Types of Welding Machines

The humans invented the first gas welding torch to locally melt metal with focused heat. These torches made way for arc soldering, which gave even more intense heat. The TIG welder is one of the most versatile welding machines that can pinpoint heat even more, which allows for smaller, precision welds. Another popular type of soldering machine used today is the MIG welder.

Arc welding

Industries use Arc welding or stick welding in a number of applications which includes construction and repair work. This type uses a welding power supply with either direct or alternating current to create an electric arc between an electrode and the base material to melt metals at the fusing point. It's covered with flux to protect the weld area from oxidation and contamination. There are two types of arc welders which include air or oil cooled AC welders or DC welders that use an air cooling system. Arc welding is only limited to soldering ferrous metals.

MIG welding

MIG or metal inert gas soldering is a semi-automatic or automatic arc welding process that is also known as gas metal arc welding (GMAW). The process features a continuous and consumable wire electrode and shielding gas, fed through a MIG torch or the CO2 fusing gun. A direct current power source is usually used with a MIG welder, although alternating current is the second choice. One of the benefits of these soldering machines is that the voltage, amperage and the speed is adjustable. These machines also feature a variety tension and valve to control the flow of gas. A MIG welder used without shielding gas in a process is known as flux core arc welding. In this process the welding wire has a core filled with flux and has a hotter arc capable of welding thicker pieces of metal. A MIG welder used to weld copper, zinc, brass, steel, tin and aluminum. These machines are versatile and easy to learn, and is the ideal choice if you want to work on a variety of metals by purchasing only one welder.

TIG Welding

TIG soldering or tungsten inert gas soldering is a process that involves a non-consumable tungsten electrode which delivers current to the welding arc. Argon gas is commonly used as the shielding gas to protect the weld area from contamination. A TIG welder is typically used to weld thin sections of aluminum, magnesium, copper alloys, and stainless steel. One of the biggest advantages of the TIG welder over the MIG welder is that the operator has extensive control over the weld.

Rent and lease new and used welding machines including used TIG Welders and used MIG Welders. There are many welder rental centers that provide this service.

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Buying or Leasing Quality Refurbished Welding Machines Makes Good Business Sense

Welding machines of various types and sizes used in most factories, construction industries, and manufacturing units; often dictates the kind of job they performs. There are welding machines used for home DIY jobs, but these are smaller units and work well for jobs around the home. During the welding process, the metal joints are heated till they start melting and then joined to the other piece and fused together.

Leased Equipment

Depending on the type of job, there are a range of welding equipment available which use different types of energy sources to do the job i.e., it could be electric, gas, laser, friction, etc. Some of the bigger soldering machines are quite expensive and buying them for just one job does not seem economically sound. This is where it would make more sense to rent a welder from a top soldering equipment renting or leasing company. They would have all the latest types of soldering equipment in stock which could include gas or LPG-driven welders, diesel engine driven welders, TIG welders, stick welders, advanced process welders, etc. They are also perfectly capable of supplying you with accessories needed when performing a welding job from automatic and semi-automatic wire feeders, welding cables, DC converters, etc.

Secondhand Welders

For companies on a tight budget, who do not want the cost of buying a brand new welding machine, there are many vendors having completely refurbished welding machines that can do the work as efficiently as the new one. Their inventory of used welders is quite exhaustive, and includes gas and diesel driven welders, stick and multi process welders, TIG welders, stud welders and other welding accessories. Besides the above, they could also supply diesel generators, power distribution panels, light towers, automatic and semi-automatic wire feeders, etc.

Welding Methods

The type of welding equipment required depends on the job to perform, because soldering is applicable on land, underwater, and even in outer space. However, most of the welding equipment used in factories, construction, and manufacturing are for arc soldering, forge soldering, gas soldering, friction soldering, resistance soldering, robot soldering etc. The most common type of soldering is gas soldering also called oxyacetylene welding, because oxygen and acetylene gases mix to produce a very high temperature at the torch to melt the edges of the metal being worked on. this is very popular as it can be used as a portable system. Arc welding is the process of creating an arc of electric current between the electrode and the material being welded fusing them together.

For companies that cannot afford to buy new or secondhand welding machine and accessories, renting or leasing one for the job makes perfect economical sense.

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Know What Is Best For You: Top Five Manufacturers Of MIG Welding Machines

MIG Welding is very popular among welders and can be done by both experts and beginners. This is why there is a steady influx of MIG Welders buying MIG machines from companies. Here is a comprehensive list of the five top manufacturers where welders mostly purchase from.

Clarke Welders

Clarke MIG Welders have good reputation in the industry, and they offer affordable machines. Its most famous model is the MIG 135TE which has a non-live torch, a professional look, and a turbo cooling fan. This is ideal for DIY repairs on cars, and other home jobs involving welding.

