How To Choose a Welder ? Here We Explained In 5 Steps

With so many different welding techniques, choosing the elder becomes difficult for someone who has just started welding. To complete a project, you need to select a suitable welding machine, depending on the technique you frequently use.

Furthermore, you also need to consider how frequently you weld- regularly or occasionally. For any welder, the main goal is to find a machine that completes the project fastest. The leading welder-producing brands are ESAB, Hobart, Miller, and Lincoln.

This article will guide you in choosing a welder for you.

Types of Welders

The most common welders that are used are:

• (MIG) Metal Inert Gas
• (TIG) Tungsten Inert Gas
• (SMAW) Stick welding Or Shielded Metal arc Welding and
• Oxy-Acetylene Welding

Besides these techniques, other techniques use high-power machine welders.

But, as a welder, you need to understand that not each technique will be suitable for the metal you use. Hence, you must have a decent knowledge of the welding process and metal thickness for this.

Step 1: Determine The Kinds of Metal You Are Gonna Be Welding

The first step to choosing the right welder is to know about the metal you will be welding. Each metal has a different skill level and may only work well with a particular welding process.

1. Carbon Steel

Most welding projects involve carbon steel materials like pipes or sheets of different thicknesses. It is more heat resistant and you need to use high heat to melt and weld the work pieces.

Using carbon steel may be a great advantage if you have just started welding. On top of that, carbon steel also works well with most welding techniques and is relatively easy, irrespective of skill level.

2. Stainless Steel

SS (made of steel, nickel, and chromium) is unlike carbon steel. It often behaves abnormally when in the presence of high heat. But, it is widely used in the auto industry and food and beverage vessels as it is anti-corrosive.

Most welding professionals use MIG or TIG with stainless steel. Due to its low thermal conductivity, stainless steel requires less current and heat. Besides that, you must control the molten metal and the arc properly to weld the joints.

If you use a stick welding method, you can use a stainless stick welder to complete the project. But, since SS is susceptible to high heat, you must opt for a thick welding stick.

3. Aluminum

The main issue with aluminum is its high heat conductivity. Due to this, you need to apply more heat to melt the metal. The high heat can lead to work piece distortion, and you must avoid that at any cost.

Hence, welding with aluminum is more complicated. While most people prefer the MIG technique that supports pulse welding, you need to use a spool gun if the wire feeder fails to work correctly.

If you are using a TIG welder, you need a machine supporting AC electricity. You can use an inverter welding machine that supports square waves, pulse current waves, etc. Hence, the price may go a little higher.

Even though you can use stick welding, you need to use a very thick stick electrode that can withstand the heat.

4. Titanium And Other Exotic Metals

Titanium is mainly used in making bicycles and airplanes. Similarly, Chromoly is used primarily in the automobile industry, especially in making cars and motorbikes. All these exotic and expensive metals have thermal sensitivity and must be handled carefully.

In such cases, the best option is a TIG welding machine that allows you to control the whole process swiftly and protects the precious metal.

Step 2: Set a Current Range That Covers All Metal Thicknesses

The metal thickness varies depending on the project and the metal you use for welding. In simple terms, thicker metal work pieces require more current and heat.

The metal thickness often depends on the project you are working on. While auto-body welding requires thinner sheets, farm welding usually requires thicker metal sheets.

Here is a compressive chart on this:

Welding project	Metal thickness
Car body	3/16  inches maximum
Boats, motorcycles, and heavy-duty cars	1/16-1/8 inch
Fencing and trailer frames	¼-5/16 inch
Thicker construction parts	More than 3/8 inch
Lawnmowers, tube frames, and bicycles	1/16 inch
Regular repair(medium to heavy duty)	3/16-1/4 inch
Landscape welding, including farm and ranch repairing	5/16-3/8 inches
Utility trailers or hunting trailers	1/16-1/8 inch

As you can see, each project has different welding thicknesses. With thinner workpieces, you can work in lower amps; higher amps are needed for heavy-duty and thicker welding projects.

Furthermore, you also need to check out how the arc works or how the metal works with the heat you are applying. For each 1/100 inch of steel thickness, they need to use one amp of power.

Choosing a welder that suits most techniques is better if you work with different metals. On top of that, you also need to consider the skill level for each welding process.

 Here is a tabular form for this:

Step 3: Decide The Part You Will Be Welding

Next is the workstation or working environment. The working environment and place are crucial when choosing a welding machine. Here are the possible aspects that you need to consider-

1. Power supply

You can plug in the welding machine and start working using an open grid or electric power supply. In this case, the voltage and amperes may differ, and you may need to choose a machine depending on that.

2. 220/240 Volts AC

It is mostly used in 30 amps circuit high-power welding machines. You can find such devices in industrial workstations requiring heavy-duty welding tasks. If you need to complete such complicated tasks, you may need to get this power supply. In such cases, hiring an electrical assistant is a great idea. The assistant will be in charge of wiring the circuit to the control panel.

3. 110/120 Volts AC

It is primarily available for homes as well as commercial workstations. But, this power can only be used for entry-level welding machines. So, if you are starting, it can be enough. But, if you need to perform advanced welding, the higher Volts current supply is better.

4. Single-phase vs. Three-phase

In general, you can find single-phase welding machines that take power from 220-240 Volts AC current. But, in many industrial welding workstations, three-phase devices are also used. In such machines, a third wire (hot wire) is added to the circuit, making powering up larger motors possible. It increases amperage availability and also increases energy efficiency. Even though these arrangements may cost more initially, in the long run, the savings are more. But, creating an arrangement is not possible in your home workstation.

