Things to Consider Before Buying a Welding Machine

A welding machine should be considered a long-term investment which makes it important for potential buyers to consider all of their alternatives before making a purchase. Unfortunately there is no such thing as a universal welding process. The situation will largely dictate which welding processes are suitable and what type of welding machine should be used. Some of the most common welding processes include metal arc welding (MIG), gas tungsten arc welding (TIG), shielded metal arc welding (stick welding or stick electrode welding), and flux cored welding.

The first thing to consider before buying a welding machine is whether or not it is actually the best solution. It is important to know that this is different from plasma cutting. Welding is a process used to join are fastened two pieces of similar metals together by melting and fusing them. On the other hand, plasma cutters are used for cutting in fabricating metal. Many people confuse the two or incorrectly assume welding and plasma cutting can be accomplished with a single machine.

The second thing to consider is what type of material will commonly be welded. Gas metal arc welding is a process which consists of feeding a bare metal filler wire in conjunction with a shielding gas through a hand-held torch unit. On contact it creates the ark which does the actual welding. For the most routine joining applications, a MIG welder is typically the best option. Not only is it the easiest process to learn, but it can weld light gauge material including the most common metals (carbon steel, stainless steel, and aluminum)

The third thing to consider is whether or not there are any time requirements which may restrict the process. This is important because each type of machine has a different duty cycle. The duty cycle is the length of time a welder can be used before it needed to be turned off so that it can cool down. Less expensive welders often have a shorter duty cycle than more expensive welders. Some welders can even continuously run at a 100 percent duty cycle.

The final thing to consider is available power and portability. If the welding machine is being purchased for use in a shop it may not need to be very portable and will constantly have a significant power supplied access. On the other hand, heavy duty field repairs will require a package which can effectively manage different sizes and types of metal while also being easily portable. Welding machines use in field repairs may not have access to electrical hookup which means a gas powered, engine driving generator will be needed to supply welding and auxiliary power.

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Hobart Tig Welding Machine Vs Miller Diversion 165

Hobart used to be one of the real heavy hitters in the welding machine manufacturing industry. So what happened? The welding supply industry has experienced buy outs and consolidations just like many other industries in the past 20 years or so. Even the welding supply chain I deal with has gone from Holox, to Linde, to Airgas in the last 7 or 8 years. And honestly, there have been some hiccups along the way but that's another story for another day.

ITW - Illinois Tool Works now owns both Miller Electric and Hobart Welding. In order to comply with the Feds rules on monopolies, Hobart has been focusing on welding machines under 250 amps.

In other words, the hobbyist market.

Does that mean that Hobart Tig and Mig Welding machines are toys that are only suitable for weekend warriors?

Absolutely not.

Take the Hobart TIGMATE AC/DC Stick and TIG Welding Machine for example. It is a fully functional Tig welder that can weld aluminum as well as steel, stainless steel, and cast iron. Hobart's specifications state it can weld aluminum up to 3/16 thick but realistically, with only 165 amps, you might be yawning while you wait for a puddle. 1/8" thick aluminum should be no problem with 165 amps...even with a 20% duty cycle. Especially if you use a 50/50 helium argon mix.

The low end minimum arc start amperage is listed at 20 amps for welding steel on DCEN. That could be a real issue on really thin body panels or thin wall chromoly tubing. It can be overcome by using a small piece of copper to start the arc.

Have you heard of Hobarts 5/3/1 warranty? It means 5 years on the transformer and main components, 3 years on the pc boards, and knobs etc, and 1 year on the peripherals like regulators, torch, etc. Not too shabby.

So what's the problem? This little sucker is listed at 167 lbs for the shipping weight. Wow!

20 years ago that would not have even raised an eyebrow. But now that inverter power sources are available, 167 lbs seems really heavy for a 165 amp tig welding machine.

That makes me want to keep shopping...So Lets look at another option.

The Miller Diversion 165 is a very comparable to the Hobart Tigmate. Duty cycle is almost identical, accessories are the same since both the Miller and Hobart TIG welding machines come with torch, regulator, and everything else needed to tig weld except a cylinder of argon.

