|
With so many choices of welding machines on the
market today, how does a novice welding operator
choose what he or she needs? There are a couple
of key questions that can guide you through the
process and narrow down your selection to make
the choice a little easier. Ask yourself the following:
1.
Which arc welding process best suits my needs?
Beginners
will usually turn to either a wire feed or stick
welding process, but which is the best one for
your particular application? Wire feed welding
(also referred to as wire welding) offers a number
of benefits. First, it provides higher productivity
efficiencies over stick since the wire is fed
in a continuous process and you don't have to
constantly change stick electrode rods as you
are welding. Second, wire welding has a lower
skill level requirement and can be picked up more
readily. With stick, you have to coordinate your
hand movements for feeding the electrode rod into
the weld puddle, while with wire you just press
the trigger and weld. Although there may be some
applications where stick might be a better selection,
most beginners should look toward wire welding
when making their first welding machine purchase.
2.
Which wire process is best for me?
Now
that you've chosen wire welding over stick, the
next decision is to choose the type of wire welding
you will perform the majority of the time. The
category breaks down into two: Gas Metal Arc Welding
(commonly called MIG) and flux-cored wire welding.
MIG is the best choice when cosmetic appearance
is an issue since it provides lower spatter levels.
In addition, MIG can weld a wider range of materials,
including thinner materials, and different material
types such as stainless or aluminum. Since a bottle
of shielding gas is necessary with the MIG process,
it might not be the most attractive option if
portability and convenience is a factor.
On
the other hand, flux-cored wire welding is the
optimal choice for outdoor procedures since an
external shielding gas is not required with the
flux built into the wire to shield the weld. This
process is most suitable for thicker materials
where weld appearance may not be as critical.
One drawback is that flux-cored can only be used
to weld mild steel, so if you are looking to weld
more exotic metals, this processes may be too
limiting for you.
Most
industrial products sold through a welding distributor
would be equipped to handle both processes. Some
manufacturers sell ready to weld packages that
include a gas regulator and hose kit.
3.
What is the thickness of material that will most
frequently be welded?
As
a rule of thumb, it is recommended to use a MIG
process on materials that are 24 to 12 gauge;
while flux-cored is only recommended down to 20
gauge. The machine's output amperage will determine
how thick you can weld. However, in general the
Flux cored process will weld thicker than the
MIG process with a single pass weld.
The
material thickness that you most often weld will
not only determine the process that you choose;
it will also determine the voltage of the unit
you need. For instance, if you plan to weld over
1/8" material the majority of the time using a
MIG process, it is recommended that you invest
in a 230v system. The higher amperage range of
this machine can better handle your welding needs
in a single pass and you won't have to waste time
with second or third passes. Examples of heavy
materials can be such things as frames to tool
benches or maybe even a fence.
If
most of your welding will be performed on material
less than 1/8" thick, a 115v MIG machine is probably
your best bet for economic reasons. For flux-cored
welding, a 115v machine will generally allow you
weld material up to ¼". A 115v unit is less expensive
and will well suit your needs. When choosing a
machine, look also at the amperage ratings of
the machine - you don't want to overburden a machine
by continuously welding at an amperage higher
than what is recommended.
4.
What input power is available?
Another
key question to ask yourself is what input power
do you have available. For instance, if you will
be doing most of your welding in your home or
garage, you may only have access to a 115v input
power source -- this will limit your selection
to a 115v-wire welder. If you have access to 230v
power in your home due to special wiring or are
doing most of your welding in a job shop, you
may look to a machine that has higher voltage
capabilities (230v is usually readily accessible
in an industrial setting).
5. What's your budget?
There
are a number of technology features that set one
compact wire feed welder apart from another. For
instance with both a 115v and 230v machine, you
can purchase either a tapped or continuous control
model. Tapped control basically offers you four
or five discrete voltage settings. With continuous
control, you have a continuous range of settings
that can provide for fine adjustments and heat
control. The continuous control is a nice feature,
especially when working with thin materials where
a finer heat control helps to achieve an aesthetically
pleasing weld - this fine control is typically
more expensive than tapped control but will benefit
those welding a lot of thinner sheet metal.
6.
What's included in the package?
Not
all compact wire feed welders offer the same accessories
in their package. Pay careful attention to what
is included. For instance, Lincoln Electric's
small SP models of wirefeeder/welders come complete
with a regulator, hose and even a sample of MIG
wire (select models even come with an instructional
video). The only extra item you will need to purchase
to be ready to weld is a tank of gas.
7.
What is the quality of the machine and the manufacturer?
It
is always recommended to buy from a recognized
name in the industry and to make sure that the
machine carries a warranty. Also, check to see
that the manufacturer offers technical support
on-line and over the phone. In this way, if you
have technical application problems, you will
be able to get them answered without hassle.
8.
What are the safety features of the machine?
Some
machines, such as those offered by Lincoln Electric,
have wire that will remain electronically cold
until the trigger is pulled. What this means is
that if you accidentally touch the torch to an
object as you are setting-up to weld, it will
not cause sparks that could damage your eyes or
the workpiece. Look also for units that offer
thermostatic overload protection to prevent high
current from damaging the machine - especially
when you are trying to weld heavy gauge material.
In addition, a machine that offers an input circuit
breaker protects the wiring in your home or job
shop setting. With Lincoln machines, the drive
motors also have circuit breaker protection so
that they will automatically stop if something
impedes wire feeding. And, last but not least,
a good fan will be sure to keep internal components
cool and provide a longer lifespan for your machine.
9.
Additional Questions
Some
of the "finer points" to consider when purchasing
include:
-
Does the machine come with a detailed instruction
manual?
-
Does the manufacture offer both welding machines
and consumables so that you will be able to
purchase system-matched components that you
know will work well together?
-
Does the manufacturer offer a welding applications
helpline in case you have a question?
-
What if the machine needs servicing - does the
manufacturer have a reputable service facility
in your area?
-
Does the machine offer upgradability such as
a kit to modify the machine for specialty welding
needs (like aluminum welding)?
-
Does the unit have industry standard parts such
as contact tips, nozzles and liners that can
be easily purchased from any distributor?
Armed
with the answers to these questions, you should
be a well-educated consumer in your quest for
a compact wire feed welder!
|
