Electric welder test
One of the most common fusion welding processes is electrofusion welding. You should have some experience in this field and wear an occupational health and safety mask. There are educational institutions where the welding technique can be learned (also for the layman). When welding, it is important to make sure that you do not overestimate your own abilities. For example, drop and overhead welding and load-bearing parts are only something for the trained professional.
Since heat, flying sparks, the bright arc and also UV rays can endanger health, special attention should be paid to occupational safety in this activity. For the safety of the welder, he should wear fully covering clothing and also leather gloves. Leather aprons, which can provide additional protection for the body, are good. Instead of using a hand shield, a welding helmet with protective glass visor is recommended. In contrast to a hand shield, a welding helmet can be used on both sides.
What is an electric welder?
Electric welding or manual arc welding is an old process, which is still up-to-date. Metal parts can be connected with it. If you take gas shielded arc welding, which requires a little more practice, the electric welding machines are cheaper to buy. In electrofusion welding, metal parts are joined with a coated electrode. The sheathing creates a stable arc.
During the incineration process, a slag is formed on the weld seam, which ensures that the weld cools down evenly and thus leaves no impurities in the weld. The workpiece is connected to an earth cable so that a short circuit occurs at the tip of the electrode. This causes the tip of the electrode to melt, as well as parts of the workpiece and a firm connection is created.
How does an electric welder work?
The strength of the welding current is infinitely variable with the usual devices. This allows you to adapt different types of material – and also thicknesses. Thus, welding seams of electric welding machines should always be processed with the slag hammer. This can remove the remains of the electrodes. Welding is an activity that joins different materials together. Since high temperatures are generated during each welding process, appropriate protective measures must be taken.
Fire safety precautions are also included. There are welding machines that can be operated with direct current and/or alternating current, but direct current is the more common variant. Electric welding cannot be learned in five minutes. Anyone who does welding work frequently should take a course or be trained by an experienced welder. Exercises can be carried out on waste pieces, which can show acceptable results after some time.
Possible applications of a welding machine
There are numerous possible applications for an electrofusion device in and around the house. If you have some skill, you can bend the arches and grids for the basement windows yourself and then weld them together. Afterwards they can be painted or galvanized. It is also possible to make balcony railings or stair railings in the same design as the grilles. It is important, when electrofusion welding at home, that the welding seams are worked accurately. After all, they should be able to withstand wind and weather for several years.
But not only new productions, also existing objects can be carried out with some craftsmanship. The ambionierte welder can then repair for example his garage door or yard and garden gate himself. If you are artistically inclined, you can weld your very own works of art from scrap metal and scrap. This way, an experienced welder can create truly unique pieces of art and give them to himself or his friends as gifts.
A sloping garden fence or a leaking gutter are also things that an experienced craftsman can do himself. In addition, the exhaust pipe can be welded to the car relatively easily. However, welding work on safety-relevant pieces should be carried out by a specialist.
For whom is an electric welder suitable?
If you want to join metallic materials permanently, you normally need a welding machine. An industrial worker can perform more than twenty different welding processes. The hobby shitter can usually choose between three techniques. Autogenous welding slides more and more into the background and gas shielded arc welding into the foreground. However, the workpiece is decisive in determining which welding equipment is needed. Whereas when working with consumable stick electrodes, the work is always delayed by the electrode change, gas shielded arc welding allows you to work with stamina.
But this is more complex and expensive. But you can also weld thin sheets with it. The supreme discipline for a DIY enthusiast is still working with metal and thus joining metal materials. This can also be done with a soldering device. While soldering does not liquefy the materials but only joins them together, welding creates a stable connection, which is achieved by the correct fusion of two materials.
What can be welded with an electric welder?
In general, all materials can be welded together. However, some special criteria must be observed. Basically, the danger point is not the tearing of the weld seam, but that the material lying next to it is damaged. For example, galvanised steels with aluminium are already more difficult. Meanwhile, two different metals (steels) can be welded well together.
