Jun. 17, 2024
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A beginners 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:
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:
As a general rule, consider the following:
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:
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
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Suggested reading:16
1/16
14
1/8
10
3/16
1/4
5/16
Decimal (in.)
.
.
.
.
.
.
.
.125
.
.
.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:
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, its 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 inductancemore arc on timehelps solve these problems.
Some features to look for that arent related to inverter technology:
Notes on Selecting a TIG Welder
Choose the TIG weldingprocess when you want the
best weld bead appearance possiblethat classic stack of dimes lookor
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:
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