What is a welder?

If you’d like to have a go at welding, there’s a few things to know before you purchase a welder. First of all, what is a welder? And how does a welder work? A welding machine or welder is among the strongest methods of joining metal, using electricity to generate heat and fuse the metal together.

The welding machine used and method of welding can differ from job to job, but most welding operations use a filler to create a welding join. This can either be a wire fed by the welding machine, or a filler rod or electrode fed by the hand of the operator.

So which is right for you? Let’s dive a little deeper.

How does a welder work?

Let’s break this down into the most common types of welding machines you’ll find on the shelves at Supercheap Auto. MIG, TIG, and ARC (also known as stick)

What is a MIG welder?

A MIG welder is a type of welder which uses welding wire. This wire is fed continuously through the welding gun to form a weld. Many people find it easiest to learn how to use a MIG welder, and it is also very versatile.

The trickiest part is setting the wire speed and voltage, which may require a few test welds and a little practise to dial in. Some higher budget machines can do this automatically. Then just pull the trigger and away you go!

MIG welding also requires a shielding gas. You can rent a bottle and purchase the gas from many welding suppliers, and with the right combination of gas and wire you can weld carbon steel, aluminium and even stainless steel to some degree.

Or, you can use ‘gasless’ flux core wire which generates gas from the flux as you weld. The downsides are that flux core is really only suitable for carbon steel, and it will be harder to get a clean and tidy looking weld.

What is a TIG welder?

A TIG welder is a type of welding machine which uses a ‘gun’ or ‘torch’ with a tungsten tip to create an arc and heat your work piece. This is held in one hand while your other hand is used to feed a filler rod into and create the weld. TIG stands for Tungsten Inert Gas and just like MIG welding, the TIG requires a shielding gas. There is no flux core or ‘gasless’ option.

A TIG welder is perfect if you want to weld a lot of stainless steel, copper, aluminium and magnesium alloys. It delivers the most precise and visually appealing welds of all welding processes, and does so with less heat distribution – meaning you can weld with less heat discolouration and distortion of thin materials.

Of course, there’s always a trade-off. TIG is the hardest to learn. And for large welding jobs on mild steel, it is a slow and inefficient choice. You’ll find it cheaper, easier and quicker to save those jobs for the MIG.

What is an ARC welder?

An ARC welder (sometimes known as a stick welder) is the simplest and cheapest type of welding machine. The welding gun is fitted with a consumable electrode (or stick) coated in flux which strikes the arc on your workpiece and melts to form the weld. Just like a MIG, voltage is set on the welder. But with no wire speed to set, you control the stick speed with your hands (a skill you’ll acquire with practice).

An ARC welder will be perfect for welding thick carbon steel and even cast iron, but you’ll struggle to get a satisfactory weld on material under 1.5mm thick. Being easily portable, and with plenty of flux on each welding stick; an ARC welder can easily be used outdoors without any concern of a breeze contaminating the gas shield.

Welding power differences

You’ll find that welding machines are available in different power outputs measured in amps, also called current. A higher current allows you to weld thicker material, and can be lowered to prevent blowing holes in thinner materials.

The duty cycle is also important to consider when shopping for a welder. Duty cycle is the percentage of time that a welder will safely operate at a specified amperage and is always measured in a 10 minute block. A welder with a 10% duty cycle at 180 amps will run for a full minute, then require a 9 minute cool down. Of course if you’re not welding at full power, or you’re welding in cooler weather; the duty cycle will be longer.

Quality vs budget

The first step to choose the best welder for your budget is deciding what you want to weld. By setting your sights on a welder that will do just what you need and nothing more, you’ll get a great quality welder for a good price.

However, if you have a higher budget and would like to future proof your welding endeavours; you might consider a multi-process welder. These are usually supplied ready for MIG welding, and with the purchase of some additional equipment; can handle ARC and TIG welding when you’re ready.

Welder Brands

Welding brand comparison

At Supercheap Auto you’ll find a range of Unimig welders available in stores with Dynaweld machines also available via special order. Unimig shines with its user-friendly designs, making it a go-to for beginners and seasoned welders alike; its Viper series is particularly noted for balancing cost-effectiveness and quality. Dynaweld, known for the Bossweld range, is praised for its robustness and durability, making it a solid choice for heavy-duty and industrial applications.

Tips & FAQs

What safety considerations should I keep in mind when selecting a welder?

Since the essence of welding is pretty much setting fire to metal, there are naturally a few safety requirements to be considered. A quality welding helmet is of utmost importance. Not only is welding extremely bright, but the process emits UV radiation. This will cause sunburn to your eyes (which IS as painful as it sounds) not to mention any other exposed skin.

Further to that, you’re dealing with molten metal which doesn’t always confine itself to the work piece, particularly with ARC and gasless MIG welding. So flame resistant clothing including full long sleeves, pants, boots and welding gloves are a must.

What are the essential accessories I should invest in when buying a welder?

Beyond the safety essentials, the best welding accessories you can grab include a variety of welding magnets and clamps to keep your hands free, a chipping hammer and wire brush for cleaning away flux and slag, welding pliers, spare welding nozzles, tips and electrodes. If you’re doing ARC or gasless MIG welding; some anti-spatter spray will make it easier to clean messy welds.

Are there any specific considerations for using a welder in different work environments, such as outdoor projects?

Always assess the environment for anything flammable. Solvents, cloth, timber or dry grass are a few obvious ones, but welding is hot enough to ignite just about anything.

If your welding job is outdoors, even a light breeze can interrupt gas shielding. Using an ARC welder or gasless MIG wire will combat this, otherwise you can try shielding your work piece, or simply choose a nice still day.

If you’re welding indoors, fumes can be a safety issue, so consider wearing a respirator if you can fit one with your mask; or ensure adequate ventilation. Just be careful not to blow your shielding gas away.

Can I weld different materials with the same welder or do I need specialised equipment?

A MIG welder is the most versatile welding machine, capable of welding mild steel, aluminium, and although not the ideal welder for the job; it will also weld stainless steel. You will require different wire for each of these materials, and the welding machine must be configured differently for each.

A TIG welder can weld a greater variety of materials than the MIG including very thin and exotic metals. The machine must be configured differently for each, including different tungsten electrodes and filler rods.