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Best MIG Welder - Reviews and Quick Buying Guide 2017


If you have landed to this page chances are you are a professional MIG welder or a passionate MIG welder who just enjoy welding and building permanent things or a slim opportunity exist that you are solely curious and not aware of the whole concept apart from imagining welders with dark smoky working condition with filthy clothes and helmets. For the latter category, I would like to give a simple idea what modern MIG welding looks like-It is the process to join metals in a way that never fails to hold each other. This permanent bond is made by heating the metal and adding two metal together with gloves wore hand. I was tempted to say bare hands, though you wear gloves and use a semi to fully automatic MIG welder-it is nothing like advanced robotic process, the process is almost manual and very easy after a few lessons. Many industries have need of an MIG welder if it is in production, and today’s MIG welders are well educated, do not work in a smoky dark room, uses safe gloves helmets, fume extraction technologies. They do far more than just joining metal, they can be involved in studying blueprints, calculating dimensions, inspecting the structures, maintaining pieces of equipment, creating ideas.

Top Rated MIG Welders - Comparison Chart

Image

MIG Welder

Brand

Power

Weight

Review

Editors' Rating

lotos mig175

Lotos
Technology

220V

85.0 pounds

Hobart 500559

Hobart

115V

65.3 pounds

Goplus MIG 130

Goplus

110V

35 lbs.

Hobart 500553

Hobart

Dual-voltage
(115V/230V)

87 lbs.

Lincoln Electric

Lincoln Electric

Dual Voltage
(120V or 230V)

62 pounds

Forney Easy Weld 299

Easy Weld

120V

41.9 pounds

millermatic mig welder

Miller Electric

120V

64.1 pounds

Hobart 500554001

Hobart

 Dual-voltage
(115V/230V)

89 pounds

2017 EVERLAST

Everlast

Dual Voltage
(110V/220V)

30 lbs

Forney 301

Forney

120V

29.2 pounds

To start MIG welding you need some basic training on 5 fundamental aspects :

1. Electric Arc,

2. MIG and TIG welding,

3. Oxygen/Acetylene Burning and

4. Blueprint Reading for Welders

Also you need a MIG welder. My effort here is to help you find the Best MIG Welder that match with your personality and your special need.

Who does not want to invest in a product that gives the best value for money? Whether it is the kitchen faucet, a tube light, a home or a MIG welder a buyer’s priority is to win big. Some may want to win at the lower price but mostly we want to win at good quality commensurate to its price (if not more).Many of the welding lovers want to buy an MIG welder that can give a professional performance at a presumably lower price. Some Best Mig welder cannot be bought at the compromised price, however, there is few best quality budget MIG welder Which you can own and claim to win the best deal for the price. Before buying an MIG welder it is important to decide on the purpose. If you are investing in a tool for home improvement and DIY projects than you should focus on one type of Mig welders which are –safe, easy to operate, portable, less expensive, need not be used frequently. In this way, before you settle on a specific model, ensure you read the MIG welder reviews underneath.

Goplus MIG 130 Welder Flux Core Wire Automatic Feed Welding Machine

Many buyers long for market’s best 110v MIG welder along with the best cheap MIG welder. Well, 110v is the most standard input unit and it works as A plus if your welder is compatible to that power strength. Goplus MIG 130 Welder Flux Core Wire Automatic Feed Welding Machine happens to be a very reasonably priced Mig welder that is compatible with 110v.

I like the handle of the welder. It has a convenient size of 12 inches.It comes with a useful safety mask of 7.87"X9.5" dimension.It comes with 2 cords-power cord of 6feet and cord with the gun is more than 5 feet. To run this welder without blickering of room light you will need a Circuit breaker of 10Amp, the main fuse of 13 amp. I called it cheap not only for the price but also for the fact that you may need not to spend any money other than that on circuit breaker because along with a welder machine and welding gun it has a Welding Wire, weld masks a brush too. Goplus MIG 130 Welder Flux Core Wire Automatic Feed Welding Machine ranks as number 1 in the automotive section of welding machine in home improvement. So if you have more faith in user’s review you that expert’s still you can safely choose this.

Forney Easy Weld 299 125FC Flux Core Welder

Forney Easy Weld 299 125FC Flux Core Welder

Cheap comes with a notation of negativity still we want a cheap product may be because the purpose is to home weld or start as an experimental beginner. When I term something as best cheap thing I mean the product is good value for money. As per today’s market’s available welders- one of the best cheap MIG welder which will not disappoint you is -Forney Easy Weld 299 125FC Flux Core Welder. It runs on 120 volt input and needs 125 amp capacities, perfectly workable with 2 and 10 pound spools.

