Welding machines: types, how they work, the characteristics of which one is better

Welding - the process of one-piece metal compounds through their heating and fusion. This is done using a special tool - welding machine.

Types of welders

The following types of welding:

• Manual arc (MMA);
• argon arc (TIG);
• Semi (MIG / MAG);
• point (SPOT);
• plasma cutting (PLASMA).

Welding apparatus manual arc welding (MMA)

Used for welding arc burning between the weld pool and electrode. The latter is a metal rod with a special coating.

The arc is formed during the end of the metal electrode contact, exposed to processing. In the place of contact surface begins to melt. Formed weld pool. The electrode is melted and serves as material for the weld.

After treatment, the metal slag is removed.

TIG welding machine (TIG)

Used primarily for use with non-ferrous metals. The effective when machining aluminum. It is a kind of alliance and gas arc welding.

TIG - Tungstren Inert Gas. The transfer means manual arc welding with non-consumable electrode in inert gas atmosphere. Electrodes for it are manufactured from tungsten, a refractory metal with a high boiling point (about 5900 ° C). Of the inert gases argon is used.

During welding, argon does not allow oxygen to oxidize the surface of the metal, which has a positive effect on its performance.

Semi-automatic welding machine (MIG / MAG)

It has a similar technology to work with welding TIG. The difference is in that the electrode material used fuse wire, and as a protective medium - mixture of gases.

Origin provides protection against oxygen, and the second penetration rate.

This type of welding has several advantages:

• ease of development;
• High speed;
• the ability to make a long seam, without the need for frequent stops and arc ignition;
• no need for cleaning the finished weld.

Apparatus spot welding (SPOT)

Used for the connection of thin sheet metal. Widely used in the automotive industry.

metal sheets placed between the clamp of the electrodes, which current is passed, the high value. As a result, the contact position is heated above its melting temperature and forms a strong connection.

Apparatus for plasma arc welding (PLASMA)

It represents a metal cutting by hot plasma jet. Through a nozzle under high pressure is fed inert gas heated by an electric arc to the plasma state.

2 large groups stand out among welders:

• welding machines for home;
• professional welders.

Domestic intended for private use. They operate from 220V and are designed for small current.

Professional can operate at mains voltage and 220V, and 380V. They have great strength of the current (over 200 amps), and are designed for continuous operation in demanding production environments.

types of devices

In the welding work the following types of equipment are used:

• transformers;
• rectifiers;
• inverters;
• semi-automatic;
• semi-inverters;
• generators (petrol or diesel).

As welders work

Depending on the type of equipment operating principle is different.

Transformer Welding Machine

This tool converts the electric current and adjusts it to the welding arc was stable.

The principle of operation is as follows. At the core acts as a magnetic circuit, arranged primary and secondary windings. In this case, one of them is fixed statically, and the second is moving relative to the first of magnistoru. This ensures that the current regulation. The main role of the instrument - down transformer.

welding rectifiers

The basis of this system, which is a power source based on the following elements:

• transformer;
• rectifier unit (a diode or thyristor);
• regulator.

The tool is powered by a supply of electric arc DC. The current flows through the secondary winding for rectifying unit. Rectifiers may be silicon or selenium.

Inverter welding equipment

Unlike conventional rectifier, which makes a single rectification current, the inverter current occurs repeatedly transform on various parameters.

The alternating current is converted to a primary network rectifier. After that he goes to the filter. In this case, the voltage parameters are not changed. Then, current is supplied to the inverter. The output is a variable high frequency.

Thereafter, the transformer reduces the operating parameter to the idle voltage values ​​of welding current. Its rectification occurs in a secondary rectifying unit.

semiautomatic device

this tool unlike vysheperechislnnyh is that when working with them does not require electrodes. Welding is produced by melting a special wire in the gaseous medium. At the heart of - conventional transformer.

In semiautomatic set includes:

• source of power;
• wire feed device;
• connecting hoses and cables;
• burner;
• - control system;
• gas containment vessel;
• wire.

