

Welding Output and Duty Cycle

The output or &#;size&#; of a welder is measured using amps, volts and rated duty cycle. Duty cycle is the amount of time a welder may be operated at a given output without exceeding the temperature limits of its component parts.

 

Duty cycle is always measured using a 10-minute cycle. For example, the Fabricator 181i has duty cycle of 20% when MIG welding at 180 amps/23 volts. This means the unit can weld continuously for two minutes at this output. It will then need to cool for the remaining eight minutes.

 

Duty cycle and welding output are inversely proportional. When welding at lower outputs, duty cycle increases. For example, the Fabricator 181i has a duty cycle of 60% when MIG welding at 113 amps/19.7 volts.

 

Note that duty cycle is evaluated at a specific ambient temperature. Thermal Arc uses 104o F. Some other industry leaders use this standard, while others use a lower temperature (e.g., 86o F); these other units will need to be &#;de-rated&#; when welding in hotter conditions.

 

Amperage and Metal Thickness

When someone asks, &#;What thickness of metal can that unit weld,&#; they are really referring to metal thickness that can be welded in a single pass while achieving full penetration.

When buying a welder, consider the following as general rules:

• A 140-amp unit can weld up to about 1/4&#; steel
• A 180-amp unit can weld between 3/8&#; and 5/16&#; steel
• A 200-amp unit can weld between 5/16&#; steel
• A 250-amp unit can weld 1/2&#; steel

Broadly speaking, you need 1 amp of power for every .001&#; of steel thickness. Stainless steel and welding out-of-position require 10 to 15% less heat input, while aluminum requires about 25% more. Here are some common metal thicknesses in gauges/fractions, decimals and metric equivalents.

Gauge or

Fraction

24

22

20

18

16

1/16

14

1/8

10

3/16

1/4

5/16

Decimal (in.)

.

.

.

.

.

.

.

.125

The company is the world’s best Arc Hardfacing Welding Machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

.

.

.250

.

Metric (mm)

.607

.759

.912

1.214

1.519

1.588

1.897

3.

3.416

4.763

6.350

7.938

 

When discussing amperage and metal thickness, be sure to consider these points:

1.    Welding thicker metal can be accomplished by beveling the edges to create a V-groove and then making multiple pass welds (often called &#;running stringer beads&#;). The heaviest construction equipment and thickest pipe is often welded with a 1/8&#; diameter Stick electrode run between 110 and 165 amps. 

 

2.    An old trick for increasing penetration on thicker metal is to heat it with a torch until it reaches about 250o F (which you may want to do anyway to drive off moisture).

 

3.    In many applications, using a smaller diameter electrode increases control over travel speed, the weld puddle, weld bead placement and heat input. When welding on thinner metal (auto body work is a good example), good arc characteristics at low outputs (e.g., good arc stability, positive arc starts, low spatter) are far more important than total power.

 

4.    Consider the nature of the projects you plan to tackle. Long, continuous wire welds on thicker metal with larger diameter electrodes will call for a welder with a higher output and duty cycle. Conversely, a Stick welding electrode burns in about 1 minute, after which you need to stop and chip slag. During that time, the welder will cool.

 

5.    The current carrying capacity of the electrode selected dictates maximum welding output. Here are a few common electrodes and typical operating ranges.

 

Stick Electrodes 

3/32&#;

1/8&#;

5/32&#;

,

40-85A

75-125A

110-165A

40-90A

80-130A

105-180A

60-100A

110-165A

150-220A

 

Wire Electrodes* 

.024&#;

.030&#;

.035&#;

Solid Steel

30-80A

40-145A

80-175A

Gasless flux cored (E71T-11)

Not made

30-140A

50-155A

Solid Aluminum

Not made

100-150A

110-170A

*Short circuit transfer process. Amperages are approximate and will vary depending on AWS wire classification and shielding gas selected.

 

Tungsten Electrodes 

.040&#;

1/16&#;

3/32&#;

1/8&#;

2% type

30-60A

60-115A

100-165A

135-200A

 

Shielding Gas Selection

Different processes and base metals require different shielding gases:

• For short circuit MIG welding, use &#;C25&#; or &#;75/25&#; (75% argon blended with 25% CO2). C25 produces less spatter and less heat than welding with 100% CO2.
• You can use 100% CO2 for more penetration on thicker material, but be aware that it creates more spatter.
• For MIG welding aluminum, use 100% argon.
• For MIG welding stainless steel, use a &#;tri-mix&#; blend of approximately 90% helium, 7.5% argon and 2.5% CO2.
• Spray transfer MIG welding requires a different gas blend, generally a 90% argon/10% CO2 mix. Basically, the spray transfer process requires a MIG welder in the 200+ amp category.
• 100% argon is acceptable for all TIG welding applications.

