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How To Choose Your First Welder
So, you decided to embark on a journey of welding, but you need to figure out where to start. After learning the fundamentals of welding processes, which you can also do by reading our comprehensive articles, it is time to buy your first welder.
In this guide, we unravel the key considerations on how to choose your first welder. From understanding welding processes to assessing power requirements, we'll demystify the technical jargon. Whether you're a DIY enthusiast or an aspiring welder, our insights will guide you through the maze of options.
Buying Your First Welder - Everything You Need To Know
Understanding the basics of welding is the first step in getting into this trade, but practice is crucial, as with everything else you can do. To get your knowledge into practice, you will need a welding machine. However, in the last years, welding has transformed from a highly specialized process for industrial applications to a favorite of many hobby and DIY lovers.
This resulted in a significant increase in welding machines, so buying your first welder can be a challenging task, especially for a beginner. But fear not, as we will go through the fundamentals in this comprehensive article, making your choice significantly easier.
Welding Processes Overview
Welding has evolved over the years, so today, we are seeing a large number of welding processes and, therefore, welding equipment. However, as a new welder, you will likely deal with the four common welding processes: MIG welding, Flux core welding, TIG welding, and Stick welding.
Therefore, the most popular types of machines are MIG and Flux core welders, TIG welders, and Stick welders. But this still doesn't explain which is best, so let's briefly explain the differences between different welding processes.
MIG welding is one of the most straightforward and a beginner's favorite methods. This is a semi-automated process that is easy to learn and perform, and it can be used to weld a wide variety of metals, including steel, stainless steel, and aluminum. It can deal well with thin and medium plate metal thickness, and the welding gun is perfect for new welders.
Flux-cored arc welding is an alternative wire welding method that uses self-shielded wire, so it doesn't need an external shielding gas. This makes it perfect for outdoor repairs and fieldwork, where wind or draft can blow away the shielding. However, flux-cored wire shields run hotter, yielding better penetration and making them more suitable for thicker materials.
TIG welding is one of the most challenging methods to master, but it yields the highest quality and extremely clean welds. Beginners rarely decide to start with TIG welding, but once you have enough knowledge, you can produce the highest-quality and critical welds. Even though it can weld various thicknesses, TIG is often preferred for thin pieces, and micro TIG can even go lower than .0025".
Stick welding is the industry's favorite, allowing welders to get the job done quickly and cheaply. Like flux core, the electrodes are self-shielded, so you can weld outdoors or burn through a dirty or rusty material and achieve strong welds. Stick welding is somewhat more challenging to master than MIG or Flux-cored welding but is still easier than TIG.
|
MIG Welding |
TIG Welding |
Stick Welding |
Flux Core Welding |
|
|
Common Applications |
Home and hobby, automotive, creating metal sculptures, DIY |
Precise welding, metal art, aerospace, automotive |
Field repairs, pipeline, hardfacing, home/DIY, outdoor welding |
Outdoor welding, repairs, hardfacing, fabrication, farm |
|
Weldable Metals |
Steel, stainless steel, aluminum |
Steel, stainless, chrome-moly, copper, brass, bronze, titanium |
Steel, stainless, cast iron |
Steel, stainless steel |
|
Metal Thickness |
Over 24 ga. |
Over .010” |
Over 1/8" |
Over 1/8" |
|
Welding Speed |
Fast |
Slow |
Moderate |
Fast |
|
Gas requirements |
Inert and semi-reactive |
Inert only |
Gasless method |
Gasless method |
|
Learning |
Easy to learn |
Challenging |
Moderate |
Easy to learn |
|
Cleanliness |
Good cleanliness |
Extremely clean |
Moderate to poor |
Moderate to poor |
What Type Of Welder Is The Best?
There is no simple answer to the question of what the best type of welder is since the choice will significantly vary depending on your needs. The first step in choosing the right welder is understanding your needs.
So, for example, if you are looking for an easy-to-use welder for general fabrication, metal art, or home/DIY, pick a MIG welder. If you are familiar with the wire feed process but want to work on farm equipment, ranch, or outdoor repair and maintenance, you can choose Flux core welder as an alternative.