But the thing that interests me most about the Miller Diversion 165 is that it has a low end arc start of 10 amps. So the bottom line is that the Diversion has even better capabilities than the Hobart TIGMATE and it weighs less than 1/3 as much (about 50 lbs). That is because the Diversion 165 uses inverter technology to greatly reduce the weight of the transformer.

The prices of the 2 tig welders are almost identical, the warranties are very similar. But the weight and the low end arc starts are enough to make the big difference.

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Portable Welding Machine - A Boon to Welders

Many welding operators need to move from one place to another. A portable welding machine is must with large multiple plants as they need to move around and it is undecided where it is going to be needed from one hour to the next. It is a known fact that the right kind of equipment for the job can save you time and increase productivity. These units are handy and advance and suitable for all applications, productions, maintenance and special purpose welding.

To provide necessary volts and amperes to the portable welding machine they are connected to generators. For them to work they require a prime mover, an electric motor or fuel powered engine. With some places having direct and other alternating there can be many problems with the device. So without the correct set up the machine would not work. To eliminate this problem, today the engine driven prime mover, fueled by gasoline, kerosene or natural gas provides the best solution for consistent and stable electricity.

Arcon develop one of the most rugged and reliable portable welding machines. Arcon Welding LLC was founded in 1999 as today it is the industry leader. Its workhorse series of portable arc welders are considered to be the most reliable stick, TIG, MIG and Stud welders. It is truly called the welding professionals daily companion. It is the only mobile constant power unit in the market. It is built for TIG welding with an industrial robot with time proven SCR inverter type power supply. It is light and weighs only 80 pounds. It features built in circuit breaker and provides 5 zone of thermal protection. It is corrosion resistant and has smooth welding.

The stud horse by Arcon is the first portable unit on the market capable of welding up to 5/8 inch full base studs with the welding current capacity of 1200 amps. It welds steel, stainless steel and aluminum. It weighs 80 lbs and comes with five years warranty against corrosion related failures in natural environment. It has digital time current set up and to withstand toughest natural environments it features solid fiberglass case. Arcon has a welding machine to meet different needs and operations. They have selected combinations that can be best used for the smoothest welding conditions.

While choosing a portable welding machine it is important to understand the nature of the work. A MIG device has greater speed but a TIG weld will be better quality weld. For manufacturing highly visible consumer products TIG is best as it delivers better appearance. MIG or Stick unit is preferred while thick metal as they put more heat into the metal. A simple MIG machine is good for hobbyist as they do not need sophisticated high tech TIG machines. Select the machine depending upon your need and work nature.

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The Need of Welding Machines in the Various Industries!

Discussing the need of machines in an array of industries

The requirements of the welders in different industries are as follows -

These machines are required in the manufacturing of transformer, machine parts, fabrication along with the electronic control manufacturing. The automotive industries totally depend on these machines for providing them the shapes and designs to the vehicles.
These are also required for controlling and giving special designsin steelprocessing industries and also for the steel plants.
The special purpose of the welding equipment's is required to provide the designs for the customer's job and the production requirements. Automation of SPM machines also comes under this welding category.
The machines include the requirements for the minimum overlap of the welders along with the prep lap welding and the C frame equipment's.
These machines are also useful to the wire industries producing cable, wires, wire ropes and other wire products.
What is a butt welding machine and its advantages?

The demand of the various products is increasing day by day. Thus it is very essential to improve the quality of the machines in every aspect. The butt welding machine is one of the latest resistance machines that fulfill the requirements by providing 25% higher joint strength than the parent metal.

They offer the following advantages to the clients

The machine is portable in size and it can be easilymoved from one place to another in the trolley.
The most important advantage of this machine is its operation. It is much easy to operate and anyone can easily do.
The housing of the main body controls and welding transformer is ventilated and the construction of the steel alloy makes it perfect.
How to pick the apt welding machine?

The welders are the requirements of the industries in cases of perfect construction and to design different objects. There are different types of machines which are available that works mostly on arc welding as well asresistance welding. The metal is the substance that needs to be welded. Now the most important thing is that how should an industry pick the right machine on a good deal? The answer must be the dealing process of the industry with the reliable provider. Dealing with a professional who has the perfect knowledge regarding the different types of welders can offer a better guidance.

