Welding Machines

In industrial context, welding refers to a fabrication process that joins materials such as metals and thermoplastics, by causing coalescence. This is typically done by softening the work pieces and adding a filler material, which is often a welding rod, to form a pool of molten material that cools to become a strong joint. Various processes and energy sources are used for welding, such as gas flame, electric arc, laser, electric beam, friction, and ultra sound.

Welding machines can be broadly classified into different categories depending on the type of welding processes and equipment used during the process. Some welding machines use transformers for converting high voltage, low current electricity into high current low voltage, often between 17 to 45 volts and 190 to 590 amperes. These types of welding machines are the least expensive and allow welders to select the output current by either moving the core of the transformer in and out of the magnetic field or by allowing the welder to select from a set of taps on the transformer.

Some welding machines use an internal combustion engine or an electric motor to drive the alternator or generator present in these machines. The process used is similar to transformer based welding machines as power is first converted into mechanical and back to electrical energy to achieve the step-down affect.

Inverter based welding machines use high-power semiconductors such as the IGBT for building a switching power supply capable of handling high loads of arc welding. These machines convert utility electricity into high voltage and store it in a capacitor bank. The stored energy is then transferred to a secondary transformer for producing the desired welding current.

Welding machines have simplified different types of machining jobs undertaken in small and large manufacturing companies. Automated welding machines are also in use and have helped in increasing the effectiveness of welding processes.

Welding [http://www.WetPluto.com/Welding.html] provides detailed information on Welding, Welding Projects, Welding Supplies, Welding Jobs and more. Welding is affiliated with Maple Work Benches [http://www.i-WorkBenches.com].

How to TIG Weld Aluminum and Get the Stack of Dimes Look, Even With an Old TIG Welding Machine

Wanna learn how to TIG weld aluminum?

First you need a decent TIG welding machine. Not a great one, just a decent one. Already got one? You might have an old Synrowave 300 or a DialArc, an old Hobart CyberTIG or you might have a brand new Miller Dynasty 350.

Know what? It doesn't really matter. The same principles apply. If you have an old as dirt TIG welding machine, you can still make good aluminum TIG welds. Weld beads that look like a stack of dimes.

First lets look at machine settings:

Set the polarity to A/c (alternating currrent)
Make sure to set the high frequency to continuous
Set the amperage to about one and one half amps per one thousandths of inch of thickness. (up to about 250 amps then things change quite a bit)
Set both the contactor and amperage switches to the remote positon.
Set the argon or argon/helium torch shielding gas to around 15 cfh. (if you are using a #7 cup) less if the cup is smaller.
Notice I said argon or argon/helium? Argon is not the only game in town. In fact, if you TIG weld any aluminum over about .063" thick, adding helium to the mix makes a huge difference.
Now lets talk tungsten electrodes
2% thoriated have received a lot of bad press for the radioactivity issue but they do work.
2% lanthanated electrodes are a really good all purpose electrode...good for TIG welding aluminum as well as steel.
Use the smallest electrode that will get the job done without quivering at max amperage.
Remote amperage control...you need a foot pedal. Period.
Once all the settings are ok, and assuming you are welding on 1/8" thick aluminum, grab a piece of 4043 filler rod in 3/32 diameter (rarely will you use a rod as thick or thicker than the metal you are welding)
extend the electrode tip about 1/4" past the tip of the TIG torch cup and pre purge the gas by tapping the foot pedal.
hold the torch like a big first grade pencil. touch the tip of the tungsten to the metal and then pull it back about 1/8 inch. flip your helmet down and press the pedal to initiate the arc.
don't melt the aluminum right away though, watch the black stuff cook away from the arcs cleaning action before you melt the metal. Then press the pedal far enough to create a puddle that is about 3-4 times the thickness of the metal you are welding.
Now comes the part on how to achieve the "stack of dimes" look. You get that by adding the same amount of rod and by moving the torch the same distance each time you add rod. Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch, lather rinse repeat. If you do this consistently, you will get evenly spaced ripples that look like a stack of dimes.