Inverter welding machines, semi-automatic

At the heart of this device - the inverter. The process is identical to normal semiautomatic welding. It combines the advantages and disadvantages of the inverter and semiautomatic.

Generator for welding unit

The main task of this unit - convert into electricity the mechanical energy.

Its main parts:

• stator magnetic poles;
• anchored to the winding;
• collectors.

The armature winding turns at the intersection with the magnetic lines of force (they are located on the stator poles) an alternating current. The collectors is its conversion to DC. Through carbon brushes it hits the clip, and from them to the welding wires that lead to the electrode.

Characteristics welders

Main characteristics

Operational frequency.

This feature allows you to determine what percentage of the cycle time (from different manufacturers it may be 5 or 10 min.) the apparatus can operate continuously, and as it is required for recreation.

Most often, the equipment has a protection system based on this parameter. When the limit level loads the unit will automatically shut down to avoid overheating.

welding current.

it can be in the welding equipment:

• variable;
• DC;
• AC / DC.

The alternating current form used in household electrical outlets. It has a reverse polarity, in which "+" and "-" are reversed with a frequency of 50 Hz. Some welders are able to increase the frequency to higher values.

Alternating current has no concept of polarity, so there is no risk of incorrect connection of the equipment. It is used most often to work with ferrous metals.

This in turn reduces the quality of the weld.

Permanent current It has a constant and unwavering focus. In this way the number of sprays is substantially less than when using alternating current, and the weld quality is better. When connected equipment is important to observe polarity.

production technology, which use direct current, much more expensive, because it requires the inclusion of rectifiers.

Scope: non-ferrous metals and stainless steel.

Apparatuses utilizing and constant and alternating current versatile. They can operate in different environments and with different metals. The cost is much higher simple tool.

Input voltage.

This characteristic shows the power source voltage for which the unit is designed. It is important to not only the value of the voltage, but also a way to connect.

There are the following options:

• single phase (one pair of "0" contacts - "phase"). Voltage - 220V. This tool works by household outletDue to what has been widely spread. Due to the large consumption increases the load on the network, so powerful devices may require a direct connection to the distribution box.
• three-phase (3 pairs of "0" contacts - "phase"). Voltage - 380V. Instruments with this voltage is not used in everyday life. They are used mainly in industrial premises with the appropriate network connection. Used for complex operations where high power is required.
• single-phase / three-phase. Voltage - 220V / 380V. Depending on the tool the destination one of the values ​​is a key or optional.

Power consumption.

This parameter is measured in kw (kilowatts) and indicates the maximum power at which the welding machine is designed.

Open circuit voltage.

voltage indicator, which displays the tool to the electrodes. The parameter value is dependent on the type of apparatus used and the type of welding electrodes. Generally in the range from 40 to 90V.

The minimum welding current.

The smallest current value at which the machine is able to weld metal. This parameter is important for assessing the shelf hardware to work with thin metal, in which the current importance disastrous.

The maximum welding current.

The opposite value indicating how much equipment is able to operate with thick metal using large diameter electrodes. The dependence of the material thickness of the welding current can be traced by special tables.

The minimum diameter of the electrode.

The indicator determines the minimum value of the electrode, which is capable of operating the device.

The maximum diameter of the electrode.

Reverse option. The range of dimensions of the electrodes must be chosen based on the requirements of the work (welding type, the metal thickness, etc.).

Additional functions

To facilitate the work of the welder equipment manufacturers equip some useful features:

• Hot start. Designed to facilitate arc ignition. During the working surface of the touch electrode current rises briefly and then returned to the standard indicators;
• Protection against welding. In this case, the apparatus automatically reduces the current to the value at which the stuck can be easily detached electrode;

Thus, to reduce the risk of this situation, you must buy them in checked specialty stores and store in a dry place with low humidity.