The demand of products enhances the using of welding machine and thus the various industries needs the latest technology.

Explaining exactly what a flash butt welder machine is; its advantages are also mentioned. At the end, it is elucidated how one can find the correct welding machine and get a good deal on it.

Laser Welding Machine - A Great Way To Start Your Own Business At Home And Quit Your Day Job

If you're looking to buy the right kind of laser welding machine in there a few things that you need to be aware of before making your purchase. The laser welding machine is a big investment that shouldn't be taken lightly. Do your research and make sure you buy the right one that suits your needs.

If you use this kind of machine correctly you should be able to all sorts of things to help enhance your business. Perhaps also you are looking to start a laser business by making engravings and such things. The laser welding machine is a perfect addition to this sort of business. What can you do with that?

With a laser machine you can start an engraving business. If you buy the record a machine you should have a laser welding computer built right into it to help you make the precision cuts that you need to make. One of the best machine to forget is the laser Star technologies laser welding machine. This is a great machine because it can move found from most of the laser welding suppliers.

Things he can make with your laser machine include iPod engravings, little trinkets, and other gifts that people seem to love. There is no end to the amount of things that you can engrave with your laser engraver. The welding comes easily for you if you are patient and you read the manual correctly.

It's amazing what you can do with your laser machine at home. All you have to do is install the fan in your basement in order for the heat generated by the machine to cool down, and then you can put your machine upstairs. Therefore you can work from the comfort of your own office with your laser machine and have it make very little noise. If you're looking to become self-employed then this is the right kind of idea for you because the startup costs are a little expensive. The most expensive lasers can cost up to $20,000, but you don't necessarily need to pay that much. If you do enough research you should be able to find a quality laser machine for around $500, and that can be written off as a business expense.

In conclusion, welding equipment can be a great addition to any sort of home business, especially if you want to escape the workforce. Just do your research and buy a laser welding machine that will be high and quality and reasonable in price.

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Basic Function of Semiautomatic MIG Welding Machine

MIG WELDING MACHINE

Functioning a satisfactory MIG Welding process requires more than just semi operative skill. The setup, voltage, current, electrode extension, and welding angle, as well as other factors, can dramatically affect the weld produced. The very best welding conditions are those that will allow a welder to produce the largest quantity of successful welds in the shortest period of the time with the highest productivity. Because these are semiautomatic or automatic processes, increase productivity may require only that the welder increase the travel speed and current.

MIG WELDING MACHINE SETUP

In complete MIG welding machine setup, we require GMAW or MIG power source, welding torch, wire feeder unit, shielding gas supply, gas regulator, flow meter & heater, shielding gas hoses and MIG wire.

If the shielding gas supply is a cylinder, it must be chained securely in place before the valve protection cap is removed. Standing to one side of the cylinder, quickly cracked the valve to blow out any dirt in the valve before the flowmeter regulator is attached.

Install the reel of electrode (welding wire) on the holder and secure it. B sure the power is off before attaching the welding cables. The electrode and work leads should be attached to the proper terminals. The electrode lead should be attached to electrode or positive (+). If necessary, it is also attached to the power cable part of the gun lead. The work lead should be attached to work negative (-).

CHECK WIRE FEEDER UNIT

Using the MIG Welding Machine that was properly assembled, we need to turn the machine on and thread the electrode wire through the system. Switch on the power and check the gun switch circuit by depressing the switch. The power source relay, feeder relays, gas solenoid and wire feeder motor should all active.

Cut the end of the electrode wire free. Hold it tightly so that it does not unwind. The wire has a natural curve that is known as its cast. The cast is measured by the diameter of the circle that the wire would make if it were loosely laid on a flat surface.

Note: With the wire feeder running, adjust the feed roller compression so that the wire reel can be stopped easily by a slightly pressure. Too light a roller pressure will cause the wire to feed electrically. Too high a pressure can turn a minor problem into a major disaster.

GAS DENSITY AND FLOW RATES

Density is the chief determinant of how effective a gas is for arc shielding. The lower the density of a gas the higher will be the flow rate required for equal arc protection. Flow rates, however, are not in proportion to the densities. Helium, with about one-tenth the density of argon, requires only twice the flow for equal protection.