Of course it looks different from underneath the welding helmet and it is harder than it sounds, but this is really how you do it. All that is left is the doing. It takes practice and lots of quality seat time.

To see a Video on TIG Welding Aluminum and how to get the "stack of dimes" look, as well as a whole bunch of TIG, MIG, STICK welding tips and a pantload of other welding information, visit http://www.weldingtipsandtricks.com/.

Also check http://welderreview.com/forney-299-125fc-flux-core-welder-120-volt-125-amp/

Working With a Welding Machine Made Easy

The industrial needs are increasing each day and almost all sector of activity make use of the welding technique in one or the other way. The welding processes have become so important that the companies are hiring welders who have thorough knowledge of the operation process, capacity to read welding symbols from blueprints and advanced working skills. These are basic characteristics that the companies seek in the welders. But the most important thing is the way the welder handles the machine and how he operates it. Certain protective steps should be essentially taken for making sure that the welding process is done safely and efficiently. The following steps would help the welding process easier.

The first and foremost thing to consider is the place where the prospective welding machine would be placed. It is advised to keep the machine in a dry area where air circulation is proper and there is proper ventilation. The air circulation is absolutely important because during welding all sorts of chemical fumes would be emitted following the technological process. Such fumes are hazardous and are highly risky for the operator's health. If at all open air access is not possible, the machine should necessarily have special ventilation which would be placed very close to the machine. Thus the air circulation can be assured to an extent. Moreover it is also important to make sure that there are no flammable substances anywhere near the welding machine. Substances like paints, solvents or any other chemicals of flammable nature increases the chances of accident exposures.

The second important thing would be the cleanliness of the area where welding takes place. The area should be cleaned prior to the welding process since any trace of paint, oil, rust or other impurities can possible reduce the efficient functioning of the welding machine. Here the need for protective apparels arises which is very important. The welder operating the machine should essentially wear protective gadgets like protective gloves which are fireproof, apron and a special helmet along with protective glasses. Such apparels would help the welder to prevent exposure to radiation, sparks, spatters or fumes that occurs during the usage of the welding. Above all, yet another important to be noted is that all the settings of the welding machines should be arranged in accordance with the characteristics of the metal that is going to be welded. If that is not done, then burn outs or low arc penetration would happen.

The welding machines are usually purchased for industrial use but if you are an amateur welder or a novice, you don't need to buy the machines. Evaluate the work before setting out to buy the welding machines and welding equipments. Compare the extent of investment possible along with the desired results. If you are only doing occasional welding, then a rented welding machine is more than enough. But if the welding machine constitute almost 60% of the activity, then it is better to buy one. There are many other cost effective options like purchasing used welders which are reliable due to the liability of the engine.

Gavin Bone is an author for Welders. He has written articles arc welder. For information visit our site Plasma Cutters

Also check http://welderreview.com/160-amp-dual-voltage-input-dc-welder-igbt-inverter-welding-soldering-machine/

How to Choose a Welder - Important Considerations For Researching and Purchasing a Welding Machine

Are you new to welding and interested in purchasing a welder? If so, there are a number of factors that you need to take into consideration in order to choose a machine that's right for you. If you're like most people, the first thing that you'll consider is the price. While price is a significant factor, there are others that are just as important, if not more. By taking the time to evaluate all the choices based upon what best suits your requirements, you'll get much more satisfaction, enjoyment, and use from a welding machine that's right for you.

The first thing to consider is what you plan to do with it. Define the size and type of metal that you'll primarily be welding. The machine power requirements for welding thick aluminum are much different than for welding thin sheet metal. Keep in mind that when it comes to prices, more amperage means more money.

