Welding Devices
This text is machine translated.
Everything about the welding machine: Different models for individual requirements
Welders are versatile in their application when it comes to connecting metallic materials with one another through heat, permanently, stable and resilient. With a welder you can make welded parts of steel and other types of metal and carry out repairs, for example in the car sector.
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What you can use a welder for
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How does a welder work?
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What is required for welding?
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What welding devices are available?
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Consider the working environment when selecting welding equipment
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Tips for selecting a welder
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This is how you work with your new welding machine
What you can use a welding machine for
Welding with a welding machine is a popular method for combining workpieces made of the same metal and partly also made of plastic by heat and pressure. The welding process connects the parts so firmly that they can only be separated with other tools and/or with great force or heat. Experts therefore also speak of an insoluble, material-consistent connection type by (joint) joining during welding.
The extreme durability even under the highest load makes welding in mechanical engineering, metal construction, steel construction, shipbuilding, automotive engineering, pipeline construction, bridge construction, locksmiths and many other areas the preferred connection method. Unlike parts assembled by bolts, rivets or bolts, weld seams can only be loosened by destroying the components .
You can weld at home or at your facility with your own welding machine. Whenever you want to connect two parts of the same metal inseparably, a welder is the suitable tool for this purpose. Welding can be used for many metals, such as non-alloy steel, iron, alloyed steel, copper, bronze, brass, zinc, stainless steel, light metals such as aluminum and aluminum alloys, sheets and thin sheets, which are common in the professional and private sector. A welder is therefore suitable for users who like to work with a hand, repair something or design something.
Modern welding devices are characterized by simple handling, quick commissioning and high safety standards. Among the most important manufacturers of welding equipment and welding technology are GYS, Einhell, Electron Aix, Greggersen, Lorch, TECHNOLIT, TELWIN and Trafimet.
How does a welder work?
Welding metals with a welding machine is based on the principle of melting-joint welding . The work pieces are joined by heat application , whereby different processes of heat generation are used, mostly on the basis of gases and/or electrical energy. The welding device converts the energy supplied from the outside into selective heat energy.
The heat melts the two parts at the connecting points . Most welding machines use melting additives in the form of rods or wires. The solidification of the weld joint during cooling creates the desired connection.
Welders are extremely versatile: They make spot welds, for example for the stitching of sheet metal – and welding seams, which you create through the passing of the welder along the metal parts. Apart from a good welding machine, a little practice is needed until the welds sit as you would imagine.
In addition to material-locking joining, i.e. solid joining of components, there are also welding devices such as plasma cutters to disassemble metal objects into several parts.
What is required for welding?
To weld all kinds of metals, you need a welder – also called a welder, suitable consumables such as welding electrodes, gas and welding wire, and personal protective equipment. Depending on the welding method used, you usually need a slag hammer, welding release agent, current nozzles or gas nozzles, crack testing agent, contact tubes and ground clamps on welding equipment accessories. We also recommend screw clamps for securing the workpieces during the welding process.
Important points for making welded joints are preparation of the weld and post-processing of the weld. Grinding machines such as angle grinders and cutting and grinding wheels are suitable for metals, filing systems and wire brushes. For welding small parts, a fireproof and height-adjustable work table or a bench with a vice is helpful.
What welding devices are available?
There are several types of welding procedures, so you can choose between different welding machines. The welding processes for steel, which are most common in the hobby, trade, construction and industry, are electric welding and gas welding.
The right machine for you depends on the materials you want to work on and the location where you will weld. Consider in advance which type of metal and in which material thickness you would like to process most of.
SMAW kit
An electrode welder or arc welder is based on the most economical and comparatively simple method of welding metal parts together. Electrode welding devices work with two poles: One is clamped to a bare place of the workpiece, the other is connected via the electrode holder with a rod electrode (MMA), which is guided by the welder at the seam. This produces an electric arc that burns off the electrode's sheath under high temperature. A protective gas bell and a layer of slag form from the sheath on the weld seam, which shields the weld material from external influences.
The electrode (MMA) itself serves as an additional material. Depending on the application area and workpiece, they are available in many versions with different lengths and sheathing. After the melting bath has cooled down, the slag is removed.
Inverter welders work with a welding inverter. It converts the line current precisely metered into welding current. Inverter welders have particularly good welding properties and are therefore suitable for many electrode variants.
Electrode welding equipment components: 1. Rod electrode 2. Wrapping 3. Core rod 4. Gas/Slag 5. Arc 6. Melted Zone 7. Workpiece
MIG-MAG welder (inert gas welder)
Inert gas welders differ according to the type of inert gas they use in metal active gas welders – IN short MAG welders – and metal inert gas welders – in short MIG welders.
In the MIG-MAG process, the electric arc burns between the melting welding wire automatically fed through the device as an electrode and the workpiece. A separately supplied welding gas protects the arc and the welding zone from outside air entry. Protective gas and welding wire are adapted to the basic material to be processed. MIG welders often use argon, helium, or a mixed gas. IN MAG welding with active gases, a gas mixture of argon, carbon dioxide and oxygen is common. Flux-cored welding devices also work with a filled wire to stabilize the arc.
