What Is Welding?
When we talk about welding, we refer to the process of fusing two parts or pieces together using heat and/or pressure to create a joint. This resulting joint may also be called a seam or weldment. To create the seam, welding uses focused, intense heat to melt the filler metal and the original metal together while being protected by a shielding arc created by gas that’s specific to the type of welding machine used.
You’ll find welding used in automotive, aeronautic, nautical and construction industries. There’s also a growing community of artists who use welding to create artwork.
Types of Welders
To create the heat necessary to melt various compounds together to create a seam, a welding machine is necessary. The most common types of welders are stick, MIG/flux-cored and TIG. Although you may also find plasma arc, gas tungsten arc, atomic hydrogen and energy beam units, these are typically reserved for highly skilled professionals. The core models are more than sufficient for the novice welder.
Understanding Equipment Types
Take a look at these standard types of equipment and learn about different types of welding to see which would be the best welder for your projects.
Stick Welders (SMAW or Shielded Metal Arc Welding)
Economical and effective, stick welding is the most popular choice for home shops. It works both in the workshop and outside, produces strong welds, and works on most alloy metals — even dirty or rusty surfaces. Stick welders can pose a challenge, however. Finished welds must be cleaned. Plus it can be difficult to master creating a lasting arc. But with time and patience, new and experienced artisans appreciate their stick welder.
MIG Welders (GMAW or Gas Metal Arc Welding)
MIG (metal inert gas) welding is an excellent choice for beginning welders. This easy-to-handle machine is usually spool-fed to create professional-looking joints on both thick and thin metals. MIG welding requires separate shielding gas but doesn’t require chipping and cleaning slag as the stick welding process can. This makes for a faster and easier welding experience.
Flux Arc Welders
A flux arc welder offers simple and efficient welding on steel, aluminum and stainless steel. Some flux-core wires shield the arc from contamination without the need for an additional shielding gas. This feature makes a flux-cored welder an excellent choice for outdoor use as it works effectively on dirty or rusty metals, creating a thick, reliable seam.
TIG Welders (GTAW or Gas Tungsten Arc Welding)
TIG (tungsten inert gas) welding is a bit more complex to learn but offers a level of precision that other welding machines can’t. TIG welders require shielding gas but offer greater control and the ability to fine-tune the current with the use of an amperage foot pedal. TIG welding is good for thin alloy steel, aluminum, magnesium and copper alloys.
Multi-Process Welders
If you want to take advantage of several different types of welding but lack the space to store multiple welding machines, a multi-process welder may be your best choice. Housing several different processes inside a single machine, this equipment combines multiple functions, like MIG/flux-cored, TIG and stick welding, in a single unit.
You can get more welding tips and how-to information with Welding Basics.
Matching the Welder to the Project
Different welding machines are suited to different metals and different thicknesses of material.
Welding Steel and Stainless Steel
Both steel and stainless steel readily accept welding by three standard types of welders:
However, the thickness of the metal determines which machine is best. TIG welding works best on thin metals, as it offers more precise temperature control through the use of a foot pedal. This prevents unintentionally cutting through the metal as a plasma cutter would. For thicker metals like structural steel or when fusing to a dissimilar metal, MIG welding is preferred, as it produces strong and reliable bonds quickly.
Welding Aluminum Alloys
Welding aluminum alloys can be tricky, so it’s best to use a welder that offers more control, like a TIG welder. The temperature regulation of TIG welding helps prevent overheating and burn-through. You’ll need to clean the surface before welding. Aluminum has a layer of oxidation that can be challenging to deal with. Try using a clean stainless steel brush on the surface.
It’s also possible to weld aluminum alloys with a MIG welder. This works well with thin gauges and aluminum sheets. Simply use a similar-strength welding wire or rod to produce a strong and reliable weld.
With the exception of a couple of gauges, it’s best to stay away from 2XXX and 7XXX aluminum alloy when welding at home, as these metals are problematic.
Welding Cast Iron
While cast iron is a difficult metal to weld, it’s not impossible. Many do-it-yourselfers experience great success by using a stick welder with nickel rods. Because of cast iron’s tendency to crack and flake, temperature control is essential regardless of the welding method you choose.
