Welders have become much more affordable over the years. Today, even many hobbyists
keep welders in the home. There is a wide range of welding machines to choose from,
including small units that are good for small projects or for occasional use. On
the other hand, there are also welders that come on dedicated carts, or with attached
wheels, so that they are easily moved from place to place. Most of these units are
suitable for semiprofessional use.
When purchasing a welding machine, it is important to look into how it will mostly
be used, and then match the specific machine to the needs of the buyer. For jobs
that need to weld thicker metal, higher amps are necessary. If, however, the welder
is to be used on 0.8 mm of steel or below, it is important to get a welder with
a low enough amp range to be able to handle such a fine piece of metal.
Welder Styles
When buying a welder, it is important to first decide which type of welder is most
suitable. Gas Metal Arc Welders and Flux Core Arc Welders are the main types of
welding machines. The difference between a Gas Metal Arc Welder and a Flux Core
Arc Welder lies in how they protect the filler metal used in welding from interacting
with the oxygen, nitrogen, and hydrogen in the atmosphere. Determining which of
the two is best for you will depend on what the unit is mostly going to be used
for and where it will be used.
Gas
Metal Arc Welders
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Gas Metal Arc Welders usually rely on a gas mixture of carbon dioxide and argon
to protect the molten metal from reacting with the gases in the air around the welding
job. This carbon dioxide and argon mixture is released through the gun and cable
assembly, and out the gun's nozzle, surrounding the welding wire as it is heated
to form a weld pool. The gas usually continues to flow for a short time after welding
so that it can continue to protect the cooling metal.
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The drawback to a Gas Metal Arc Welder is that the carbon dioxide and argon protective
shield can be blown away by the wind. Unless a suitable windbreak is constructed,
a Gas Metal Arc Welder should not be used outdoors.
The advantages to using a Gas Metal Arc Welder lie in the quality of work produced.
The weld will be clean, with no slag and almost no spatter. Gas Metal Arc Welders
are better for jobs that will require painting after the welding is done. This is
due to the smoother job of welding that is done by the machine. Because of this,
many users prefer Gas Metal Arc Welders when working on the body of a car.
Flux Core Arc Welders
Flux Core Arc Welders use a wire that, in its core, contains materials that release
the shielding gases necessary to protect the molten metal from the environment.
There is no need for any external shielding agent, and the shielding gases released
by the wire can withstand even strong breezes.
The drawback to Flux Core Arc Welders is that they use a very forceful
arc, creating a large amount of spatter. In addition, there will be slag on the
final welding job, and it will have to be removed for a neat, clean finish. Other
disadvantages can occur as a result of mechanical problems, such as irregularity
in the wire feeding. The filler material is also more expensive than that of Gas
Metal Arc Welders.
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Many users like the Flux Core Arc Welder because it is fast and portable. Some of
the Flux Core Arc Welder units are very handy in size, and easily moved from job
to job. In addition, Flux Core Arc Welding jobs require less pre-cleaning of the
metal surfaces than do Gas Metal Arc Welding projects. Flux Core Arc Welders can
also be used in jobs that require awkward positioning of the unit.
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Some welding machines offer both gas and gasless welding in the same unit. Generally,
these are Flux Core Arc Welders that use an optional external shielding gas. The
external shielding gas is preferred for welding thicker metals, but not in jobs
that are in odd positions. The slag created by the flux in a job that uses an external
shielding gas is easier to remove.
When buying a wire-feed Flux Core Arc Welder, a 115-V input unit is ideal for good
portability. However, if the buyer plans to work often with thicker metals, a 230-V
input welder is probably more ideal.