These connections are called black and white connections which are subject to the Schaeffler diagram. The diagram can be used to determine the welding filler material. Anyone who acquires the necessary specialist knowledge, seeks good advice on materials and welding techniques and also observes the necessary safety measures can carry out welding work themselves.
Handling of an electric welding machine
Electric welding, or manual arc welding or manual electric welding, is one of the oldest electrical welding methods for metal. As early as 1891 carbon electrodes were introduced for arc welding and Nikolai Gavrilovich replaced them with a metal rod, which served both as a carrier of the arc and as a welding filler. However, since the metal rods were not coated, the seams had no protection against oxidation and made welding difficult. But the instructions for welding have remained the same.
Today the stick electrodes are coated. When melting off this coating, gases are produced which protect the joint and the arc from oxidation. During cooling, less distortion occurs because the coating of a slag reduces the surface tension and binds impurities. After clamping the electrode in a holder and igniting the arc by contact ignition, which is equivalent to a short circuit by briefly tapping the electrode on the workpiece, the torch is guided to the welding point.
The performance characteristics of electrofusion units are manifold. A wide input voltage range +/-15 %, compact, light, portable. Stepless regulation of welding current, functions for electric welding: Hot-Start, Arc-Force, Anti-Stick, TIG welding, the separate control input supports the so-called Lift-Arc function. Thermal overload protection, stable metal housing. Functional carrying handle (G141 i), the welding equipment is also wrapped around it, S-sign.
Positive properties of an electrofusion unit
- no gas cylinder or welding rod is needed massive and robust material thicknesses easy to weld and handy welding equipment, compact design, low weight suitable for working outdoors dirt and rust can also be welded well a favourable price can be decisive
Negative properties of an electrofusion device
- Slags and, if necessary, slag inclusions are recommended for car body work
What is tested for electric welding equipment?
The current performance is tested. It is important that the device can be operated with 220 V alternating current and 380 V three-phase current. Its power should be about 160A at 220V and about 200A at 380V so that thick sheets can also be welded. The scope of delivery of a welding unit should also be examined carefully. A power cable for 380 V and an adapter cable for 200 V should be included. It is advantageous if a welding shield is included in the scope of delivery. The further criterion for testing a welding device is the technical equipment of the device.
As many welding machines are very heavy, the machine should have castors so that it can be easily transported. The cables for the earth clamp and for the electrode holder should be of sufficient length to allow unhindered working. It is also advantageous if the welding equipment has an electrode holder on the welding equipment itself. In addition, the welding current should be infinitely variable and it should also be possible to switch from 220 V to 380 V without any problems. One should also make sure that the transformer is not overloaded, so it should have a thermal monitor that switches off the current in case of overload.
Care and cleaning of an electric welding machine
For the care of an electric welding machine there is a spray that protects the workpieces and also the equipment against welding spatter. The spray is used for cleaning and keeping the welding nozzles clean. At the same time, it also protects against the effects of spatter without affecting the welding seam. Thus, it is not necessary to clean the workpieces with a brush or chisel. A good device is dust-tight, the thermal components cool down from the outside, at most the fan and the heat sink need to be cleaned. In addition, the devices can be blown out with compressed air. Instructions for this can usually be found in the operating instructions.
Who repairs an electric welder?
There are many companies that are specialized in repairing welding equipment. You can find them on the Internet. Most of them repair defective welding equipment of almost all makes. But they do not only repair, but the equipment can be overhauled or modified. Likewise, these companies usually also offer maintenance and inspection according to accident prevention regulations with inspection book. Not only that, spare parts for almost all makes can also be found in the shop of the respective supplier. Some suppliers also offer VBG4 and EN60974-4 tests with a certificate at the customer’s site. A cost estimate can also be requested.
How many amps in an electric welder?