TIG welder is the best fit for more experienced welders who can use its heat input control and advanced features, allowing it to weld thin, delicate, or exotic metals easily. Operators who want to spend less on welding equipment and look for the most economical method often choose Stick welding machines. These versatile welders are easy to set up and work well on most carbon steels, but it might take some time to get the hang of it.
The best part about today's welding market is that machines for hobby welders aren't limited to a single process. As a result, we are seeing many multi-process welders capable of running two, three, or even all four most popular welding processes. A perfect example is the YesWelder MP200, which features four arc welding processes (MIG, Flux core, TIG, and Stick), and plasma cutting. The all-in-one approach is often the best choice for many metal fabricators and hobby welders.
But, choosing the welder is about more than selecting the right type and welding process. Welding machines also have different factors you'll need to consider, such as:
- Input power requirements
- Welding output
- Duty cycle
- Portability, size, and weight
- Features of the welders
- Safety Features
- Budget and value
Input Power Of The Welder
Electrical arc power supplies or welders use electricity from the power grid or generator to produce an arc. AC current is standard electricity in both US and European homes. However, the US home outlets provide 110-120V AC power with a 60Hz frequency, while European homes utilize 220-240V with a 50-60 Hz frequency. On the other hand, welders can use AC and DC current with a 110/220V, so the choice again varies on your needs.
Most steel welding is carried out at DC current, so you'll be more than fine with a regular DC welder, which is typically cheaper and more spread on the market. However, if you want to weld aluminum or other exotic metals, you will need a welder capable of running at AC. So, if you are welding steel, stainless steel, or copper alloys, choose a DC-only welder, and if you weld aluminum, go for an AC/DC welder.
Hobby welders can also use a one-phase 110V or 220V input to create the welding output, and industrial machines go even higher with a three-phase 480V. The higher the input, the higher the output, so 110V machines typically produce up to 140 amps, 220V machines go over 250 amps, while 480V welders go well over 400 amps.
The input power depends on your needs. The 110V welders are simple and small machines that require a minimum breaker size of 20A with 30A and will cover most of your light-duty needs. Meanwhile, a 220V welder requires a minimum breaker size of 30A with 50A, and they will produce significantly higher output suitable for metals up to 1/2" thick. If you are still determining which one is the best for you, choose a dual-voltage welder capable of running at 110/220V.
Inverter Or Transformer Welder?
All welders transform input power into a suitable output power required to create an arc and reach the desired temperature. However, they can use an inverter of transformer technology to do so.
Transformer welders are old, rugged, and reliable welders who were the first to appear on the market. This old but reliable technology has proven durable and reliable, but it comes with specific drawbacks. Transformers within the welder are large and heavy, which makes welders relatively hard to move and transport. In addition, transformers are known to be inefficient, as they use only a tiny portion of input power to produce output.
Inverter welders are state-of-the-art technology and have become the industry's standard today. Due to the nature of inverter technology, these machines are smaller, lighter, and more efficient, which makes them widespread today. Even though some consider them less rugged and more sensitive to damage than transformers, they are slowly pushing them out of the market. Still, they lack specific arc-starting performances on E6010 electrodes.
Welding Output
The welding output is the power your welder produces to melt the pieces and filler metal, measured in voltage and amperage. However, most welders use amperage to describe the welder's capability or power. Each welder has rated welding output with the lower and upper ends (e.g., 5-250 amps).
The lowest amperage a welder can produce is the lower end, which is essential when welding thin pieces. For example, TIG welders are suitable when fusing thin materials and typically have the lowest amperage of 5 amps, but some can even go down to 1 amp. This is essential when controlling the piece and preventing burning through the thin pieces.