• Forcing the arc. By lowering the critical distance between the metal electrode and increases the welding current device, which allows to increase the melting rate of the electrode and the depth of the weld pool. Another way to avoid sticking;
• Transport wheels. Allow one person to even move heavy equipment.

Options and accessories

Depending on the specific model of equipment may be different equipment. However, there is a necessary minimum, which must be present in each set:

• welding machine;
• 2 welding cable (about 2 meters);
• warranty certificate;
• instruction manual.

Also included additional elements may be present:

• welding mask;
• carrying case;
• carrying handles;
• shoulder straps;
• brush for cleaning equipment.

accessories

To facilitate the work of the welder and the subsequent maintenance of the equipment, there are all sorts of accessories that can be identified in several groups:

Electrodes for the welding machine:

• for welding of carbon and low alloy steel;
• for surfacing;
• for welding cast iron;
• for welding non-ferrous metals;
• cutting;
• welding a high alloy steel;
• welding alloy heat-resistant steel;
• for welding of dissimilar metals.

Sprays and pastes. The compositions are designed for different purposes:

• fire protection surfaces in the immediate vicinity of the welding;
• protection against spatter adhesion;
• non-stick protection gas burners and others.

Supporting materials:

• welder mirror;
• Construction pencils and holders for small talc;
• lines and triangles.

Just to the accessories include:

• Burners.
• Plasma cutters.
• Electroholders.
• Grounding clamps.
• Welding cables.

pros

transformers:

• simple and inexpensive construction;
• high reliability;
• ease of maintenance;
• Efficiency of about 90%.

Welding rectifier:

• reliability of the weld;
• stability of the electric arc;
• low noise level.

Welding inverter:

• compactness;
• accuracy;
• resistance welding arc;
• ability to work in a wide range of current;
• overload protection;
• the ability to work with all types of electrodes.

Semi-automatic:

• high quality weld;
• slight splashing metal;
• high performance.

Welding generator:

• stability of the electric arc;
• high quality weld;
• low sensitivity to voltage surges;
• the ability to work with all known types of electrodes;
• the ability to use in places where there are no sources of electricity.

disadvantages

Transformer:

• large dimensions and weight;
• high energy consumption;
• heavy dependence on mains voltage surges.

Welding rectifier:

• dependence on surge;
• sensitivity to dust and shock.

Welding inverter:

• high price;
• sensitivity to contamination of the electronic board.

semiautomatic device

• low mobility;
• sensitivity to weather conditions.

Welding generator:

• complexity of maintenance;
• high price;
• compared with transformers low efficiency value;
• high energy consumption.

How to choose

Pick up the welding machine is necessary, depending on the purpose and conditions of use. Before deciding to buy should answer some questions:

• Under what conditions is planned to carry out works (space / Street)?
• Is it important whether compactness and mobility tools?
• Do I need a lot of power (how thick the metal is supposed to process)?
• Whether there is access to an electrical outlet in the work place?
• What type of metal is supposed to process?

Having defined the scope and purpose of the work, it is easier to choose the machine with exactly those characteristics that are suitable for the specific conditions.

If the amount of work is small and does not require high accuracy, but on the ground there is no electricity, no need to purchase the expensive welding generator. It is more logical to buy a compact single-phase device and gasoline / diesel generator 220V.

What better welding machine

There is no specific model that would have been better in all respects. It all depends on the specific needs and conditions.

The device for the professional welder. This requires a versatile device having a high power and a wide range of settings for operation in different conditions with different metals.

Household welding machine. For these purposes, nowhere to buy an expensive and powerful machine. potential tool certainly will not be used until the end, and to pay for it is not worth it. With household work cope inexpensive device for manual arc welding with alternating current.

In any case, you should pay attention to the following factors:

• manufacturer;
• the conditions of the warranty;
• level of service;
• availability of spare parts.

Exploitation

Maintenance, care and prevention

Timely service, care and prevention of welding equipment - necessary tools long life. The regular holding of these works provide a good performance in the future will help to avoid serious damage.

the following steps should be carried out:

• regularly check the main elements of the device in order to identify external signs of failure (insulation fault, melting of contacts, etc.);
• cleaning and lubrication of parts;
• testing and performance analysis.