The two special characteristics of welding equipment are the welding current (in amperes) and the duty cycle (ED( in percent. Often, the maximum welding current in amperes or the ED, or both, are noted in the equipment type designation. As an example, a welding machine can supply a maximum of 160 amperes at a duty cycle of 30 %. This means that 30 % of the time 160 amps is used for welding and 70 % of the time is a break because the unit has to cool down.
This means that you can weld for 3 minutes and have to pause for 7 minutes, then you can weld again for 3 minutes and so on. However, if the machine has 120 amps and a duty cycle of 60 % and at 100 amps a duty cycle of 100 %, then this means that with 100 amps you can weld for any length of time. In general, it can be said that for do-it-yourselfers a maximum current of 160 amperes at a duty cycle of 30 % is completely sufficient. These areas include, for example, welding on car bodies and railings or other steels up to 6 mm thick. 30 % is therefore sufficient, as high welding currents are rarely required for these areas.
What does an electric welder cost?
There are devices for the beginner, cheap or expensive. Prices range from 50 euros to hundreds of euros. Electric welding machines for the beginner can cost between 200 and 500 euros. But there are machines for beginners and experts alike. These devices are easy to use and are suitable for beginners.
Also the fuses do not blow out. Then there is an electric welder for 98 euros and a machine for 79 euros. The latter device has earth clamps and electrode holders already pre-assembled, and there is also a fan cooling for high duty cycle. These devices have received consistently positive feedback. Those who decide to buy an electric welding device should not only look at the price but also pay attention to what a welding device is needed for.
5 major manufacturers and their respective characteristics
- The Merkle MobiARC 160 mobile electric welding machine is a welding device for the experienced do-it-yourselfer, semi-professional and professional. It works very well, is easy to use and at the same time very well processed. The GYS electrode welding inverter GYSMI 160 P has an optimized arc stability, the Hot Start optimizes the ignition behavior, the anti sticking, the electrode guidance. The device is suitable for generator (the generator must have at least 6 KW/7,5 kVA. Price 221 Euro.The Güde electrode welding machine GE 145 W for 59 Euro has a powder-coated sheet steel housing with thermal overload protection. The welding station equipment which is included consists of welding shield, welding cable with electrode holder, earth cable with earth clamp, slag hammer with wire brush The Einhell electric welding machine BT-EW costs 69 Euro and is especially suitable for joint welding of angle iron, flat iron, pipes or similar. The advantage is that the materials do not have to be preheated and can be welded directly. DECa welding inverter MOS 168E – the electric welding machine for the professional. Suitable for welding of coated electrodes or for TIG welding. Welding stainless steel, cast iron, steel, bronze and brass (watch out for aluminium). Price 262 Euro.
What accessories are available?
For electrofusion welding, there is the electrode warmer, electrode holder sets, extension cables, electrode pliers, a slag hammer, welding cables, cable couplings, pole screw clamps, an adhesive welding magnet, torch holders and wire coil adapters, brushes, welding protection blanket, welding protection wall, safety helmets and glasses, and an extinguishing spray.
What to look out for when buying?
Those who weld a lot will sooner or later need their own welding equipment. The first question that will arise is whether I need an electrode welding machine or a gas-shielded welding machine. The decision depends on which materials are to be processed. For thin sheets and bodywork, for example, a gas-shielded welding machine is recommended. It offers more flexibility for the different welding jobs. Of course, the price is also a decisive factor in the decision, as are the higher operating costs.
An electrode welding device, for example, is only suitable for thick materials. As a general rule, the welding equipment should have a multi-scale. This enables the used welding current to be set optimally. A long earth cable and electrode or torch cable are also important. This means that the welding equipment does not need to be moved, for example to reach a higher position. As far as safety equipment is concerned, the unit should either have a special protection class or the S-sign. This ensures that it is possible to weld even in narrow welding areas.
5 good reasons for an electric welder
Electrode welding is…
- a simple welding technique that is inexpensive and can be carried out by a laymanWelding with this equipment is simple and safeEven so are the compact units easy to handle and transportWelding outdoors is possible as no gas is required