Welder Features to Consider
Live Torches
Safety should be the first consideration when buying any equipment that can do the
potential damage that a welder can do. There are some welding machines that don't
include a contactor, meaning that the torch on the machine is always live. This
is a dangerous situation because even a slight diversion of attention can result
in arc eye. Most welders include a trigger mechanism to ensure that the torch is
only live when the trigger is depressed. There are, however, manufacturers who cut
corners by leaving off the trigger mechanism. It is never a good idea to buy a welder
without a trigger mechanism because the potential for danger is too great. Always
ask whether the welding machine has a trigger, or whether the torch is perpetually
live, before purchasing. If it has a perpetually live torch, it is better not to
choose that unit.
Amps
When the user knows what the machine is to be most often used for, it will be time
to decide on how many amps will be required. A welder that has a maximum range of
90 amps can be comfortably used for a 2.0 mm piece of steel for a butt weld, and
a 3.0 mm piece with V and root gap. A maximum range of 180 amps will be good for
a 5 mm piece of metal for a butt weld, and a 7.5 mm piece with V and root gap. While
some manufacturers might give slightly different ranges, this seems to be the most
comfortable thickness for most welding machines.
A point some buyers overlook is that it is also important to consider how fine a
job the welder might be used for. If it is mostly to be used for a job on thinner
metals, like body work on a car, it is important to have a minimum amp range small
enough to handle the thinner metal. Some very cheap models have a minimum amp range
of 30 amps, which is too high for some body work. A minimum range of 25 amps would
be much better for work on thinner metals. Besides the cheap machines which may
not have a low enough range, some very powerful machines also have ranges too high
to handle thin metals neatly.
Duty Cycle
Duty cycle refers to the percentage of a 5- or 10-minute block (depending on the
manufacturer) that a welder can be used continuously without overheating. If a welder
has a 50% duty cycle for 100 amps over 5 minutes, that means it can be used continuously
for two and a half minutes before needing a break of two and a half minutes. For
body work, duty cycle might not be very important because the machine is mostly
operated at very low amps. But for larger jobs, duty cycle might become a consideration.
Torch
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Most welders come with an included torch. Some users, however, might prefer a detachable
torch, since the torch that comes with a welder may not last the lifetime of the
machine anyway. It is possible to purchase a torch with a quick release that is
easily attached to the welder. These units are easily replaced, and are inexpensive.
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Portability
Some of the smaller Flux Core Arc Welders can be easily moved from place to place.
For good portability with a more powerful machine, it is a good idea to buy a unit
that either comes with a cart or that has wheels attached. The units with attached
wheels are more ideal for jobs that will be closer to the ground, such as work under
a car.
Welding Mask
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Most welders for hobbyists come with a hand-held welding masks. Many users find
such a mask difficult to use because it ties up one hand that could be made better
use of in the welding job. A good over-the-head welding mask, with a flip down face
mask, does not have to be expensive. Safety should not be overlooked, and it is
important to always wear a protective mask when welding.
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Wearing protective clothing and leather gloves is also necessary when welding.
Price Range
Gas Metal Arc Welders
Gas Metal Arc Welders can be found for prices just under $300. There are several
models ranging from just under $300 to just under $400. Clarke Power Products and
Hobart Welders both make Gas Metal Arc Welders in this price range.
Gas Metal Arc Welders that come equipped with either wheels or a cart are more expensive.
Craftsman makes several mobile units, all of which have the option to use gas or
not to use gas. The MIG 180, manufactured by Craftsman, sells for $750. Craftsman's
two units with attached wheels sell for prices ranging from $1,500 to $2,000. These
units are lower to the ground, and therefore are more easily used in places that
might be hard to reach from a raised cart, such as the undercarriage of a car.
Flux Core Arc Welders
There are several models of Flux Core Arc Welders that sell for prices between $200
and $400. Lincoln Electric, Hobart Welders, Century, Craftsman, and Firepower each
have options available for under $400. Lincoln Electric also sells units priced
between $450 and $550.
Century Welders sell s Flux Core Arc Welders with attached wheels for prices ranging
from $1,300 to $1,600. These larger units have maximum amps ranging from 210 amps
to 270 amps.
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