Consult with your welding supply distributor if you have any questions about shielded gas choices. 

 

Notes on Selecting a Stick Welder

Stick inverters make it much easier to learn to weld because they have a &#;hot start&#; function. During Stick arc initiation, the rod is prone to sticking because the voltage drops to zero when the rod touches the work piece. Hot start helps to free the rod and establish the arc by automatically boosting the welding current for a fraction of a second during arc starts. Once the arc is established, the hot start function shuts off.

 

Stick inverters also have the ability to adjust arc force or &#;dig&#; characteristics. Increasing dig creates a stiffer, more driving arc that helps prevent the rod from sticking when welding overhead or welding in tight fit-up situations. electrodes especially tend to run better with a little more arc force added, while and electrodes favor less or neutral arc force settings.

 

Note that some conventional Stick welders are built specifically to excel at welding with one type of electrode or in one particular application (it has to do with their volt/amp curve, which is an advanced topic). Because Stick inverters with arc force adjustment enable you to adjust the arc characteristics from soft to stiff, you always get the best performance in any situation.

 

People who grew up welding with a classic Stick buzz box and its AC output might be concerned about switching to a DC output. However, if you imagine an electric current flowing only in one direction, it&#;s easy to picture how a DC output creates more positive arc starts, helps keep the arc established and makes the rod less prone to sticking. These benefits make Stick welding a lot easier to learn! Other benefits of a DC output include reduced spatter, easier out-of-position welding and better weld bead aesthetics.

 

Notes on Buying a MIG/Flux Cored Welder

Inverted-based MIG welders create extremely positive arc starts (little or no popping) and a very stable welding arc with minimal spatter. They can react to changing welding conditions (typically arc length and electrode stick out) extremely quickly and adjust their output to maintain consistent performance. 

 

Inverted technology also makes it affordable to incorporate features found on industrial MIG welders, such as inductance control. Without going into too much technical detail, adding inductance decreases the number of short circuits per second while increasing the amount of arc-on time per short circuit. This creates a more fluid weld puddle (better &#;wet out&#;), which in turn produces smoother beads and a flatter crown.

 

Inductance noticeably improves results on stainless steel. The properties of stainless keep the heat of the welding arc very localized. The puddle does not like to wet out, resulting in a ropey looking bead with a high crown. Adding inductance&#;more arc on time&#;helps solve these problems.

 

Some features to look for that aren&#;t related to inverter technology:

• Burn back control, which improves arc starts by regulating how much wire &#;stick out&#; remains after you let go of the MIG gun trigger. If your application requires a large number of arc starts or very positive arc starts, such as for spot welding or on thin metal, you&#;ll really appreciate burn back control.
• Spool gun compatibility. Spool guns are considered essential for MIG aluminum, are an easy way to quickly switch to a second type of wire and are a good way to prevent stainless steel wires from becoming contaminated by the steel wire shavings in your regular MIG gun liner. 
•   A quick note about MIG aluminum: If you plan to weld aluminum in critical applications or on a commercial basis, consider a power source with sufficient output for spray transfer or pulsed spray transfer welding. These processes ensure better fusion when welding aluminum.

Notes on Selecting a TIG Welder

Choose the TIG weldingprocess when you want the best weld bead appearance possible&#;that classic &#;stack of dimes&#; look&#;or need more precision and control, such as for chrome-moly tubing in motorsports applications.

 

As with MIG and Stick, TIG inverters provide positive arc starts and a smooth, steady welding arc. Industrial-grade TIG inverters may also have pulsing controls, which help increase travel speed and reduce warping in thin stainless steel applications.
Here are other considerations when selecting a TIG welder:

 

•  As with Stick, the process requires more starts and stops compared to wire welding. Because of this, duty cycle is less of an issue.
• Use a DC output for welding ferrous metals, titanium, nickel alloys, brass and copper. Welding non-ferrous materials requires an AC output, and here Thermal Arc recommends its ArcMaster AC/DC units.
• What type of remote amperage controls are available? Some people feel more comfortable with an optional foot control, others prefer the amperage control integrated into the torch while those who are cost-conscious are fine with controlling amperage at the power source.
• For this latter group, note that the Fabricator 181i incorporates a down slope or crater function that ramps down the current over a period of 1 &#; 10 seconds after being initiated via the torch trigger switch. Ramping down the current helps prevent crater cracking at the end of a weld (one of the most common flaws).

The best starting point when purchasing the Best Welding Machine is to match your personal needs with a suitable welder. It is also essential to understand the different welding processes and their limitations. Apart from the technical aspects of welding machines, consider other factors such as the build quality, warranty, and the accessories that come with the welder.