This plug and play unit can weld up to a quarter inch. It can hold up to 10 lb. Forney Easy Weld 299 125FC Flux Core Welder weighs only 41 pound, with a dimension of 23 x 11 x 18 inches. It takes electric power source. It comes with a very long 6 feet cord for user’s convenience. If you plan to claim for warranty be sure made the claim within 90 days of the date of purchase with a proof of purchase. It is also a great choice for your car welding and also best mig welder for home use .

Millermatic 211 MIG Welder

Millermatic 211 MIG Welder With Advanced Auto-Set And Cart 951603

Millermatic 211 MIG Welder With Advanced Auto-Set and Cart 951603 are a bit pricey for its lots of features and convenience of operation. It comes with a running gear and cylinder rack. This is a plus for those who conduct a lot of welding job. This welder can run on both 120 volt and 240-volt input power. It draws very less power and has a result very good quality arc.

Though it is full of supreme feature it weighs almost half of other welders of this category. One desirable feature of Millermatic 211 MIG Welder With Advanced Auto-Set And Cart 951603 is it can do mild to very thick steel welding The best feature it offers is not the rack, nor the double option of power input or the versatile welding capacity but the advanced Auto-Set, which means if you are new in welding and do not want to research on the voltage wire feed manuals that we have to another side of the home page you can still survive as a successful welder.

Because Advanced Auto-Set successfully let you go away with the guesswork to set voltage and wire feed speed for the MIG welding application. You need to know the material thickness and select it along with wire diameter. And the machine does the calculation to set you with proper parameters. Amazon understand the desire to buy the best thing with ambition to spend less so they offer an interest-free EMI for 12 months for Millermatic 211 MIG welder

Lincoln Electric K2185-1 Handy MIG Welder

Lincoln Electric K2185-1 Handy MIG Welder

One of the low budget Mig plus flux cored welding equipping welder is Lincoln Electric K2185-1 Handy MIG Welder. It uses standard 115V power outlet. To use this you need a 70 amp voltage stabilizer. Super Deal Black Commercial MIG 130 AC Flux Core Wire Automatic Feed Welder Welding Machine. With Dimensions in. 12 3/4 x 8 3/4 x 18 it is compact and light enough to be controlled in anywhere. With the package you will get a Clamp Cable with a Length of ft. 8, Power Cord ft. 8 long and a Regulator for Wire Feed Speed Control.

For mig welding you can weld 1/8 inch thick steel. You need a 1 lb spool wire diameter of. 0.035 do the job. For beginners who are afraid that welding is an accident prone job, there is a good news- the welder has a special feature of Cold contactor safety feature, it aims on keeping welding wire electrically cold as long as you do not press the trigger. Adjustable wire feed speed control will help the welder to not blow it out of proportion. It has a duty Cycle of 35-88 20 duty cycle at 70 Amps. With 49 pounds its own 4.4 star out of 5 in Amazon. If you take account of those 106 people who used it you are likely to choose it.

Lincoln Electric K2185-1 Handy MIG Welder

Lincoln Electric K2185-1 Handy MIG Welder

One of the low budget Mig plus flux cored welding equipping welder is Lincoln Electric K2185-1 Handy MIG Welder. It uses standard 115V power outlet. To use this you need a 70 amp voltage stabilizer. Super Deal Black Commercial MIG 130 AC Flux Core Wire Automatic Feed Welder Welding Machine. With Dimensions in. 12 3/4 x 8 3/4 x 18 it is compact and light enough to be controlled in anywhere. With the package you will get a Clamp Cable with a Length of ft. 8, Power Cord ft. 8 long and a Regulator for Wire Feed Speed Control.

For mig welding you can weld 1/8 inch thick steel. You need a 1 lb spool wire diameter of. 0.035 do the job. For beginners who are afraid that welding is an accident prone job, there is a good news- the welder has a special feature of Cold contactor safety feature, it aims on keeping welding wire electrically cold as long as you do not press the trigger. Adjustable wire feed speed control will help the welder to not blow it out of proportion. It has a duty Cycle of 35-88 20 duty cycle at 70 Amps. With 49 pounds its own 4.4 star out of 5 in Amazon. If you take account of those 106 people who used it you are likely to choose it.

