General Information Regarding Welding Processes and Welder Selection for Newbie Hobbyists

GMAW (Gas Metal Arc Welding) Gas welding Notes:

MIG !"AW and S#ielded !"AW A" only and A"$%" &'y(acetylene )IG (%" only and A"$%")
Level of Skill Required Moderate Skill Required Moderate to Difficult Difficult: Most Skill Required
Typical metals welded by hobbyists
1 amp per .1! thick"ess 1 amp per .1! thick"ess #$% 1 amp per .1! thick"ess
&' (au(e ) *$1+! ,Miller 1'- 1. (au(e ) 1$.! steel
&& (au(e ) 1$&! ,Millermatic &/&-
#o #o 0es #o
#o 0es 0es #o
%dditio"al readi"( is required.
1o"sumables 23tra Tips4 5ire type$si6e4 (as
7ery 8mporta"t 7ery importa"t
SMAW (S#ielded Metal Arc
Welding)
G)AW (Gas )*ngsten Arc
Welding)
Least Skill Required of the '
weldi"( methods me"tio"ed.
%ll methods will require practice for
adequate pe"etratio"$fusio".
9e"erali6atio" of costs for hobby
level equipme"t ,#25-
11volt machi"es : ;1. )
;<. ,=> >lu3core o"ly a"d
MM1'-
11volt machi"es : ;1. )
;&.?. ,=arbor >rei(ht-
;&. ,small portable torch kit
from #orther"Tool- ) ;..?
,8"dustrial @it ? Lar(e Aottles ?
1art-
D78 ,11 volt a"d &&volt- :
;1<. ,Miller Diversio"
,%1$D1--
Brices are merely (e"erali6atio"s
with low prici"( i"dicati"( =arbor
>rei(ht level equipme"t as the low
e"d a"d Miller$Li"col" at the hi(her
e"d. #ote: Ti( machi"es ca" be
D1 ,mostly steel- or %1$D1
,alumi"um- This sectio" is too
broad a subCect to be completely
covered o" a" spreadsheet. More
readi"($research is "eeded. Dsed
prici"( ca" vary widely based o"
(eo(raphic area a"d a(e of
equipme"t. %dditio"al research is
required.
&&volt machi"es : ;+/ )
;&/. ,==1.< a"d MM&/&-
&&volt machi"es : ;&/ )
;/.? ,Li"col" %1&&/ a"d %1$
D1 &&/$1&/-
&&volt machi"es : ;&/. )
;*.? ,Aare bo"es =arbor
>rei(ht D1 o"ly a"d Miller
Sy"crowave &/ ,%1$D1--
1arbo" steel4 Stai"less steel4
%lumi"um
1arbo" steel4 Stai"less steel4
%lumi"um4 Ether
1arbo" steel4 Stai"less steel4
%lumi"um4 Ether
1arbo" steel4 Stai"less steel4
%lumi"um. Ether
9e"erali6atio": M89$>lu3core is
least versatile as it relates to the
types of metals that ca" be welded
,typical M89 set up-. E3y)
%cetyle"e a"d T89 offer the most
versatility as it relates to the types
of metals that ca" be !Coi"ed!. The
weldable metals listed te"d to be
the most commo"ly used materials
A0 =EAA08STS. 8t is "ot a"
e3haustive list.
%mpera(e to thick"ess rule of
thumb
Typical mi"$ma3 thick"ess with 11
7olt supply
#o electricity "eeded. Mi"$Ma3
thick"ess of weld a"d cut will
depe"d o" cutti"( a"d weldi"(
torch a"d tip si6e
&' (au(e ) *$1+! steel ,Miller
Diversio" 1.-
SM%5 is the least capable ,most
difficult without bur" throu(h-
process for thi" metals. T89 is
ar(uably the most capable process
for weldi"( thi" metals. Thick"ess
claims will vary based o"
ma"ufacturer a"d si6e of the
machi"e. 23amples were obtai"ed
from ma"ufacturer website.
Multiple pass welds will allow
(reater thick"ess. More readi"( is
required.
Typical mi"$ma3 thick"ess with &&
7olt supply
1+ (au(e steel a"d up ,multipass-
,Li"col" %1 &&/-
* (au(e ) 1$&! steel ,Miller
sy"crowave &/-
%bility to bra6e or solder with this
processF
E3y)acetyle"e is the most versatile
si"(le process ,of the ' processes
discussed- whe" co"sideri"( itGs
ability to solder$bra6e$weld a"d cut.