The other 110 Voltage models are ideal for metals measuring up to 3/16" thick sheet metals such as auto body parts. On the other hand, the 220 Volt ones are better for carbon steel, aluminum, stainless steel, and iron castings that are about 7/16" thick.

Aside from these, what is often most appreciated with this brand is its good warranty and great performance which enables it to compete with the major brands.

Lincoln Electric

MIG Welders produced by Lincoln Electric are best to be used by those who put more prime on the cosmetic appearance of the finished weld. Great, smooth, and clean looking welds can be made from these models because the arc initiated is smooth and will not easily burn thin metals.

Time-efficiency is also another characteristic of Lincoln MIG Welder models which is very appealing. This because there are no slags to chip off after the welding process as the models have spatter levels that are considerably lower than those machines with flux cord. Lastly, they are best to work with aluminum and stainless steel.

Miller Welders

The Miller MIG Welding machines offer top quality models and they have a great variety to choose from. Most of their products are mainly used by/for light to medium fabrication, garage shops, auto body shops, farms and ranches, and other home welding projects.

Miller MIG models are classified into heavy duty and light-medium duty. The former can easily weld 3/8" thick or ½" thick metals in a single pass, depending on the model. The light duty ones can weld 3/16" to ¼" thick metals in a single pass. These brand's products can last longer but costs more than the others.

Hobart Welders

There are a lot of great reviews on this brand and it is also one of the most popularly bought MIG welding machines. They are reliable, durable, and portable which makes work easier to finish. They can also work in mild or solid stainless steel, and can be easily adjusted to accommodate other materials. They also have great warranty offers. Though, unfortunately, they do not weld aluminum well.

ESAB

Versatility and dependability are the marketable qualities of ESAB MIG Welders which puts them stably in the top manufacturers of MIG welding machines. These MIGs can weld different materials and some are even capable of doing TIG and Stick welding. They are, however, designed mostly to withstand construction and other rugged industrial environments where MIG welding machines are used for a long period of time. Since ESAB is a major brand, its parts can be bought in a lot of sources.

Choose well. Because aside from good workmanship, one of the best ways for MIG Welders to show case their experience is in the way they choose their equipment.

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Various Types of Arc Welding Machines

A look at some of the various welding machines and supplies will give you a clear glimpse into their quality and versatility.

The Inverter DC ARC Welding Machine (EWDA Series): There are four different machines in this series. Torch cable and earth cable accessories are available for the entire series.

Features include:
• IGBT module-type control
• Electric shock protection built in
• Electric power conversion efficiency greater than 85%
• High duty cycle
• Automatic output cutoff at high interior temperature

The Inverter AC/DC Tig Welding Machine: There are two different machines in this series. Accessories available for both include torch and earth cables, as well as a regulator.

Features include:

• DC TIG, DC Pulse TIG, DC MMA
• AC TIG, AC MMA
• Arc spot welding
• Crater off/single, repeat selection
• High frequency start
• Pulse width/frequency, after-flow time control
• Up/down slope time control is possible
• Start/crater/pulse current control
• Mild Steel, nickel alloy, copper alloy, stainless, aluminum alloy, titanium alloy

The Inverter Mig/Mag C02 Welding Machine: There are three different machines in this series, both including torch and earth cable accessories.

Features include:
• DC TIG, DC Pulse TIG, DC MMA
• AC TIG, AC MMA
• Arc spot welding
• Crater off/single, repeat selection
• High frequency start
• Pulse width/frequency, after-flow time control
• Up/down slope time control is possible
• Start/crater/pulse current control
• Mild Steel, nickel alloy, copper alloy, stainless, aluminum alloy, titanium alloy

Submerged Arc Welding Machine (Saw and Gouging): There are two machines in this series with available accessories of a welding cable, a carriage rail, and flux recovery.

Features include:

• Application: 1) Carbon arc air gouging 2) Submerged arc welding for various steel products
• Electric circuit automatically operated by the gouging switch and can decrease unnecessary non-load electric power when arc is off
• Feedback of constant current
• Unified PCB, which allows for easy replacement and maintenance
• High efficient Thyristor control
• Main transformer, reactor, and radiator designed to consider temperature characteristics, insulation, and safety factors.

Inverter Plasma Cutter:

Features include:

The beginner can available for easy operation
Cutting is available by contact or non-contact of no-nozzle
High speed cutter is available without thermal distortion
Auto-stop at low voltage, over-current, overheat, air pressure error strong power

Other welding machines and supplies include a "DC Tig Machine", a "Welding Carriage", and more.

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Miller Welders - All Welding Machines Break Eventually - What Then?