Super Deal Black Commercial MIG 130 AC Flux Core Wire Automatic Feed Welder

Super Deal Black Commercial MIG 130 AC Flux Core Wire Automatic Feed Welder Welding Machine w Free Mask 110V

With compatibility with 110 V this welder is one of the best cheap mig welder. In this price if you think you may need to buy all accessories extra than you will be in surprise, MIG-130 AC Flux Core Wire Automatic Feed Welder has -Main Unit along with Welding Spool Wire, a very much usable Welding Face Mask, one unit of chipping Hammer/ Wire Brush, a moderately powerful 2.5M Torch, 2 extra Tips. Also you will find a ground cord.It needs welding current ranging from 50-120 AMP. It has a duty cycle of 10% at 105AMP and 35% at 60 AMP. While you are welding it gives you the advantage of Variable Feed Speed Control which is vital for smooth weld. Also it has a torch With Full On / off safety control.

It is a great catch for mig and stick welding. The wire it comes with gives you raw material for first few welds. Next you will need to spend on 25$ on next spools. One caution is to be taken that is after it is switched on it is always one, do not misunderstand the feed motor’s trigger with the on off switch. It has a 2 rank in automotive section of welding equipment in tool/equipment. All reviews suggest it is a good deal for price

Lincoln Electric Easy MIG 180 Flux-Core MIG Welder

Lincoln Electric Easy MIG 180 Flux-Core MIG Welder

When you are in need to work with diverse set of metals than you will surely love Lincoln Electric Easy MIG 180 Flux-Core MIG Welder. It is workable on- steel, stainless and aluminum. This works on both gas-free flux core welding and gas-shielded MIG welding. The wire feed speed control has 50–500 IPM wire compatibility. It is a great welder with fully adjustable drive system. This system reduces wire tangle and crush. The gun has supreme conductivity as this is brass made. The body is aluminum made and equips user with a rigid drive that aids wire alignment.

If you are a home welder than this is a good choice. It is master piece for- farm, light fabrication, home or auto projects. You can buy a spool gun and team it up with 208/230V power for professional uses. With this power you can weld up to 3/16in. The price is totally justified with its multipurpose usage – a Welder, a Gun with 10-ft cable assembly, a.025in. And .035in. contact tips, one unit of a Gasless and gas nozzles and a Spindle adapter for 8in.Also manufacture provides- Shielding gas apparatus, Sample spool of .025in. for MIG wire and Sample spool of .035in for flux cored wire. What you will need for using it as the package arrive are- two plow 20A breaker, two hoots and one ground. Those who used it also said it works better than the 4000 $ and works as long as you may live if maintained occasionally.

Hobart 500568 Handler 130 Welding

Hobart 500568 Handler 130 Wire Feed Welder 115V

Hobart 500568 Handler 130 Welding Equipment is an 115V welder still can handle 1/4”. With EZ-Mode feature this one is very easy to handle, it means all you need is to adjust a single knob for the thickness of the mild steel this one has self-shielded flux-cored wire. The welder has a built-in gas valve, so it is very much suitable for solid wire welding applications. Hobart 500568 Handler 130 Welding Equipment is a steel welding machine. Which can Welds 24 gauge up to 3/16 inch steel? It does not need a spool gun as it has a built-in wire feeder; the feeder has a quick-release drive roll tension lever meaning wire will be released frequently without much struggle.

This one is a safe machine for home users and security features are much more upgraded than expected from this price range. Like it has a Proven Self-resetting thermal overload and motor protection, in our language that is the system that does not let the motor burn or high amount of electricity do damage to the machine by cutting of the electricity as it goes over a limit.Hobart 500568 Handler 130 Welding Equipment can weld 1/16" and 1/8" steel, and this machine is more than powerful enough to weld1/4”steel.With 51 pounds and 13 x 10 x 17 inches dimension this one surely is a keeper for beginners to regular home users.

Amico Power DC-160A 160 Amp Dual Voltage IGBT Inverter DC Welding Machine1

If you are interested in a handy light weighted arc stick welder, than Amico Power DC-160A 160 Amp Dual Voltage IGBT Inverter DC Welding Machine is the one. This welder best welds Metal & ABS. This USA made welder also grabs ESL certification for safety welding equipment. This is great for home use but much stronger than the flux core welders on same range and gives deep penetration. This is a DC which works great with stainless steel and steel rod. It can weld steels like (E6011) at a max thickness of 3/16"; of course your choice of polarity and requirement of penetration will help you to decide how deep you want to weld. If you want to weld aluminum you will need helium and aluminum filler to buy separately for this purpose. As the best stick welder this may get a little expensive and not give a as good penetration as an AC, but it will serve the purpose.