%bility to cut metal with this
processF
%dditio"al 2quipme"t Required to
weld metals other tha" mild steelF
Spool (u" or ,Bush$Bull (u":
(e"erally "ot used by hobbyists-
"eeded for alumi"um.
7arious electrodes appropriate for
the metal ,a"d polarity- bei"(
welded
7arious filler rods appropriate for
the metal bei"(
soldered$bra6ed$welded.
7arious filler rods appropriate for
the metal bei"( welded.
%dditio"al 2quipme"t "eeded to (et
up a"d ru""i"( beadsF
>lu3core ,(asless- : #o"e4 M89
a"d 9as shielded flu3core will
require a ta"k a"d appropriate
shieldi"( (as. Re(ulators typically
come with "ame bra"d M89
welders.
Some ma"ufacturers may i"clude a
few differe"t types of electrodes ?
chippi"( hammer.
1omplete packa(es ca" be
purchased ER all E3y)acetyle"e
equipme"t for may be purchased
separately.
Ta"k4 >lowmeter4 9as4 23tra
Tu"(ste"s4 7arious filler rods4
7arious (as cups$le"s
Do "ot for(et the additio"al costs of
ta"k,s- purchase$re"tal a"d (as.
L5S ,Local 5eldi"( Supplier-.
More readi"( is required.
7arious 2lectrode,s- types a"d
si6es
9as4 >lu34 7arious >iller rods4
7airous Tips4 Torches4 etc.
9as4 >iller rods4 Tu"(ste"s4 9as
cups$le"s4 etc.
Dsually purchased from a L5S.
More readi"( is required.
Material prepF ,clea"li"ess of
metal-
8mporta"t ,Metal prep is more
importa"t for M89 tha" (asless
flu3core-
Least importa"t of all four weldi"(
methods me"tio"ed based o"
electrode type a"d deo3idi6ers ,flu3
coati"(-
Aetter prep : better welds. Aest
practice for all processes is to
remove all surface rust$pai"t$scale$
etc. dow" to shi"y bare metal.
More readi"( is required.
BB2: Berso"al Brotectio"
2quipme"t
5eldi"( helmet4 weldi"( (loves4
>ace shield4 safety (lasses4
5eldi"( clothi"(4
5eldi"( helmet4 weldi"( (loves4
>ace shield4 safety (lasses4
5eldi"( clothi"(4
5eldi"($bra6i"( (o((les4 weldi"(
(loves4 >ace shield4 safety (lasses4
5eldi"( clothi"(4
5eldi"( helmet4 weldi"( (loves4
>ace shield4 safety (lasses4
5eldi"( clothi"(4
%dditio"al BB2Gs may be required
based o" the e"viro"me"t o"e is
weldi"( i". 23ample: >ume
e3tractio" a"d$or respirator4 etc.4
etc. %dditio"al readi"( is required
to e"sure perso"al safety.
#iceties: Ae"eficial 2quipme"t for
weldi"( a"d fabricatio"
5eldi"( Table4 1lamps ,lots a"d
lots-4 a"(le (ri"der,s-4 (ri"di"(
wheels4 wire cups4 flap discs4
1utti"( equipme"t: %brasive saw4
=ori6o"tal ba"d saw4 Reciprocati"(
saw4 1ircular saw with abrasive
blade4 etc.4 etc. ad "auseam.
5eldi"( Table4 1lamps ,lots a"d
lots-4 a"(le (ri"der,s-4 (ri"di"(
wheels4 wire cups4 flap discs4
1utti"( equipme"t: %brasive saw4
=ori6o"tal ba"d saw4 Reciprocati"(
saw4 1ircular saw with abrasive
blade4 etc.4 etc. ad "auseam.
5eldi"( Table4 1lamps ,lots a"d
lots-4 a"(le (ri"der,s-4 (ri"di"(
wheels4 wire cups4 flap discs4
1utti"( equipme"t: %brasive saw4
=ori6o"tal ba"d saw4 Reciprocati"(
saw4 1ircular saw with abrasive
blade4 etc.4 etc. ad "auseam.
5eldi"( Table4 1lamps ,lots a"d
lots-4 a"(le (ri"der,s-4 (ri"di"(
wheels4 wire cups4 flap discs4
1utti"( equipme"t: %brasive saw4
=ori6o"tal ba"d saw4 Reciprocati"(
saw4 1ircular saw with abrasive
blade4 etc.4 etc. ad "auseam.
There always seems to be a"other
tool that you "eed.