5. Off-grid Scenario

If you do not want to have a conventional power grid system or work in a place where power outages are frequent, you can consider going off-grid for welding. You can use either a welder generator or an engine-driven welding machine. Similarly, these machines are also great for outdoor workstations where you cannot get power from a grid supply.

Mostly, farmers, ranch owners, and those who work in the field choose this system.

You can buy gasoline, liquid propane, or a diesel generator to power the welding torch or gun. Primarily, the generators are used for stick-welding guns.

If you want to go off-grid completely, always look for a generator that has symbols of Constant Current (CC) or Constant Voltage (CV) to get a constant power supply.

6. Presence of wind

If you are working outdoors, the presence of wind creates a significant factor in any welding. The air can often react with molten material. Hence you need to use a gas shield (Inert gas shield in MIG) or a gas shield made of carbon dioxide or a mixture of inert gases and carbon dioxide to protect the work pieces. But, if the breeze is too frequent, the gas shield may not work.

In such conditions, flux–cored MIG welding works great as it offers dual shielding. The coated wire stick offers excellent shielding, and you do not require extra gas shields.

If there is a light breeze, you can use stick welding machines that create an extra shielding layer.

In both cases, the wire feeder contains strong deoxidizers that prevent oxidation of the molten metal.

Step 4: Understanding Main Features To Compare

1. Duty Cycle

While buying a welding machine, you must consider the duty cycle of that particular machine. It is about how much welding you can complete for a ten-minute cycle.

In some models, the duty cycle is mentioned as a percentage. You may need to calculate that.

Most entry-level welding machines generally have a maximum of 70 amps current level with a 10% duty cycle. That means you can weld one minute against each ten-minute cooling down cycle.

Here is a recommended level of welding machine duty cycle:

• Light usage/entry level- 20%
• Heavy-duty welding machine- 60 to 80%
• Medium duty machines- 40 to 60%

But the trend has changed now. Brands may offer higher duty cycles based on lower amperage settings. For example, if a welding machine has a 10% duty cycle against 140 amperages; it may come with a rating of 30%, with amperage of 115. So, always make sure to check the amps before deciding on a machine.

The thumb rule is to buy a welding machine with a higher maximum current than the level you use. It will allow you to increase the duty cycle effectively without spending a lot.

2. Open-Circuit Voltage

Open circuit voltage refers to the voltage emanating from the welding gun when the current is not flowing.

If you keep the circuit live, it can cause grave situations, even life-threatening injuries.

OCV controls how the touch works while striking the arc. It may offer you some extra power while you start welding.

For welding stocks E6010 & E7018, higher OCV is required to ensure the arc is crisper in the initial welding stage.

Striking the arc with low OCV can be difficult if you are a beginner. Hence, learn about the OCV in detail to weld properly and safely.

3. Thermal Overload Protection

You will be working with the welding machine for a long time. Hence, go for a device that has thermal overload protection. It cuts the output power whenever the machine circuit gets overheated.

On some machines cooling fans are installed to cool down the machine while you are working.

It is safe bait as you will not have to worry about heat-related issues.

Step 5: Determine If You Need To Use Compressed Gases

If you are using a gas shield, you must buy a cylinder that produces a continuous shield while working. In general, a single inert gas or inert gas mixture with carbon dioxide or only compressed carbon dioxide is used as a gas shield. You can use argon, carbon dioxide, helium, and nitrogen as a blend or single. Most of the time, a combination of carbon dioxide and argon is used.

In most TIG welding projects, argon gas is used. But, depending on the project, a mixture of helium and argon may also be used.

If you need to use a compressed gas shield, here are some factors that you must consider:

• Some welding machines come with an in-built pressurized to store compressed gas shields. Make sure to refill it from time to time. It is better to find a supplier who offers tank refills. Alternatively, you can replace the empty tanks with a filled one.
• If your welding machine does not have an in-built tank, get a spare gas cylinder to create the gas shield. You can find cylinders in different shapes and sizes. So, before buying, always consider how frequently you weld or which type of projects you must complete by buying the perfect gas shield cylinder.
• You can buy MIG welding filler wire instead of stick welding. These rods with flux-core are great as these filler rods eliminate the cost of purchasing shielding gas cylinders.
• Always make sure to get the gas cylinders inspected by the authorities. Even if you buy a used cylinder, check it on time to prevent any unnecessary issues. On top of that, always keep the papers ready while you go for the inspection.
• Different mixtures of gas shields are used. For example, 75% argon and 25% carbon dioxide gas shields are used in MIG steel welding. For stainless steel, a mixture of 7.5% argon, 2.5% carbon dioxide, and 90% helium gas is used for shielding. On the other hand, aluminum welding requires a pure argon gas shield.
• Always check out the blend while buying. If you work with different metals, you may also need to buy one cylinder for each type.
• Most welders use oxy-acetylene torches, as buying only acetylene or oxygen is expensive.

Conclusion

Buying a suitable welding machine requires proper research and planning. Always consider the material you weld, the technique, and the material thickness first. Furthermore, view the working environment, the power status, and the gas cylinder. For effective results while welding, get a machine with a reasonable duty cycle also.

You can create a proper shopping plan by using this article as a shopping guide before you venture out to get the sewing machine for your upcoming projects.

Source: How To Choose a Welder?