Welding Buyers Guide:

Definitions:

SMAW- Shielded Metal Arc Welding
GMAW- Gas Metal Arc Welding
FCAW- Flux Cored Arc Welding
GTAW- Gas Tungsten Arc Welding
RSW- Resistance Spot Welding

What does it mean to Weld?

Welding is a lot like a marriage. When two become if the joining is good then nothing can break the two apart, but if it’s bad then the broken pieces become a little edgy and take a lot of work to mend back together.

Welding is the most economical and efficient way to join metals permanently.

Welding is a process for binding two pieces of similar metals (work pieces) by melting and fusing: the base metals being joined and the filler metal applied. More commonly than not, work pieces are welded by melting both of them and adding more molten metal or plastic to form a pool that cools to form a strong joint. The energy to form the joint between metal work pieces most often comes from a flame (e.g. oxy-acetylene) or an electric arc.

Fun Facts:

Welding ranks high among industrial processes and involves more sciences and variables than those involved in any other industrial process.

Most welding involves ferrous-based metals such as steel and stainless steel. Welding covers a temperature range of 1500º F - 3000º F. Weld joints are usually stronger than or as strong as the base metals being joined.

It is often said that over 50% of the gross national product of the U.S.A. is related to welding in one way or another.

Plasma Cutting

Plasma cutters are best for cutting all kinds of metal, thin or thick. An inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. This plasma can reach 30,000 F. Some torches can slice steel up to 12 inches (300 mm) thick. Unlike laser cutting, the process of plasma cutting is only successful on materials that conduct electricity.

Help me understand the Welding Process

(RSW) - Resistance Spot Welding / Spot Welding for short

Two separate pieces of metal are joined by passing current between electrodes positioned on opposite sides of the work pieces. No arc is used; rather, it is the resistance of the metal to the current flow that fuses the pieces. It’s portable and easy to use. It’s ideal for light, industrial applications.

Recommended metal: Steel, stainless steel
Skill Level: Low

GMAW) – Gas Metal Arc Welding / MIG Welding

A process used with a wire feed welding machine. Metals are joined by heating them with an arc, which is between the continuously fed filler metal electrode (solid wire) and the work piece. Externally supplied gas or gas mixture provide shielding. The welder is easy to use on thinner metals. Equipment can be used for Flux Cored welding.

Recommended metal: Steel, stainless steel, aluminum, cast iron
Skill Level: Low

(FCAW) Flux Core Arc Welding – Gasless

This welding process uses a wire-fed welding machine. Metals are melted and joined by heating them with an arc between a continuous, consumable electrode wire and the work piece. The weld is tubular with flux material contained inside the shielding. Added shielding may or may not be supplied from external gas or gas mixture, depending on the type of flux cored wire being used. It works well on rusty material and be used with or without shielding gas.

Recommended to weld: Steel, stainless steel
Skill Level: Low

(SMAW) – Shielded Metal Arc Welding - Stick Welding

This process uses a consumable electrode to support the arc. Shielding is achieved by the melting of the outer flux coating on the electrode. Filler metal is obtained from the electrode core. Stick welding is good for outdoors, even on windy days and works well, even on rusty metal.

Recommended metal: Steel, stainless steel, cast iron
Skill Level: Moderate

(GTAW) – Gas Tungsten Arc Welding - TIG Welding

This process uses welding equipment with a high-frequency generator. The arc is created between a no consumable tungsten electrode and the work piece. Filler metal may or may not be used, and argon inert gas or inert gas mixtures are used for shielding. It provides high-quality, precise welds and is highly aesthetic weld beads.

Recommended metal (AC TIG): Aluminum, magnesium alloys (DC TIG): Steel, stainless steel, copper, brass, and titanium.
Skill Level: High

What should I look for when I’m looking for a Welder?

Things to Consider:

Welders are designed for certain applications, depending on rated output, duty cycle and other features. For example, heavy-duty repairs in the field requires a welding package that can handle different types and sizes (thickness) of metal, whereas repairing a wrought iron railing can be done using a stick welder.

Common Uses:

• - Construction
• - farm/ranch
• - general maintenance/repair
• - Home
• - Auto body/repair etc.

Available Power Input
If electrical hook-up is not available, a gas-powered, engine-driven welding generator can supply welding and auxiliary power.

Single-phase products require single-phase input power usually found in homes and garages (Welders operate off either 115 or 230 Volts)

Portability
Can the welder be brought to the work pieces, or do the work pieces need to be brought to the welder? Accessories can be used to make most welders portable Hand-portable welders are typically 70 lbs. or less.