With standard 115 v compatibility it has AC 115V & 230V Dual Voltage facility. With a high duty cycle of 60% it can runs on 160 Amp power if your outlet has 210-230 voltage. With the welder you can get an electrode holder, work clamps, Input power adapter cable, plugAnd a very long cable (10 feet long). For buying stick you can work satisfied with 3/32 welding sticks. With higher amp like 220 amps 1/8" sticks can perform better. It is one of the best cheap stick welders for your home garage or trips. So if you are a beginner and need to work with steels than Amico Power DC-160A 160.

ViperMig 180amp MIG Welder

ViperMig 180amp Mig Welder by RazorWeld

ViperMig 180amp Mig Welder welds fantastic both mig and stick. With fluxcore wire of 1/8" 7018 you can get a nice and clean burn. With this mig welder you can easily get into serious welding projects like- trailers, tractor, hitch and repairs. Another feature of the welder is it does not eat up your time in the name of down time, even after burning 5 pounds of sticks.

Customer care of Razor world is another reason to go for this welder. They are really quick in response whether it is a query or a maintenance support. For simple to powerful welding you can choose the power strength ranging from 110v to 220v Dual Voltage with Included Pigtail.With package you will receive - 10' Mig gun, a 9' Ground, a Stinger, a Flow meter. It has a duty cycle of 30% so choose your power outlet accordingly. Manufacture gives you a 1 year warranty and if bought through Amazon you can enjoy a 30 day return policy. In general it can give a 1/8" penetration but with higher volt good prep and great skills more penetration is possible. So ViperMig 180amp Mig Welder is your pick if you need a multiply usable mig welder that can work both on home and in stores.

Hobart 500559 Handler 140 MIG Welder

Hobart 500559 Handler 140 MIG Welder 115V

Hobart 500559 Handler 140 MIG Welder is another top-notch creation from Hobart the 90-year-old welding manufacturer. Definitely, it is a little expensive than that of same capacity different manufacturer made machines one reason is that it has aluminum drive system, made in the USA. It is best in the industry for Mig welding. If you are a beginner and looking for a machine where all you m=need is to select the proper voltage and wire feed rate for the wire you are using then you can rely on this. Because rest of the job is automated. Also, Mig is relatively easier than stick welding. As a precaution do not forget to wear, gloves, welding musk, and earphones for protecting the ear from the sound of the arc ionizing.

In duty cycle, it needs to be cooled down for 2 minutes in every 8 minutes. Which may sound more but when you are in action it is not easy to run the welder nonstop for 8 minutes unless you are a pro. So this is standard for home users. The package comes with a 5-year limited warranty. It can weld 1/4 inch mild steel with 24 gauges. You can easily set it up and plug and play in your 115-volt household current. Minimum to maximum amp requirements are-25 - 140 amps. The cherry on top is it has industry’s one of the best customer care.

ARKSEN MIG-130 Gas-Less Flux Core Wire Welder Welding Machine

ARKSEN MIG-130 Gas-Less Flux Core Wire Welder Welding Machine Automatic Feed

Another piece of best cheap mig welding machine is ARKSEN MIG-130 Gas-Less Flux Core Wire Welder Welding Machine Automatic Feed. It needs no gas a DC output supporter and can be used for a long time without the risk of overheating. It has Thermal Overload Protection, this system Shuts down the machine and activates the over-temperature light when it senses the airflow of the unit has been blocked or the limit of duty cycle has exceeded. It has a 10% duty cycle at 105AMP but it improves to 35% at 60 AMP.

It is designed to be used for household peruses so the electricity input it conforms to is 115 volt, also it has no other power requirement. It is a very light mig welder with19 x 11 x 17 inches dimension and 38 lb weight. It works on Steel and Stainless Steel with wire ranging from -0.023'' To 0.035'' Steel and Stainless Steel, and for Aluminum, 0.030'' To 0.035'' for Flux-Cored it works with wire of 0.030''. Even at such low price you need nothing to add other than the additional wire because the package includes- Welding Wire, Welding Mask (you may like to replace that with an automatic darkening one), and Chipping Hammer or more commonly known as Wire Brush, a convenient welding Torch and Ground Cord.