The upper end shows the maximum welding output of the welder, and it is often used to explain the capability of a welder or the maximum metal thickness a welder can fuse. For example:
- A 140-amp welder can weld up to about 1/4" steel
- A 180-amp welder can fuse steel between 3/8" and 5/16"
- A 200-amp welder can weld approximately 5/16" steel
- A 250-amp welder can weld up to 1/2" steel
Duty Cycle
Having enough power for the job is only essential with a good duty cycle. The duty cycle is a time within the 10-minute period when you can weld without having to take a break and let your machine cool down, and it is expressed in percentages. For example, a 40% duty cycle means you can weld for 4 minutes straight before making a 6-minute break.
When choosing a welder, opt for a machine with a reasonable duty cycle of 40-60% at maximum power. This is enough to let you finish any welding project without interruptions or waiting for the welder to cool down. Due to higher efficiency, most inverter welders usually produce a higher duty cycle.
50%, 75%, and 25% Duty Cycle Examples
Source: https://learn.sparkfun.com/tutorials/pulse-width-modulation/duty-cycle
Portability, Size, and Weight
Welding machines in the past got their reputation as robust and heavy pieces of equipment that are hard to carry and move around as they weighed well over 100 lbs. However, things today have changed with inverter technology, so most welders are now compact, lightweight (30-40 lbs), and easy to carry around. Even though many seasoned welders are skeptical about small and light units, they have proven highly durable, and many have the proper IP rating.
When choosing a welder, you'll need a perfect portability, size, and weight balance for your applications. If you are doing a lot of repairs and on-field work, always look for a portable and lightweight welder. Easy transportation will make your everyday jobs much more efficient.
However, if you only work in your shop or garage and rarely move your welder, you don't need to worry too much about the size and weight. Larger and heavier welders will be fine, and you can build a cart if you need to move it occasionally.
Photo by Andy Legresley
Welder Helpful Features
Today's welders bring many advanced and standard features that are not the most essential thing in the world, but they can make your everyday welding much more accessible. Each type of welder has different features to help you carry out your daily tasks.
MIG welders are relatively simple machines, but they can have a pretty helpful feature known as Synergic MIG or Auto Set. This feature will automatically adjust the wire feed speed and voltage according to the metal thickness, wire type, and diameter you use. This is an excellent starting point for any beginner learning to weld.
In addition, new welders such as YesWelder DP200 feature pulse and dual pulse options to MIG. With pulse, you get excellent heat control for heat-sensitive metals such as aluminum. Dual pulse features a second pulse on top of the first, producing TIG-like welds on aluminum and even better control and weld aesthetics.
Today, Stick welders incorporate features such as hot start, anti-stick, or arc force. The hot start will make arc starting much easier, the anti-stick will prevent electrodes from sticking to the surface, and arc force will battle voltage fluctuations, which is crucial in achieving a stable arc.
TIG welders are the most advanced when it comes to features. They will allow you to adjust starting amps, ramp-up amperage, peak amperage, ramp-down, end amperage, and post-gas flow. In addition, they can have pulsing options for heat control on delicate welding material; you can adjust the balance and more, allowing you to weld virtually any metal.
Safety Features
Welding is a hazardous profession, and welding machines, especially inverters, are prone to damage, which is why safety features are crucial. To ensure your welder will work well even if you do something wrong, look for a welder with built-in overheating, overcurrent, or overvoltage protection.
These features will detect potential risks such as high temperatures, current, or voltage and shut down the welder to prevent damage to the internal components. This will ensure your welder will last and serve you well.
In addition, there is a helpful Stick welder feature that will keep you safe from unexpected shocks. Stick welding requires a high open circuit voltage to start an arc, but accidental touches can cause small shocks. You should look for a Stick welder with a voltage reduction device (VRD) that lowers the open circuit voltage to keep you safe and tunes it back up once you start an arc.
Available Budget and Value
As welding has become popular in the hobby, home, and DIY fields, welders have become more widespread and cheaper. Many seasoned welders were skeptical about the quality of the new and affordable welders, and they were right to do so at the beginning, but today's latest machines have proven them wrong.
The truth is you don't have to spend a fortune to get a capable, efficient, and lasting welder, and YesWelder is a living example. If you are buying a new welder as a total novice or beginner, you don't want to break the bank, but you still want a welder that will serve you once you master the technique, which is why we recommend YesWelder machines in the first place.