MIG/MAG welding offers a number of advantages which make this welding technique the most widely used welding process today. The high welding speed, the minimum rework and the low distortion ensure high efficiency. The welding seam strength, the good thin sheet properties and the simple and safe handling of MIG/MAG welding machines in steel, aluminum and stainless steel make this process universal.
Components of a MIG-MAG welder: 1. Protective gas nozzles 2. Power nozzle 3. Electrode 4. Shielding gas 5. Arc 6. Melted Zone 7. Workpiece
MIG solder welder
MIG soldering welding is a hard soldering process and is particularly used in the processing of galvanized fine plates. The electric arc burns between the melting, continuously fed solder wire electrode and the workpiece. The inert gas supplied protects the arc and the liquid solder from the effects of the ambient air. The lower melting temperature of the solder wire compared to MIG/MAG welding results in only minimal zinc burning in the area of the direct solder zone. The low heat input reduces the distortion even with thin sheets.
Components of a MIG welding machine: 1. Protective gas nozzles 2. Power nozzle 3. Solder electrode 4. Shielding gas 5. Arc 6. Solder 7. Workpiece
Wig welder
In the TIG welding process – the brief TIG in TIG welding stands for tungsten inert gas – the electric arc burns between the non-melting tungsten electrode and the workpiece. The arc in TIG welding is intense and easy to guide. Inlet argon gas protects the arc and the welding zone from the entry of ambient air. If necessary, add additional material by hand or by cold wire feed.
The advantages of TIG welding are the ease of use, because there is little smoke and little dirt. The welder thus has a good view of the welding area and can work precisely. The narrow welding zone, the elimination of flux and the spray-free arc ensure exact seams without slag inclusions, so that rework can often be omitted.
Components of a MIG welding machine: 1. Gas nozzle 2. Tungsten electrode 3. Shielding gas 4. Arc 5. Melted Zone 6. Workpiece
Plasma cutting devices
The plasma cutting process can be used to cut steel, stainless steel, aluminum, copper, cast iron, brass and other metals. During plasma cutting or plasma running, the electric arc is formed between the non-melting electrode and the workpiece.
Compressed air and rarely shielding gases are fed through a nozzle. A high-heated gas with a high energy content is produced in the burner, which is blown out by the nozzle and thereby ionizes the air. The ionization makes the air conductive and establishes a conductive connection to the workpiece. The ionized gas that transfers the arc to the workpiece is called the plasma. The high energy density of the plasma arc results in a high cutting speed.
Components of a plasma cutter: 1. Electrode 2. Cutting gas 3. Cooling gas 4. Plasma nozzle 5. Plasma Arc 6. Workpiece
Consider the working environment when selecting welding equipment
Before purchasing, consider whether you want to use the device outdoors or indoors only. Electrode welding devices work with a wind-resistant electrode, with which you can also weld outdoors. On the other hand, inert gas welding devices are wind-prone and primarily intended for indoor use. Otherwise, the wind blows away the shielding gas from the welding area, which is no longer protected against oxidation.
Tips for selecting a welder
The following tips will help you choose a welding machine that is tailored to your needs.
- Effective working time: The higher the effective working time of a device specified in the product description, the longer you can weld at a time.
- Ventilation: Make sure your new welding machine has built-in ventilation whenever possible. The fan better transports the resulting heat and provides for a long usage time without interruption.
- Thermal overload protection: A built-in thermal fuse prevents the welding device from overheating. If the temperature limit is exceeded, the device switches off temporarily to initiate a cooling phase.
- Multi-scale or continuous welding current control: With this practical function you can adjust the welding current according to the planned task as required. In this way, the device can be aligned without compromises to your project.
- Mobility: Are you planning welding work primarily in one place or should your new welding machine be mobile? In addition to standing models, there are also lightweight, more compact designs that are easier to transport.
- Remember the consumables: Order a basic equipment of welding equipment accessories together with your new welding machine. This means you have everything together from the start and can start welding immediately.
This is how you work with your new welding machine
Before you start, clean the workpieces and put on your personal protective equipment.
- Remove dirt: Remove dirt, dust, paint, grease and foreign objects from the components. If necessary, fix the workpieces on a suitable, non-flammable surface.
- Clean up work area: Remove all combustible and easily flammable materials from the work area, as sparks can spray during use.
- Ensure ventilation: Ensure excellent ventilation when welding in closed rooms. Welding creates hazardous vapors, gases and dust, so the working environment must always be adequately ventilated.
- Wear protective clothing: During welding, heat, sparks, the bright arc and UV rays can endanger your health. Therefore, always wear suitable protective clothing in addition to clothing completely covering the body. Personal protective equipment for welding includes a welder helmet with protective glass or a hand shield with protective glass visor, welding gloves made of leather and work shoes. Make sure that all areas of the skin are covered.
- Protect the audience: Colleagues, employees and spectators who observe the welding process must not look at the welding site and the arc without eye protection.
- Carry out post-inspection: Check the working area after the welding work has been completed in order to avoid a subsequent fire risk.