Lincoln Electric MIG Welder, Handheld, 208/230VAC

MIG Welder, Handheld, 208-230VAC

Lincoln Electric MIG Welder, Handheld, 208/230VAC is an AC welder from Lincoln Electric. It has the dual option to be set up for gas-free flux core welding or gas-shielded MIG welding for steel, stainless and aluminum. The Higher price is attributed to manufacturer’s 90 year’s reputation to make best welding machines and some really exclusive features. It has highly conductive brass made the gun. The drive system is fully adjustable, that means you do not have to worry about wire to tangle. The wire feed speed control is 50-500IPM.It welds aluminum, steel, stainless steel everything that you can ask for a Mig or flux cored welder to weld on.

Many people jump into the same category but much cheap welding machine wondering why they should spend more on this, well budget is something we cannot always negotiate, but if you have the opportunity to spend more than investing into this model will be much more yielding as it is durable, easy, have a Cast aluminum body unlike those plastic bodies of cheaper models. Another feature I like is it has a wide output range from Wide 30-180 amp. For MIG weld you will need 24 gauges this can weld up to 3/16 in. (4.8 mm) sheet metal at a stretch. To weld up to 1/2 in steel if you use using self-shielded Lincoln Electric Inner shield (FCAW-S) wires. It comes with a reasonably lengthy 6 feet 3 inches power cord. It has a duty cycle of 30% at 130Amp.Output ranges from 30 - 180 Amps DC This is useful for both home and for the garage, basically it is a consumer grade welder.

Lotos MIG140 MIG Wire Welder 

Lotos MIG140 140 Amp MIG Wire Welder Flux Core Welder and Aluminum Gas Shielded Welding

Lotos MIG140 140 Amp MIG Wire Welder Flux Core Welder and Aluminum Gas Shielded Welding is the brand new edition of Lotos in2017.It has 2 digital displayers for the beginners who like to know about and adjust feeder speed and welding voltage. This upgraded version has reduced difficulty to switch between plus minus power connection through ground cable quick connectors. Lotos MIG140 has an output capacity of 140 Amp and it can also be used for powerful industrial welding. It is compatible with 110 Volt standard home power outlets.

The Mig welder comes with thermal overload protection system to protect you from unwanted disorders. While using it for professionals it is recommended to use spool guns. If you need a welding machine for Welding diverse metals like- Stainless steel, Mild Steel, Aluminum. Then this is a reasonably priced unit. With 140-amp you can weld Stainless Steel up to 3/16" at 110/120V. For Solid Steel You can use wire ranging from 025"-.030", for Flux Cored welding choice varies between .030"-.035". Along with the entire accessories like- MIG torch, Gas Hose, Ground Clamp Cable, Argon Regulator, Contact Tips, Welding Mask the welder comes with a 30 days money back offer and 1-year warranty.

F2C AC Power Auto Feeder Mig 130 Gas-less Flux Core Wire Welder

F2C AC Power Auto Feeder Mig 130 Gas-less Flux Core Wire Welder Welding Machine Cooling Fans

Warning: If you like to do window shopping this review should be avoided-because after reading it you are not going to buy any other welder if you are a first-time welder and want to spend less on this experiment. This is a value deal.F2C AC Power Auto Feeder 130 Gas-less Flux Core Wire Welder Welding Machine is a Mig welder with a single phase 110v amp.It requires only 50-120 AMP welding Current. Being flux cored your alacrity with a continuous flow of gas from the bottle and steamy condition extinct. Also, the need to spend extra on CO2 and other gases are obliterated in the process. F2C AC Power Auto Feeder 130 Gas-less Flux Core Wire Welder Welding Machine, is only usable to a very limited penetration but on the variety of metal like- steel and stainless steel, aluminum.

For welding seamlessly you need wires of 0.023'' to 0.035'' for steel and stainless steel and wires 0.030'' to 0.035'' for aluminum, 0.030’’ for flux-cored. It enjoys a 10% duty cycle at 105AMP and 35% duty cycle at 60 AMP. Another thing to note is this low price flux core MIG welder weights (33.07 lbs) significantly less than the same category another MIG welder. In case you are wondering at this price you may only get the welder and the gun than I like to clarify. Every single important part or accessory is included from MIG-130 Main Unit toWelding Wire, a decent Welding Mask, Chipping Hammer/ Wire BrushTorch, Tip Ground Cord you can have it all and yes pay really much less than having to buy them separately each. This small welder comes with multiple facility like-Variable Feed Speed Control, Torch with on / Off Control, Automatic Thermal Safety Protection, 4 adjustable heating. This super inexpensive yet full of convenient functional featuring best budget welder gives the dream to weld to the teenagers with a summer break, parents with a knack for DIY projects, and car lovers with a desire to fix cars at own garage.

