Welding metals is a process requiring huge amount of power and a good apparatus or welding equipment. Welding requires a power supply with good voltage and current for welding. The voltage helps to create and maintain arc, current is required to create heat and melt the metal i.e both base metal and electrode or filler metal. I have been taking online welding classes and doing research on welding forums. This is a new interesting article on the things that should be checked for better welding,
Arc Welding requires a constant voltage and current which is provided by sources like traditional transformers or new inverter circuit welder. Latest models have DC supply mod in them also which is very good because some rods require DC in specific polarity like Aluminum. Aluminum rods are best weld in DC- but aluminum welding with Arc Welder is not recommended. We only suggest to well all Iron except Galvanized iron. The zinc fumes are carcinogenic and really harmful, so weld them in open ventilated areas wearing good gas mask.
While building an arc welder I got some new information by doing things, making mistakes and looking in some forums and consulting with welders. Try to weld with enough voltage that is a minimum 30 volts to get a smooth arc and a minimum 100 amps because less than that you will be running too cold and the penetration is not going to be well. So it is a guarantee that good welder won’t be less than 3000 watts.
Why Thick Cables?
I have seen too many welders and the thing that came to my mind is that why are the welding cables or jumper cables so think while the secondary is not The thickness order is
mostly Jumper Cable>Secondary Cable>Primary Cable. After some thinking and research I found out the simple physics involved. The voltage is always inversely proportional to length. If the length increases the volt decreases. As the wire gets away from source like transformer the voltage starts to drop in relation with distance so thick cables should be used to prevent voltage drop and to handle huge current. The AC current actually makes the electrons vibrate in the wire where as in DC the electrons flow smoothly. A DC welder is a recommended one for Arc welding specially for Aluminum welding. I used 12 gauge wire instead of jumper cable so they started to heat up quickly and starting arc was also hard. Then with 25mm jumper wires that cost me $1.5/m was good enough to weld and start a smooth arc.
So to sum up, proper welding need good and suitable supply of power, good work ground, ventilation, protection, welding cables and always respect with passion. Learn here to make your own arc welder or learn here the basic of arc welding.