Precautionary measures

Violation of safety when working with welding equipment can lead to serious consequences:

• fire;
• explosion;
• injury (electric shock, burns, mechanical damage);
• deaths.

For admission to the welder must have:

1. training;
2. documented admission to work;
3. medical work permit.

To avoid unpleasant consequences, it is necessary to observe the following precautions.

• To avoid electrical shock necessary to wear protective clothing and dry leather. It is forbidden to touch with bare hands to the electrodes and the equipment housing under voltage. It must be especially careful when working under conditions of high humidity.
• Welding mask to protect against arc radiation and welding face defeat.
• The room in which the work must be ventilated well to prevent gas poisoning and smoke.
• With the high level of noise necessary to have hearing protection.
• Near welding operations should not be flammable and flammable substances. In the immediate vicinity should have fire-fighting equipment.

Guarantee

Manufacturers of equipment for welding set different warranty period. On average, it ranges from 1 to 3 years. warranty conditions are specific to each model. They can be found in the data sheet or on the manufacturer's website.

The warranty is calculated from the date of transfer to the buyer device. In addition a free routine maintenance of equipment can be offered within the framework of the guarantee program.

It includes:

• diagnostics;
• replacement of electrodes in agreement with the owner;
• setting;
• cleaning;
• parameter testing.

The guarantee does not apply to equipment:

• having external damage;
• modified holder;
• used in unacceptable conditions;
• having tracks unauthorized repairs;
• Operated with violations of the requirements;
• with defective marking;
• completely exhausted the resource declared by the manufacturer;
• beyond the warranty period.

Also, the manufacturer does not apply to:

• individual parts subject to normal wear and tear;
• parts, the wear of which depends on the operating conditions;
• adjustment of equipment.

In case of breakage of welding equipment through the fault of the manufacturer's user has the right to free repair. To do this in person or by mail (use protective transport packaging) to send the equipment in the warranty service center. In this case, be sure to present the warranty card.

Handling complaints from buyers is regulated by the "Law on the Protection of Consumers' Rights. In accordance with its requirements, the repair period may not exceed 45 calendar days. For each day of delay the customer is entitled to demand payment of penalties.

Faults and repairs

Common faults and failure depend on the particular type of welding machine.

Faults welding transformers.

Poor contact in the terminal block, which is connected to the welding cables. It leads to strong heating connections, insulation breakdown and short-circuit. Eliminated by iterating the heating compounds stripping contact group and a clamp for sealing contact.

Spontaneous shutdown equipment. It occurs immediately after turning on the unit to the network due to a trip. Probable cause - circuit in the high voltage circuit between the turns of the coils and capacitors fault. For repair be sure to turn off the machine and remove the defect, restoring insulation or replacing capacitors.

Excessive transformer hum. Often accompanied by overheating. Probable cause - the weakening of bolts or overloading of the transformer. Also buzz occurs because the insulation between cables, or sheets of the magnetic circuit.

Strong heating apparatus. The most common is due to exceeding the allowable load level.

Otherwise, the equipment may be damaged.

The disadvantage of the welding current. It arises due to the low breakdown voltage or current regulator.

Consumption of large quantities of power with no load. The reason - the closure of the winding turns. It is necessary to restore the insulation. For the same reason, can the sudden interruption of the arc without the possibility of its restoration.

Faults welding inverters.

A blown transistor. Considered a weak point of the inverters. In the event of equipment failure, you must first verify it is transistors. To check this you need to use a multimeter.

Faulty driver elements. Checked with an ohmmeter. If necessary, the faulty components can be replaced by suitable analogues.

Defect input and output rectifiers.

Faulty control board. The most complex piece of equipment. Serviceability is checked using an oscilloscope.

arc instability. It arises due to incorrect current settings.

