How to choose a

Welding Machine

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 How does a
Welding Machine
Work?

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What is Welding?
Welding is a fabrication process whereby two or more parts are fused together by
means of heat, pressure or both forming a join as the parts cool. Welding is usually
used on metals and thermoplastics but can also be used on wood. The completed
welded joint may be referred to as a weldment.

How does Welding work?

Welding is a high heat process which melts the base material. Typically with the
addition of a filler material.

Heat at a high temperature causes a weld pool of molten material which cools to
form the join, which can be stronger than the parent metal. Pressure can also be
used to produce a weld, either alongside the heat or by itself .

It can also use a shielding gas to protect the melted and filler metals from
becoming contaminated or oxidized.
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(i) (iv)

(ii) (v)

(iii)

(vi)

Common Joint Configuration

1. Butt Joint 4. Edge Joint

A connection between the ends or edges of A connection between the edges of two
two parts making an angle to one another of parts making an angle to one another of 0 to
135-180° inclusive in the region of the joint. 30° inclusive in the region of the joint.

2. T Joint
5. Cruciform Joint
A connection between the end or edge of
A connection in which two flat plates or two
one part and the face of the other part, the
bars are welded to another flat plate at right
parts making an angle to one another of
angles and on the same axis.
more than 5 up to and including 90° in the
region of the joint.

3. Corner Joint 6. Lap Joint

A connection between the ends or edges of A connection between two overlapping
two parts making an angle to one another of parts making an angle to one another of 0-5°
more than 30 but less than 135° in the region inclusive in the region of the weld or welds.
of the joint.

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Types of Welding
Technique

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Stick Welding/SMAW

Stick welding uses an electric current flowing from a gap between metal and welding stick (arc
welding electrode).

• works with most alloys or joints

• can be used indoors and outdoors, and in drafty areas
• works with rusty and dirty metals
• good for thicker metals
• economical

MIG Welding/GMAW

This technique uses a wire welding electrode on a spool that is fed at a constant speed. The arc is
created by an electrical current between base metal and wire.

• easiest to learn
• high welding speeds
• works well with thin and thick metals
• cleaner welds with no slag
• same equipment can be used for flux -cored arc welding

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Flux-Cored Arc Welding

This process also uses a wire electrode that is constantly fed, though it does not need a shielding
gas. The flux-cored wire shields the arc instead.

• works well outdoors and in windy conditions

• works well on dirty and rusty metals
• good for out-of-position welding
• deep penetration for welding thick areas
• high metal deposition rate

TIG Welding/GTAW

This welding process uses a non-consumable tungsten electrode. A constant current feeds energy
cross the arc. A shielding gas protects the weld area.

• works well with thin sections of alloy steel, stainless steel, and non -ferrous metals
like aluminum, magnesium, and copper alloys
• high quality, precise welds
• weld beads that look good
• allows for heat input adjustment while welding with a foot control
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Welding Machine
Consideration

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Quality of the weld

If you need a high-quality weld that looks good, you want to choose a TIG welder. If you
need to create a strong weld between rusty or dirty metals, you might consider a stick or
flux-cored welding machine.

Welding conditions

Rough outdoor conditions, such as wind, require a stick or flux-cored welder. This may
occur at construction sites or shipyards.

Metal thickness

While you can use stick welding machines for thick metals, thin materials call for MIG or TIG
welders. The car manufacturing industry involves a lot of welding of thin metals.

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Metal types

TIG welders work well with all metals or alloys, except for cast iron. MIG welding is ideal for
steel, stainless steel, and aluminum alloys. Stick welders work best on steel, stainless steel,
and cast iron.

Basic or complex machine

If you just started welding training and the welding job is simple, a basic machine like a
small MIG welder would suffice. If you are advanced and the welding job requires more
power, you may want to get a high-tech TIG welder.

Welding power source duty cycle

The duty cycle is the amount of time you can weld without having to worry about
overheating or burning the power source. While a hobby welder may only need a 20%
duty cycle, a professional might use a complex TIG welding machine that has a 100% duty
cycle. In most settings, duty cycles of 40%-60% are sufficient.

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Industries where
Welding is used

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• Aerospace
• Automotive Industry

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• Construction and Infrastructure
• Railroads

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• Shipyard

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• Manufacturing • Oil and Gas • Mining

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