It's also a good idea to factor in the cost of consumables. If you're considering a gas shielded type of welding - metal inert gas, (MIG), or tungsten inert gas, (TIG), - you'll need to know what type of gas is required for the type of metal you'll be welding. Recently the prices of gases, especially shielding gases containing helium, have skyrocketed. Conversely, a stick or arc welder doesn't require shielding gas and can be cheaper in the long run. Along with gases, you'll need to pay attention to the prices of electrodes/welding wire, tips, nozzles, and other related related accessories that are specific to the type of welder that you purchase. Over the course of time, these can have a significant impact on the operating costs associated with your welder.

The power that you have available to run your welder is a very important factor that shouldn't be overlooked. Welding machines are power hungry, and often require more power than what you have available at the point of use. If you don't have enough power to adequately supply one, you'll need to upgrade your service which will add to the overall expense. An alternative to this is an engine driven welder. With the rising prices of fuel though, this may not be the most cost effective solution.

One of the best pieces of advice is to seriously consider a used welder. You'll often find many older welders for sale and there is a good reason for this - old welders were built to last. A properly maintained welder can easily last you for as long as you want. These welders can often be purchased for a fraction of the cost of a new one too.

These are just a few of the many questions you need to ask before choosing a welder. As you can see, it's a lot more complex than driving down to a big box store and buying what's on the shelf. If you educate yourself before you make your purchase, you'll save money, and end with a welder that will be much more useful in the long run.

John R. Thompson has worked in the engineering and construction fields for over 25 years. During this time he has held many different jobs that range from welding/fitting to engineering and project management. On his website you can find much more information related to welding, equipment, safety, and general information related to the welding and construction fields. You can also find a guide on How to Choose a Welder.


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MIG Welders - Why a 115 Volt MIG Welding Machine is the Best Way to Get Started Welding

Before you read this article on 115v mig welders, you need to promise that you will never weld a trailer hitch with anything less than a 230 v mig welder, or a 230 volt arc welding machine...Promise?  OK read on.

115 volt mig welders have some limitations but they are still an excellent way to get started welding. For way less than 500 dollars, you can order a good 115 v  MIG welder online and start practicing welding within a week. (sometimes shipping is even free) What can you get for less than 500 dollars?  You can buy the most powerful 115 v MIG welder available that will weld up to 1/4" steel.

I don't ever recommend buying a 115 v MIG welder that is a flux core only welder...(unless it is a smokin deal like a reputable brand for less than 200 dollars). A flux core only MIG welder is just not versatile enough. Once you add the ability to weld with bare wire, lots of options become possible.

For less than 500 bucks you can buy a Hobart mig welding machine that runs off of 115 volts and welds with bare wire or flux core.

What can you do with a 140 amp 115 volt MIG welding machine?

Fix a lawnmower deck
build up a lawnmower or bush hog blade
make a set of shelves
modify or build a custom bicycle
fix a cracked exhaust manifold ( with a few tricks like preheat and adding a nickel rod with the other hand)
make welding sculptures
weld patches in auto body panels
make shooting targets for your buddies
make a mailbox guard
build beam brackets for an outdoor deck
modify the motor mounts in your brother in laws 1970 Chevelle Hot Rod
The great thing about a 115 volt mig machine is that if you ever decide you need to upgrade to a 230 volt mig welding machine, The 115 volt machine is still very useful because it will run .023" bare wire which is the best thing since sliced bread for welding thin auto body patches.

To learn more about a Hobart Mig Welder along with Down and Dirty welding tips. For TIG, MIG, STICK welding along with a buttload of other welding information, visit http://www.weldingtipsandtricks.com


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Multiprocess Welding Machine - Longevity Welders - And a Chinese Tig Welder Review

Have you seen the multi-process welding machine that Longevity advertises?

Maybe you have been thinking of buying one of these Chinese Tig Welders but you have been wondering if they  are any good at all?

The features of Longevity 160 amp multi-process welders are kind of impressive: 160 amps, ability to tig weld aluminum, can also be used as a plasma cutter and stick welder...Wow!