Welding Chromoly
Lightweight and exceptionally strong, chromoly shows up often in automotive projects. Because it’s a bit different from other alloys, metal preparation and cleaning are essential for welding success with your TIG welder. When welding chromoly, move slowly so as to not shock the metal.
While all of this may seem to push a do-it-yourself welder toward a TIG or MIG welding machine, you should consider all the options and how you want to use the welding machine. A stick welder works on steel, stainless steel, nickel-based alloys, chrome, regular steel and aluminum. However, another type of welding machine may produce more professional results. It’s up to you to weigh the importance of certain aesthetics with basic function.
Buying Your First Welder
There’s no welder that’s perfect for every craftsperson. That’s why it’s important to understand your task, goals and budget.
Research your workload and determine the types of metal you’ll most often work with, as well as their thickness. For example, are you primarily working to fix cars? Create metal sculptures? Build backyard furniture? Or are you performing maintenance on heavy-duty farm equipment?
Don’t just stop with your first project. You may need to repair a metal fence this weekend, but try to also see what’s down the road. Have you wanted to add a spare-tire mount to your trailer and didn’t know where to start? This helps to give you an idea of the type of machine and amount of training you’ll need to be successful.
Next, consider your budget. Whether you’re a weekend warrior or you’ll use your welder as part of your professional services offering, you’ll find a host of welding machines to fit a variety of needs and budgets. You’ll also need to consider the cost of protective equipment and materials to go with your welder. This means that the best welder for you isn’t necessarily the most expensive machine. You want to plan for equipment that’ll do the job you need to tackle now, plus your future tasks and growth, while leaving you a little money left over for safety gear and supplies.
Take your time as you go through this process. Research, study the craft, look into the products and services offered by welding equipment manufacturers, and talk to a few people about their machines, keeping a bit of objectivity as everyone will have their preferred brands. Ultimately, though, the best choice for you is the one you’ll work with regularly to perfect your craft.
Maintaining a Healthy Respect for Your Welder
As with all power tools, safely using a welder requires a healthy respect for the welding equipment. The correct safety gear and equipment will protect you against many things, but be aware of the risk of electric shock, noise hazards, burns, exposure to UV (ultraviolet) and IR (infrared) radiation, as well as fumes and gases.
That’s why it’s essential to save part of your budget for the right welding safety and protective gear. Your welding machine documentation will tell you what you need, such as proper eye and face protection.
Welding Helmets
A welding hood or welding helmet with the appropriate lens for your machine protects your eyes from damaging UV and IR flashes from welding arcs. Though there are a variety of options available, you’ll want to choose one that’s well suited to the work you’ll be doing. Some of the best-rated welding helmets offer features such as variable lens shades to allow you to tackle different kinds of projects, a combination solar and battery power supply, a large viewing area, and a lightweight design to help reduce neck strain and fatigue when working for long periods of time.
Another feature to consider is automatic darkening. An auto-darkening welding helmet is equipped with sensors that allow the lens to automatically adjust once you start welding, protecting your eyes from dangerous flashes. One of the biggest benefits to this type of helmet is that you can leave it in place whether you’re working or not since the shade adjusts on its own, as opposed to a helmet with a fixed lens. Helmets with fixed lenses require you to manually lift and lower the mask. If you use different welding techniques and work on different materials, consider auto-darkening options.
Other Protective Gear
Also look for:
- A quality welding jacket
- Light- and heavy-duty welding gloves
- A welding cap
- Several pairs of safety glasses
- Steel-toe shoes
- Earplugs
Reliable fume extraction solutions should also be part of your safety gear shopping list and budget.
Learning a new skill can be both exciting and overwhelming. Remember to take your time, learn as much as possible about your equipment and practice your new craft often. You’re well on your way to adding a skill with a great payoff — whether you’re working at home or on the jobsite.
Follow the welding equipment manufacturer’s instructions for use and safety, including the use of welding safety equipment and other safety gear.
Before shopping for welding PPE (personal protective equipment), take a look at our work gloves, eye protection and hearing protection buying guides.