Klutch MIG 140SI Inverter-Powered Wire-Feed MIG Welder

Klutch MIG 140SI Inverter-Powered Wire-Feed MIG Welder

Klutch MIG 140SI Inverter-Powered Wire-Feed MIG Welder is a resourceful welder. It has a professional-grade inverter. It works on 115V power outlet. You can guess that from the feature of its being inverter-based .The inverter system increases total power output generated from a smaller transformer. The machine thus looks small (Dimensions L x W x H in inch. 17 1/2 x 9 1/4 x 14 ½), weight ultra-light in compare to same power category of other units. The MIG 140SI offers better welding control with an amperage output ranging from 30-140. The inverter system easily handles fluctuations of input power concomitant to consistent output .It makes the welding less demanding in terms of input amperage. This will go easy on your electricity bill and pressure on whole system.

With this welder you can easily weld- mild steel, stainless steel and aluminum. It uses welding wire with diameter of 0.023-0.035.Mig 140 has a duty Cycle of 30 % 90A.It can weld sheets with thickness of in. 24 ga.-3/16 at Amps 140.While using normal wire shield gas is required for flux cored wire that need is eliminated. This welder is not the one for home usage; it was built for industrial and commercial jobs. So if you need a powerful welder which will consume less power and weigh light than this is it.

Chicago Electric Welding Systems 170 Amp MIG

Chicago Electric Welding Systems 170 Amp MIG/Flux Wire Welder by Chicago Electric Welding Systems

With research and manufacturing experience for over two decades, the Chicago Welding line at Harbor Freight claims to be the pioneer in the field of ammeter safe welding equipment making. Chicago Electric Welding Systems 170 Amp is one of these kinds with MIG/Flux Wire option. You are free to use any wire with the concomitant wire dia size but easiest will be to buy wire from the same brand. Also if you are an amateur the company has plasma cutting tips and welding lens covers made for safety consideration which can be given a try.

One inconvenient feature I noticed is it is not competent with the standard 120volt outlet, it has 240 Volt requirements. It adapts power source from AC. So powerful welding on aluminum is the kind of thing it gives better finishing for. If you do not have access to 240 volts you can ask a technician to convert it for standard 220. It has a 50 amp plug so you can use it with 2 unit of 20amp circuit breakers safely. For a fantastic welding job, I am not leaving you to guess the wire size if you can get hold of. 30 Blue Demon 2lb FC, .030 and .035 10lb Italian solid wire and use a 75/25 gas (argon and co2)you are all set for all types of jobs. This welder is powerful enough to penetrate deep in 3/16" square tube and 1/4" steel plate. So if you are wondering if this can handle strong penetration you can be well assured.

ZENY MIG-130 Gas-Less Flux Core Wire Welder Welding Machine

ZENY MIG-130 Gas-Less Flux Core Wire Welder Welding Machine AC Current MIG 130 60 AMP Automatic Feed Unit DIY, Black

The diverse product seller company ZENY has achieved good reputation on selling good value for money products in almost every aspect of home and outdoor products. Formed in 2009 this company has a big line for welding equipment’s too. ZENY MIG-130 Gas-Less Flux Core Wire Welder Welding Machine is one of them. ZENY MIG-130 Gas-Less Flux Core Wire Welder Welding Machine works on 115 V / 60 Hz Single Phase. Welding Current it may consume ranges from 50-120 AMP. It has a duty cycle of 10% at 105AMP and 35% at 60 AMP. Max open voltage of 37V is operatable with the system. With ZENY MIG-130 Gas-Less Flux Core Wire Welder you need wires of 0.023'' to 0.035'' for steel and stainless steel, for flux-cored wire size is 0.030'' to 0.035''

Best features to high light is -this one of the best cheap mig welder in the industry with gas less welding option. The welder will impress you with its in build easy control operational options-Variable Feed Speed Control ,Torch With Full On / Off Control ,Automatic Thermal Safety Protection and 4 adjustable heating . It is like the twin sister of F2C AC Power Auto Feeder 130 Gas-less Flux Core Wire Welder Welding Machine with identical features and same price. Zeny gives you some advantage like 90 day return policy and no shipping cost. All the necessary accessories’ like-gun, welding mask, Chipping Hammer/ Wire Brush, 2.5M Torch, extra 2 Tips Ground Cord are included in the package.