ARC VOLTAGE AND AMPERE CHARACTERISTICS

The arc-voltage and amperage characteristics of MIG Welding are different form most other welding processes. The voltage is set on the welder, and the amperage is set by changing the wire feed speed. At any one voltage setting the amperage required to melt the wire must change as it is fed into the weld. It requires more amperage to melt the wire the faster it is fed, and less the slower it is fed.

ELECTRODE EXTENSION

Because of the constant-potential (CP) power supply, the welding current will change as the distance between the contact tube and the work changes. Although this change is slight, it is enough to affect the weld being produced. The longer the electrode extension the greater the resistance to the welding current flowing through the small welding wire.

With a standard MIG Welding CC power supply this would also reduce the arc voltage, but with a CP power supply the voltage remains constant and the amperage increases. If the electrode extension is shortened, the welding current decreases.

WELDING GUN ANGLE

The term welding gun angle refers to the angle between the MIG Welding gun and the work as it relates to the direction of travel. Slight changes in the welding gun angle can be used to control the weld as the groove spacing changes. A narrow gap may require more penetration, but as the gap spacing increases a weld with less penetration may be required. Changing the electrode extension and welding gun angle at the same time can result in a quality weld being made less than ideal conditions.

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Methods of Arc Maintenance in Welding Machine

Once a stable arc with proper thermal equilibrium has been established, it is essential to maintain it so that welds of consistent quality can be achieved. Normally, it is not difficult to re-ignite a stable arc, if it goes off momentarily. Whereas thousands of volts may be required to initiate an arc in TIG welding machine (gas tungsten arc welding), it may require only tens or at the most hundreds of volts to reignite it.

Maintenance of an arc when welding with an ac power source is rather a problem because the arc extinguishes every half cycle when the current is zero, that is, it will extinguish 100 times a second with a normal 50 hertz mains supply. For re-ignition the required voltage must be available at the time the current is zero. This is achieved in ac welding by keeping the current and voltage waves out of phase by using a power source with a low operating power factor of about 0.3.

For these conditions, almost the full OCV (open circuit voltage) is available to re-ignite the arc while the current is zero. The operating power factor of a power source can be improved while maintaining the ease of re-ignition only by using auxiliary means of maintaining or re-igniting the arc, for example, a high frequency high voltage spark gap oscillator can be used to supply a high voltage pulse at the appropriate instance. If such a technique is used to maintain the arc, then the power factor of normally adopted for gas tungsten arc welding using an ac welding power source. The situation can be further improved by using thoriated electrode with better electron emitting property.

Similarly, in arc welding machine (shielded metal arc welding) the electrode coatings with lower ionisation potential help in easy re-ignition of the welding arc.

In dc welding machine the arc maintenance is rather easy and it is only at the time of short-circuit between the electrode and the workpiece that the arc is extinguished. However, this problem is solved by providing suitable dynamic volt-ampere characteristics of the power source. Here again electrode coatings with low ionisation potential or with better emissivity can help in easy initiation and maintenance of the welding arc.

Role of Electrode Polarity

Arc welding machine can be carried out either by ac or dc. If ac is employed there is no question of electrode polarity as it changes every half cycle. However, if dc is used it is possible to make electrode either negative or positive.

More heat is produced at the anode therefore in all processes using non-consumable electrodes it is better to connect the electrode to the negative terminal to keep the heat losses to maintain. However, it may not be always possible to do so because, at times, the cleaning action of the mobile cathode spot needs to be utilised to release the tenacious refractory oxide layer from the metal, for example, in welding aluminum and magnesium. In such cases it is preferable to use ac so as to make compromise between thermal efficiency and cleaning action. Thus TIG welding machine (gas tungsten arc welding) and carbon arc welding machine processes normally employ ac power sources when cleaning action on the work piece is necessarily needed. When such a compulsion is not there than dcen may be used.

When consumable electrode is used, the metal transfer from the wire electrode to the work piece is more uniform, frequent and better directed if the electrode is made the positive. DCEP or reverse polarity is, therefore, popular with mig welding machine (GMAW) which also provides necessary cleaning action on metals with tenacious oxide layer such as aluminum.