We shall start by going through the different welding processes, their applications, and their limitations before going through the key features of a welding machine.

Understand the Different Welding Processes

The first step when buying a welding machine is to understand the various welding processes, how they work, their applications, and their pros and cons. The goal here is to choose a welding process that suits your personal needs.

1. Stick Welding

Stick welding is the most popular welding process because of its simplicity and versatility. This process is also called:

• Shielded metal arc welding (SMAW)
• Flux shielded arc welding
• Manual metal arc welding

This welding process involves melting a consumable electrode (or what people call a stick or metal filler rod) using electricity. The electrode is held using an electrode holder.

The electrode is usually covered by flux that melts and shields the weld pool from contamination by the atmosphere. When you complete the welding, you will need to remove the slag formed by flux on the top of the weld bead.

Advantages of Using a Stick Welder

• Portable and affordable
• Perfect for outdoor environment
• Easy to learn and execute
• It can be used on metal with rust and dirt

 Disadvantages of Using a Stick Welder

• Produce more slag and spatter
• Clean up needed after the welding
• Low-quality weld compared to TIG welding

2. MIG Welding

MIG welding process or Metal Gas Inert Welding (GMAW) just like stick welding process uses a consumable electrode. This process uses gas stored in a gas tank to protect the molten metal from environmental factors such as carbon dioxide and oxygen.

The arc created melts the electrode wire to form the weld. After removing the heat, the weld cools and solidifies. MIG welding machines are ideal for both home and commercial purposes. These machines work perfectly for metals such as stainless steel, mild steel, and aluminum.

Where to use a MIG Welder

• In the automotive industry to repair vehicles and motorcycles.
• In the construction industry to weld steel
• DIY home projects

Advantages of using a MIG welder

• No slag and less splatter
• less welding fumes
• Great for thin metals
• Cleaner weld is formed
• More control over the arc

Disadvantages of using a MIG Welder

• The gas tank limits portability
• Easily affected by wind
• Requires a clean surface clean from dirt and rust

3. TIG Welding

TIG (Tungsten Inert Gas) or Tungsten inert gas welding (GTAW) welding process uses a non-consumable tungsten electrode, while the arc is protected by a flow of inert gas, mostly argon or helium. The tungsten electrode used does not melt during the welding process.

The gas is usually fed through a supply pipeline from the welder to the TIG torch holding the electrode. Unlike stick welding, TIG welding is more versatile and expensive but produces immaculate welds.

Advantages of TIG Welding

• Produce very clean, and high-quality welds
• Can work with most metals
• Less fumes, spatter, and sparks are produced
• Easy to see what you are doing when welding, since there is less smoke
• Great for thin metals

Disadvantages of TIG Welding

• TIG welding machine is more expensive than stick welders
• Relatively slow and expensive
• Steeper learning curve
• Not easily portable

4. Flux-Cored Welding

Flux Core Arc Welding (FCAW) is like MIG welding. However, instead of using gas stored in a tank to protect the weld, it uses flux. The process uses a tubular wire that is filled with flux inside. This welding process is considered one of the most effective.

Advantages of Flux Core Welding

• High deposition process
• Easier to learn and execute than MIG and TIG
• The process has better shielding
• Best for joining thicker metals
• Convenient and portable
• Offer more flexibility with alloy metals
• Offer more improved arc stability
• It&#;s an all-position welding process

Disadvantages of Flux Core Welding

• Produces more smoke
• The FCAW wire is pricier
• Clean up required after the welding process

Best Uses for the Most Popular Welders

   Stick WeldingMIG WeldingTIG WeldingFlux-Cored WeldingPopular uses-Farm repairs -Steel fabrication -Structural welding -Construction of ships -Oil and gas pipeline -Repair and maintenance work -Construction of steel structures -DIY projects   Cannot be used for Aluminum or Titanium and thin metals-Automotive -Fabrication of steel structures -Metal Designs -Sheet metal welding  
not ideal for: building applications and farm and outdoor welding&#; Aircraft construction -Auto body repairs -Automotive industry -Precision welds -Welding ferrous metals    -Manufacturing plants -Industrial piping -Shipbuilding -Railroads -Hard facing  

Apart from these four welding processes, there are more welding processes that includes:

• Laser Beam Welding
• Electron-Beam Welding
• Atomic Hydrogen Welding
• Plasma Arc Welding
• Submerged Arc Welding (SAW)
• Forge Welding
• Resistance Welding

What type of metals will you weld? What projects will you be handling?

Another consideration when buying a welding machine is your personal needs. The main consideration here is the projects you will be undertaking and the metal(s) you will be using.