Overheating of the device. Likely Causes - long work under heavy load, cooling system failure or contamination of the board.

Repair of transformers fully able to make their own hands. Welding inverters have a more complex structure, and to repair them you need to not only have the appropriate equipment, but also have the specialized knowledge and skills.

It should be remembered that the repair and maintenance of welding equipment can cause serious injury. In the absence of the necessary knowledge and experience for these purposes it is better to turn to professionals.

manufacturers

Aurora-PRO

Phones of this brand are made exclusively on the basis of inverter technology. AURORA joint production of a group of companies and Chinese companies RILAND Industry, where he collected the equipment to Russia. Official website of the manufacturer - www.aurora-online.ru.

The company offers a wide range of welding equipment in all directions: MMA, MIG / MAG, TIG, SPOT, PLASMA.

The warranty on all kinds of tools - 2 years.

BlueWeld

The Italian company, a leading European manufacturer. Start of production of welding equipment - 1963. The beginning of deliveries in Russia - 2002.

It specializes in manufacturing all known kinds of tools and accessories. Production is established in Italy. Official site - www.blueweld.ru.

Warranty - 1 year.

Brima

The German manufacturer of welding equipment. The output is adjusted in several countries in Europe and Asia. A wide range of equipment and accessories for a variety of purposes (inverters, rectifiers, transformers, semi-automatic).

Official site - www.brima.ru.

Warranty - 1 year.

Elitech

Manufacturer of welding equipment, accessories and garden machinery. It offers a variety of equipment for welding and cutting metals, as well as welding multisystem MMA-MIG-MAG-TIG.

Official website of an online store - elitech.com.ru.

Warranty - 1 year.

Eurolux

The company is engaged in manufacturing inverter welding machines. Line small models. Official site - www.eurolux-russia.ru.

Warranty - 1 year.

FoxWeld

Italian brand with production in China. Wide range of welding equipment and accessories. It has offices and service centers in 16 cities of Russia, which facilitates maintenance. Official site - foxweld.ru.

Warranty - 1 year.

Fubag

The German company, which produces various types of equipment for construction and repair: vibrators, Drills, screwdrivers, spray guns and TL Welding tool - inverter. The factories are located in Germany and Switzerland.

The company has its own staff of professionals who create new technologies. Official site - www.fubag.ru.

The warranty for the equipment purchased after April 1, 2014 - 2 years. Prior to this period was 1 year.

Kedr

Russian manufacturer of welding equipment: inverters, semiautomatic machines, devices for argon-arc and manual arc welding. The company has positioned itself as a manufacturer adapted to the harsh climatic conditions of the tools. Official site - www.kedrweld.ru.

Warranty - 2 years.

Patriot

The US company, which produces inverter welding machines, among other equipment. This area is not a major. It has a wide network of service centers. Official site - www.onlypatriot.com.

Basic warranty - 1 year. In case of purchase of equipment for personal use provided an extended warranty period of 3 years. At the same time every 6 months, the consumer is obliged to take scheduled maintenance to the service center.

RedVerg

Another American manufacturer of equipment for construction and repair. It offers among other Welding Machines: Inverter and semi-automatic. It has a research center. It has a network of authorized service centers. Official site - www.ru.redverg.com.

Warranty - 1 year.

Resanta

One of the most popular on the market, the manufacturer of inverter welding machines. Besides them specializes in the manufacture of voltage regulators. Service development. Official site - www.resanta.ru.

Warranty - 1 year.

Stavr

Russian manufacturer of power tools. Collects inverter and semi-automatic welding machines. It has an extensive service center network. Official Site - stavr.rf.

Warranty - 2 years.

Svarog

The company, specializing in the production of inverter welding machines. The product was collected on a Chinese factory. Official site - www.svarog-rf.ru.

The warranty period depending on the equipment - from 2 to 5 years.

Wester

The British company, which produces welding equipment and accessories of various kinds. It has a good service center network. The official site is absent.

Warranty - 3 years.