LOTOS 175AMP MIG Welder

LOTOS MIG175 175AMP Mig Welder with FREE Spool Gun, Mask, Aluminum Welding Wires, Solid wires, Argon Regulator, Standard MIG Gun

Being reputed for providing affordable industrial and consumer based portable welders Lotos another California based manufacturer has a long line of strong welders one of them is LOTOS MIG175 175AMP Mig Welder. Lotos 175AMP Mig Welder comes with a Spool Gun which I guarantee is not an ordinary item that usually comes with welders. Spool guns make welding a 10 year Old’s job. It is very safe and handy tool that ease down welding as a process. Other items like Mask, Aluminum Welding Wires, Solid wires, Standard MIG Gun are also good to have and comes in the package. I like their Argon Regulator which will minimize the fuss of controlling the balance of gas while welding. This is another supreme feature which makes the unit special from others.

The LOTOS MIG175 is one of the most versatile welders claims the manufacturers. It is the best welder when you have to weld aluminum because it has the ease of using the complementary spool gun and an argon regulator. It uses durable transformer technology .It has the option to be connected to existing 220V wall outlet. Installation is a 10 minute’s job. It can work with industrial standard 4" or 6" wire spools .The overload protection it has is resettable to the amp you are using and the heat is bypassing. This feature certainly assures a longer operating life.

Everlast Poweri-MIG 140E MIG Welder, 110-120-volt, Green

The big name in boxing industry Everlast has a line of everlasting welders through Ever last Power Equipment. Everlast Poweri-MIG 140E MIG Welderis one of the welders this company delivers inside USA with 5 year warranty.It uses standard 110/120 volts outlet has flux cored mig welding option and takes 140AMP. It uses the IGBT INVERTER system that magnifies the inlet power to high amount. It has strong durable and safe driver rolls of cast alloy. The wire diameter is 023"-.035” a safe standard in the industry. At 135A/21V it has duty cycle of 35% in 40º C. If you have either 4" or 8" Wire Spools you can safely feed them into the welder. Wire speed and voltage are automatically controlled with built in technology. This makes the operation very easy.

The package includes 15 Series MIG gun, Work clamp, a very convenient Argon and CO2 Regulator .Also they include a Consumable start kit with a range of steel/aluminum/stainless steel. It has 3/16" single pass steel/stainless/aluminum to maximum of 3/8" multiple pass steel/stainless/aluminum. So no more guessing about the thickness of penetration possibilities. The warranty feature of Everlast Equipment will surely take your feet off the ground; this company in quest of securing a good market value is offering a 5 year warranty to the original owner of the welding machine against breakage, breakdown or failure resulting from manufacture end. So remember to keep the voucher or purchase slip and warranty crd sealed for a long time ahead.

Hobart 500536 Ironman 230 MIG Welder

Hobart 500536 Ironman 230 MIG Welder With Wheel Kit & Cylinder Rack

Hobart 500536 Ironman 230 250 Amp MIG Welder is for those who want higher output amperage and longer duty cycle in a small unit. It can weld diverse material ranging from -mild steel and stainless steel to aluminum. If you buy a Hobart DP-3545-20 spool gun or any other compatible spool gun welding aluminum becomes simple and easy. This USA made unit can penetrate 1/2 inch aluminum with 18 gauges. It is strong and designed for Industrial Performance; you could guess it from the title of ironman. Best feature of this ultra-strong unit is it creates arc with smooth and flawless welding. If you had fear of spatter and post-weld mass than I suggest you buy this one with least to nonexistent spatter.

Wondering if it is soft enough to handle home projects than that part is resolved it is perfect for delicate and low need penetration. Suitable for Fabrication, auto repair, home use too. The Ironman 230 comes with 15 ft. 200 amp MIG gun, regulator/flow meter, 5 ft. gas hose with fitting, primary input power cable with plug, 10 ft. work cable with clamp. A 030/.035 in. dual groove drive roll as mentioned earlier, , 2 plastic cable hangers with mounting hardware (so not need to carry it), and extra contact tips. The big brand name of Hobart guarantees durability and convenience. Easy setup, detailed owner’s manual and supportive parameters chart labels leave you to zero guess work.

MIG Welder, Handheld, 120VAC

MIG Welder, Handheld, 120VAC

MIG Welder, Handheld, 120VAC gives you to choose between gas-free flux core welding or gas-shielded MIG welding. It is useable for steel, stainless and aluminum (with a spool gun). The complimenting features of Lincoln’s MIG Welder, Handheld, and 120VAC are its 50-500 IPM wire feed speed control making welding easy and safe. It has an adjustable drive system so no more worries wire tangle and crushing’s.The gun has a brass finishing making Brass-to-brass gun connection easy and assures enhanced conductivity. The body is made of Cast aluminum, Lincoln does that to its welders for rigid drive that ultimately aids wire alignment.