While it&#;s a good idea to buy a machine that supports several welding processes and can weld the most metal types, single-process welding machines sometimes deliver the best performance in their respective fields.

Will you be dealing with just one metal, or do your projects involve different types of metals?

For instance, if you will be dealing with cast iron, your only option will be to buy a stick welder machine. The MMA or MMAW welding process is regarded as the best welding process for cast iron projects.

Cast iron is often used to make flywheels, gearbox cases, cookware, pipe fittings, cement mixers, farm equipment, washers, and brackets, among others.

This is the same case with welding aluminum. Unlike steel which can be welded using the three most popular welding processes, aluminum is best welded using an AC-TIG welding machine. This is to curb the introduction of impurities and prevent oxidation and porous issues.

You can also use a MIG machine but make sure it has a pulse welding feature and a spoon gun.

Tig welding is also the best for metals such as magnesium, brass, copper, and titanium.

The table below shows you different metals and the best welding process

MetalMIG weldingStick WeldingTIGFlux-cored weldingSteel&#;&#;&#;&#;Stainless steel&#;&#;&#;&#;Aluminum&#;         &#; (AC) Brass  &#; Iron         &#; &#;Titanium  &#; Chromyl  &#; Steel&#;        &#;&#; Copper  &#; Cast Iron &#;  Magnesium  &#; 

Another consideration when buying a welding is your skill level.

It is best to start with the easy-to-use welder machine if you are a beginner. MIG welding is the best option for beginners since it is easy to learn and use. However, don&#;t just pick a MIG welder because it&#;s beginner-friendly; consider the type of metal and projects you will handle to ensure it can weld them.

Since MIG welding machines can weld various metals, it might be the only machine you will ever need for all your home welding needs.

When buying a welder, ensure you consider the power supply needs since the devices have varied power requirements.

110/120 Volt AC

This is the standard voltage provided to residential and commercial properties by energy companies. If you see a welder rated 110v, that is an entry-level welding machine for the most basic welding projects. However, only a handful of 110v welders are worth buying.

220/240 Volts AC

Most welders are rated 220/240 volts. These are machines that can handle both simple and complex welding projects. If you buy a 220/240V welder, you will need to check your supply&#;s rating and make proper adjustments if needed.

Generator-powered Welders

If you will be welding outdoors with no access to a power grid, you will need an engine-powered welder. These welders are powered by gasoline, liquid propane, or diesel generator.

Generator&#;s Key Features

Duty cycle of the Welder

One thing to note about welders is that they overheat hence the need to let them cool after some time. The Duty cycle of a welder refers to how long the welder can operate at the full output before letting it cool down.

If a welder has a 70% @ 300A duty cycle, it means it&#;s supposed to weld for 7 minutes at full amperage, then cool for 3 minutes in a 10 minute cycle. A welder with a 20% duty should run for 2 minutes, then rest for 10 minutes.

If you are a light welder, a 20% duty cycle will suffice. When the machine is cooling, you can be cutting or preparing the metals. For medium-duty welding, go for a 40-60% duty cycle and 60%-80% for heavy-duty welding. 

Open-Circuit Voltage (OCV)

Also referred to as no-load voltage; open circuit voltage refers to the voltage that exists between the work piece and the electrode holder when there is no current flowing (no welding in progress).

For safety purposes, welders have a maximum OCV of 80V to prevent injuries when the welder is sitting idle. While high OCV is dangerous, it makes electrode ignition easier. The lower the OCV, the harder it will be to ignite the electrode, especially with stick welders.

Accessories the welder comes with

A welder will also come with different accessories when buying it. Some of the standard accessories that you will get include a power adapter, flow meter, gas hose, contact tips, Tig torch, and electrode holder. Note that what is included depends on the welding machine you buy.

Brand and Budget of the Welder

There are hundreds of welder models, all claiming to be the best in their category. However, not all of them are high quality. To avoid disappointments, consider getting a welder from one of the top brands in the industry. With a top brand welder, you can expect it to offer high-quality welding and will last for years. Most of the top brand welders cost more but provide value in the long run.

The leading welding machine brands include CRUXWELD, Miller, KEMPPI, PANASONIC, ESAB, Hobart Welders, Fronius, Lincoln Electric, and Eastwood.

Below is an average of how much welders cost.

• Entry-level welder &#; $200 to $400
• Intermediate welder &#; $500-$800
• Pro-level welder- $-$

What we have Covered in this Article

As you have seen, before purchasing a welding machine you need to consider personal needs to buy a suitable welder. Understand the different welding processes and the types of metals they weld, and the technical aspects of the welding machines.

Also consider factors such as the welding machine build quality, length of warranty, and what accessories that come with the welder that you want to purchase.

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