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GMAW (Gas Metal Arc Welding) Gas welding Notes: MIG!"AW and S#ielded!"AW A" only and A"$%" &'y(acetylene )IG (%" only and a"$%") Difficult: most Skill required typical metals welded by hobbyists 1 amp per.1! thick"ess &' (au(e ) $1+!,M
GMAW (Gas Metal Arc Welding) Gas welding Notes: MIG!"AW and S#ielded!"AW A" only and A"$%" &'y(acetylene )IG (%" only and a"$%") Difficult: most Skill required typical metals welded by hobbyists 1 amp per.1! thick"ess &' (au(e ) $1+!,M
GMAW (Gas Metal Arc Welding) Gas welding Notes: MIG!"AW and S#ielded!"AW A" only and A"$%" &'y(acetylene )IG (%" only and a"$%") Difficult: most Skill required typical metals welded by hobbyists 1 amp per.1! thick"ess &' (au(e ) $1+!,M
General Information Regarding Welding Processes and Welder Selection for Newbie Hobbyists
GMAW (Gas Metal Arc Welding) Gas welding Notes:
MIG !"AW and S#ielded !"AW A" only and A"$%" &'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.