Miller Welders are built tough and made to last. But we all know that nothing lasts forever and everything breaks eventually,..You with me?

I like Miller Electric because of their people and their service. The best thing Miller has going for them is that when one of their welding machines breaks, They have great customer support.

Miller welders are tested and tough and even go through a harsh series of tests like the "Arizona room" as well as a salt spray corrosion test to simulate real world conditions and to ensure durability of the product.

But like I mentioned earlier "Everything Breaks eventually". And Miller Welders are no exception. The newer inverter power sources do all sorts of neat things like arc shaping and pulsing but they seem to break more often than the old transformer style machines like the Syncrowave 250.

And just what do you do when your machine breaks?

If you are a weekend warrior welder tinkering in your garage, you might be able to wait for your local welding supply to pick it up and fix it for you....no big deal, so you won't get your brother in laws lawnmower deck fixed for a few more days (he is a jerk anyway).

But what about those of us who are facing a deadline for completing a real paying welding job? If you are in that boat with me, then you know you either need a spare welding machine, or you need to be able to fix your problem quickly and get to welding again.

Miller Electric has a reputation for really good customer support. With a 3 year warranty and availability of parts, Miller can usually get you up and running quickly. And the best thing about them is that they seem to have common sense... And They will usually even work with you in the grey areas.

I am sure there are other welding machine brands available like Lincoln or Esab that offer good customer service but my experience has mostly been with Miller Welders and Miller's Reps...and so far so good.

I remember attending a seminar once where those in attendance were mostly technicians who fixed welding machines.

To a man, they all preferred working on Miller Welders. Not so much because of innovation or simplicity, but they knew they were going to get help when they made the telephone call to Miller's Support Dept.

That sold me on Miller right there on the spot. I have since heard that other welding machine companies have been stepping it up a notch in customer support. I hope that's true. This country needs good products with good support to compete with the cheap Chinese welders on the market.

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Arc Welding Machine Power Source

For striking a welding arc it is essential to have the desired current in the welding circuit. Depending upon the type of current required (ac or dc) it may be obtained from the following sources.

A welding machine or frequency changer (for ac welding machine).
A dc generator of a welding rectifier (for dc welding).
The no load or open circuit voltage (OCV) should be high enough to strike an arc, but not so high as to endanger the welding operator, for example, for a 2000A transformer the OCV should not be over 90 volts through for lower currents of say upto 600A OCV may be upto 100 volts.
With direct current, the OCV must be at least 30 to 35 volts while with alternating current it should not be lower than 50 to 55 volts. An open welding arc can be sustained at 18 to 40 volts.
The minimum voltage for arc ignition is 25 volts which must be attained within 0.05 second for the maintenance of a stable arc.
The power of the welding source should be sufficient to provide the required welding current.
It should be possible to tap the desired current within the available limits either in infinite steps 9stepless regulation) or in a large number of discreet steps (stepped regulation).
The voltage of the power source should adjust itself rapidly with the change in arc length.
The short-circuit current must be within limits of safety for power source windings.
It should have output characteristics which match the arc characteristics.
It should incorporate a low voltage supply for the operation of auxiliary units.
It should have a desired duty cycle and provide the required volt-ampere characteristics.
It should be light in weight, small in size, low in cost, convenient in service and easy to maintain.
Volt-Ampere Characteristics of a Welding Power Source

All welding power sources have two kinds of operating characteristics viz., static characteristic and dynamic characteristic. The static output characteristic can be easily established by measuring the steady-state output voltage and current by conventional method of loading by variable resistors. Thus, a curve showing the output current versus output voltage for a given power source constitutes its static characteristic.

The dynamic characteristic of an arc welding power source is determined by recording the transient variations occurring over a short intervals in the welding current and the arc voltage. Thus, it describes instantaneous variations occurring over a short interval of time say a millisecond. Arc stability is determined by the combined interaction of the static and dynamic colt ampere (V-I) characteristics of the welding machine power source.

The intrinsic transient nature of a welding arc is the main reason for great importance of the dynamic characteristics of an arc welding power source. Most welding arcs have continuously changing conditions which are mainly associated with striking of the arc, metal transfer from the electrode to the weld pool, and arc extinction and reignition during each half cycle of ac welding.

The transient nature of the welding arc is also due to variation in arc length, arc temperature and electron emission characteristic of the cathode.

The rate of change of voltage and current in arc welding machine is so fast that the static volt-ampere characteristic of a power source can hardly be of any significance in predicting the dynamic characteristic of a welding arc. However, it is only the static volt-ampere characteristics of a welding power source which are supplied by the manufacturer. Through they cannot give the nature of behaviour of the power source regarding its dynamic response but they are of considerable importance in determining the general overall response in controlling the process parameters.

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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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