What Do We Recommend As The First welder?
As a recap of our article, we'll give you some recommendations for your first welder. The following welders are within the most common welding processes, and they have perfect combinations of everything we noted above (power, portability, weight and size, duty cycle, welding and safety features, and affordability). Besides the combination, the first welder should be easy to set up and use, and the following machines offer precisely that.
What Is The Best First MIG Welder?
As a first MIG welder, we recommend the YesWelder DP200 Dual Pulse MIG Welder. With its features, large LCD Screen with an intuitive interface, and smart MIG, this is a perfect MIG welder for beginners learning how to weld. However, this machine also offers advanced features, such as pulse and dual pulse, allowing you to weld aluminum with TIG-like results. It can also run Flux core, Stick, and TIG welding.
This dual-voltage inverter has an output range of 30-200A, covering most of your needs. It is relatively simple to set up and use, and you will enjoy learning how to weld with it. The biggest advantage of DP200 is the fact it is built for both beginners and seasoned welders. You can use it to learn how to weld, practice skills, and later use the acquired knowledge for professional results.
As an alternative, we recommend YesWelder MIG205DS-Pro Multi-process MIG welder. This is also a beginner-friendly machine suitable for steel, stainless steel, and aluminum. However, it lacks advanced features and ease of use compared to DP200.
YesWelder MIG205DS-Pro Multi-process MIG welder
What Is The Best First Stick Welder?
If you choose a stick welder as your first welding machine, we recommend YesWelder ARC-205DS-Pro. This sub $200 IGBT inverter weighs approximately 9 lbs, so you can easily carry it to your job site or outdoors.
It provides 20-205A output, enough for most hobby welding projects, home repairs, or even thicker metals. However, it also offers advanced features we noted (hot start, anti-stick, and arc force), which will make learning how to stick weld significantly more manageable, and it will allow you to run E6010s, which can be tricky to run on inverter welders.
What is The Best First TIG Welder?
As a first TIG welder, we recommend YesWelder TIG200P-AC/DC welder. This TIG welder can run on both AC and DC and use any non-consumable tungsten electrode, allowing you to weld a wide variety of weld materials (steel, stainless steel, aluminum, exotic metals).
TIG-200P-ACDC-PRO AC/DC Aluminum TIG Welder
For approximately $500, you'll get all the advanced features, such as pulse and balance, with a high-frequency start, which is excellent for beginners. Even though it might take time to master all the settings and features it provides, once you get the hang of it, the world is your oyster.
What is The Best First Multi-process Welder?
While most machines we recommend as a first welder offer two or more processes, as a true all-in-one machine we recommend YesWelder FIRSTESS MP200. This 5-in-1 welder combines MIG, Flux core, Stick, and TIG welding with plasma cutting, offering an all-in-one solution for metal fabricators, and beginner and seasoned welders.
This lightweight and portable welder rated at 200 amps is easy to set up and use. MP200 uses a large LCD screen with intuitive controls, making it highly convenient for beginners. It features a synergic MIG for new welders.
Plasma cutting is not something you’ll get with an ordinary multi-process welder, and everything you need to weld and cut is included in the package. The overall value for the money spent is exceptional, making the MP200 the ideal choice for the first multi-process welder and cutter.
🧐How To Choose Your First Welder FAQ
1. How to choose the duty cycle when selecting a welder?
When choosing a welder, select a machine with a reasonable duty cycle, ideally between 40-60% at maximum power. This allows you to weld for 4-6 minutes within a 10-minute period before needing a break to let the machine cool down. A 40-60% duty cycle is sufficient for completing most welding projects without interruptions. Additionally, consider inverter welders, as they typically offer a higher duty cycle due to their efficiency.
2. What factors should be considered when choosing a welder?
When choosing a welder, consider several key factors beyond just the type and welding process. Important aspects include the input power requirements, welding output, duty cycle, portability, size, and weight of the machine.
Additionally, look at the welder’s features, safety aspects, and ensure it fits your budget to get the best value. Taking all these elements into account will help you select the right welder for your needs.
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