Whether you run a manufacturing plant or an industrial facility, downtime due to equipment malfunctions can cost up to 20% of your productive capacity. One way to minimize downtime is to ensure you can access a reliable welder.
Our guide explores different welding machines and their features. Learn how to select the right welder for the metal you use and which additional resources will help ensure project success.
There are four primary welder types. Each machine has different power specifications and features to handle welding for different metals. While purchasing a multi-process welder is possible, single-process machines ensure more specialized applications.
Metal inert gas (MIG) welding, also called gas metal arc welding (GMAW) uses a machine encompassing a continuous wire electrode that you feed through the welding gun. When the wire and the metal come into contact, it creates an electric arc that melts the wire, effectively joining two metal pieces. MIG welders work with a shielding gas — such as CO2, argon or helium — to protect the molten metal from air contaminants.
Technicians value this machine for its versatility, as it’s effective in welding aluminum, steel and stainless steel. However, your business needs to factor in the additional gas costs when calculating project expenses.
As the name suggests, tungsten inert gas (TIG) or gas tungsten arc welding (GTAW) uses a tungsten electrode to connect two mental components. These electrodes are nonconsumable, meaning they can withstand the heat of the electric arc and remain intact. Instead, the technician must add a filler rod, which melts to form the weld pool. One similarity between TIG and MIG welders is that they both require an inert gas to shield airborne impurities.
TIG welding is a popular method for applications that require high precision — it ensures a cleaner finish, making it ideal for superior welds. One drawback to this process is that it’s more time-consuming than most, resulting in longer project times.
Flux-cored arc welding (FCAW) is similar to MIG in that it works with a continuous wire electrode. However, the tubular wire contains flux — a substance that assists in fusing metals and producing shielding gas.
FCAW machines are a good option for outdoor projects. They also effectively join many heavy-duty materials, even those affected by rust and corrosion. One important point to note is that FCAW is incompatible with some metals, such as brass and silver, making it less versatile.
Stick welding, otherwise referred to as shielded metal arc welding (SMAW), is a popular method that requires a flux-coated electrode to fuse metals. When the electrode meets the metal, it triggers an electrical arc, which melts both the electrode and the material. The flux coating melts in the process and releases a protective gas.
While stick welding requires a higher level of skill, it’s a preferred option for projects affected by wind and rain. It’s also a highly effective method for joining thicker metals for optimal strength.
The type of welding you require will determine whether you need a MIG, TIG, FCAW or SMAW machine — yet there are some other factors to consider when choosing the right welder. Use these pointers to make a solid investment.
Welders are compatible with different metals, so you need to establish which material you primarily use. For example, the construction industry relies heavily on steel, making a MIG or stick welder a good choice. In comparison, the aerospace sector would benefit from a TIG machine since these businesses mainly work with aluminum and titanium.
A further material consideration is thickness. While some metals come in thin sheets — such as aluminum and copper — other materials are much thicker. Understanding the typical width of your material will help you choose the right machine size.
A “duty cycle” is the length of time a technician can use a welder before it fails. To determine the approximate operation time, your business will need to know the machine amperage, or the charge that runs through the machine and impacts how much heat it produces during operation. If you work with thicker materials, you’ll require more amps to complete the project.
Voltage is another power requirement. It pertains to the force that propels the electric charge through the conductor. Smaller welding tasks require a voltage of approximately 110 volts, whereas industrial applications require machines with a 220 volts capacity.
The location of your projects will influence whether you need a stationary or portable welder. For instance, if your team takes on welding tasks within a plant, there will likely be power outlets available to generate a consistent electrical current. However, if you typically handle projects in remote locations, selecting a battery-powered welder is a logical choice.
Both portable and stationary welders have pros and cons. Stationery machines generally offer more power, allowing you to work for longer and on thicker materials. However, unexpected power outages could lead to downtime. The clear benefit of battery welders is their mobility, yet you may have to sacrifice less power and stability.
Once you’ve selected your welder, your business will have a better idea as to which additional resources to purchase. Some common options include:
Metrius Gas Partners has collaborated with several distributors specializing in welding equipment, consumables and filler metals. With locations around the United States, it’s easy to find the exact supplies for your needs. Some partners that can assist you with superior hard goods include:
When working with one of our trusted suppliers, you can expect high-quality components and exemplary customer service. Contacting a Metrius Gas team expert can also help you narrow down your welder options.
Businesses have different welding needs and considerations — but fortunately, there are numerous welders to fit your specifications. Understanding the various welding processes and your project requirements will help you make the right choice.
Meritus Gas Partners strives to provide businesses of all sizes with the welding supplies they need to scale their operations. Whether you’re looking for a MIG, TIG, FCAW or SMAW machine, our professional team can assist you in finding a trustworthy partner in your area!