A good Miller, Lincoln, or Thermadyne Tig Welder Inverter will cost you well over 3000 dollars by the time you get all the extra welding supplies you need  like foot pedal, tig torch, flowmeter, ground clamp and all.

Longevity welders do not have some of the advanced features like A/C waveshaping that the Miller Dynasty 200DX and The Lincoln Invertec v205t have, but the basic features actually are similar...and you cant use the Miller or the Lincoln as a plasma cutter.

So it is very intriguing when you see a Chinese Tig Welder that will also do plasma cutting and stick welding, advertised for around 750 dollars with all the accessories included.

What?  750 dollars? That is like one fourth the cost of a Miller or Lincoln A/C DC tig welder.

So you start wondering to yourself, Is a Lincoln or  Miller tig welder 4 times better?  Am I paying for a name?  That's a lot of money for just a name.

I spent the last several hours looking on internet forums, welding websites, and eBay feedback reports and guess what? The jury is still out on Chinese Tig Welders.  You can find good reviews, bad reviews, and mixed reviews on Chinese tig welders. A lot of the reviews I read were about how the chinese tig welder arrived  somewhat non-functional and damaged in shipment and that a customer phone support call was all it took for the support team to talk the buyer through fixing a loose connection.

And somehow, that was looked upon as a good thing.

I did see one Shocking video review on a Longevity Multiprocess welding machine that I will not soon forget. I am still shaking. I have never seen someone disrespect a welding machine like that.
See this Video Review of a longevity multiprocess welder and while you are at the site, take in some Down and Dirty welding tips.
http://www.weldingtipsandtricks.com/

Cables Used For Welding Machines

This is a very specific cable used for welders called "welding cable". Yes, it's as simple as asking your supplier for welding cable and they will ask you what color insulation and what AWG size you need. There is typically black and red in stock and you can get orange from most suppliers at a slightly higher price.

Residential Welders

Welders used in garages and small shops usually use the smaller AWG sizes of welding cable because they don't require as much power as larger welding machines. Smaller gauge sizes are 6 AWG, 4 AWG and 2 AWG which are cut-to length on many websites online. That means you can buy 84 feet if your application requires that amount. Simply input the quantity, pick the color and on some website you'll be able to get free shipping on order over $250.

Commercial Welders

Larger welding machines used larger cables because they require more power. Be careful because some industrial applications also require approvals, more protection and even more flexibility. Industrial applications have much more going on in the warehouse, or job site, such as multiple welding machines, large equipment and outdoor environmental conditions to worry about.

The industrial style welding cable is referred to as Super Vu-Tron which comes in an orange color jacket for safety reasons. It has UL, CSA and MSHA approvals so that it's much easier to pass inspection when necessary. The insulation is much more durable for added industrial use and daily ware and tare. Super Vu-Tron also uses 34 AWG copper strands instead of 30 AWG copper strands for added flexibility.

Cable Colors

If you're looking for a color of welding cable other than black, red or orange you may be required to purchase a minimum amount and wait about 4-6 weeks. It will have to be manufactured from scratch and, in order for it to be worth it for the manufacturer, there will need to be a minimum amount purchased. Now, your supplier may work with you by purchasing the minimum amount and splitting it with you, since they probably get many requests for it each day.

Cable Lugs

Many suppliers will also have the ability to terminate lugs on each end of the welding cable for you. Lugs can be expensive, depending on the AWG size you're going to be working with, so make sure you ask questions and understand everything about your purchase before buying it. When suppliers add lugs to the cable it may take an additional week or two to receive the product.

Buy welding cable online from WesBell Electronics at www.weldingcable.net. You can also buy Super Vu-Tron Cable on this website with exact cut lengths on both types. WesBell offers free shipping on orders over $250 to anywhere in the continental USA.


Check http://welderreview.com/arksen-arc-welder-250amp-rated-input-voltage-110v220v-dual-mode-red/ as well.