MIG Welder, Handheld, 120VAC comes with two spools of wire (0.25), for flux core you need to buy 0.030 flux core wire. It can weld Mild Steel from 24 gauges. to 3/16", aluminum from 22 to 10 gauge. For excellent result users suggest to speed at 3 and B volt for smaller grate welding, and speed at 3 and C volt for thicker framing job done. For uninterrupted power supply you need a dedicated 20 amp circuit breaker. When it comes to buying welding you e do not need to introduce Lincoln, the name says it all. So moderate to high need of welding requirement is easy to satisfy with this unit.

Handler 210 MVP MIG Welder

Handler 210 MVP MIG Welder

Hobart 500553 Handler is Multi-Voltage Plug that means you can use it either 115V or 230V receptacles in a twist with no other added tool. The unit will adjust itself by design to the proper input power. Thus it gives a superior arc performance no matter what the power source is. This US made unit gives best performance with aluminum if used with Optional Spool Runner 100 Spool Gun. In case of mild steel it can weld 24 gauges up to 3/8 inch. It has a rugged outlook but very much portable with 87 lbs. It may sound heavy but with this much power it is still lighters than other mig welder of this much power. This 210 amp mig welder has cast aluminum drive system.

At– 115V enjoys a duty cycle of 20% and at 230V it has duty cycle of 30% .It has 7 voltage settings at 230Volt and 4 voltage settings at 115Volt. This mig welder is a good choice for hobbies in terms of Easy to Set-up and a weld set-up guide that comes with the package and provides all necessary information to carry on welding. It has a Built-in gas solenoid valve and dual-gauge regulator making gas balancing super easy. Other than gas valve, handler 210 MVP and H100S4-10 MIG welding gun with the package you can get -dual gauge regulator and gas hose, 10 ft. work cable with clamp, power cord along with plug. 8 inch wire spool adapter will make the package an all equipped deal for welding.

2017 Everlast PowerMIG 200 200amp MIG stick welder dual voltage 110v/220v spool gun ready

2017 Everlast Power MIG 200 is a 200amp MIG stick welder and one of the best stick welder in the market. It is equipped with digital IGBT Inverter. This transform low power to high power and gives more powerful weld. The design is favorable for stable and reduced to no spatter arc performance. While you are welding the feature of arc force control will help you to receive an adjusted inductance, that is when the arc length varies and voltage varies concomitant to it usually covers a 10% up and down (10% more amp for long distance arc and 10% amp for less distance arc) With presence of Arc force the coverage of current goes farther. Arc force control has a preset electricity coverage if arc force is set to its optimum footage arc force will add extra current that is beyond that 10% and within arc force full power, it may range like 75 amp in 50% less power. This will make welding flawless and preserve the good condition of the machine, as welder need not to be stretched. Also it will eliminate the need to turn up the original current setting every time the distance fluctuates or joints changes. This arc force control facility is available both in MIG and Stick modes.

As multiple volts are possible, gauge changes depending on power, at 240V Weld with a minimum of 24 gauges and maximum of 1/8" single pass. On the other hand, at 120V Weld use maximum of 1/4" gauge. Weld with an electrode, that ranges from minimum of 1/16” of diameter 120/240V to electrode with a maximum diameter of 5/32" 240V. The machine is great for-Stick/Mig/Flux core welding. Aluminum welding can also get done with optional spool gun Adjustable Burn back control. In case of MIG you can use weld up to a maximum of 7/16" in a single pass .In multiple pass it can weld up to 3/4" in 240V.

Hobart 500554 Handler 190 MIG Welder 230V

Hobart 500554 Handler 190 MIG Welder 230V

I totally get impressed with Hobart’s handler series, so I covered Hobart 500554 Handler 190 Wire Feed Welder too and previously reviewed Hobart 500553 Handler 210 MVP for Use with Spool Runner 100.This one is comparatively cheap with less power of 190v. It successfully operates on 230V input power also offers an output range of 25 to 190 amps. It has a 7-position voltage switch you can preset depending on the arc type and penetration required. It has industrial performance edge, and has a Hobart 5/3/1 Industrial Warranty (different products of Hobart enjoys 5 year, 3 year and 1 year warranty) so before buying do not forget to see the whole warranty clauses.

It does not need any control box to add a spool gun, so it is spool runner ready for aluminum welding. It can use 24 gauges up to 5/16 inch for mild steel. It has a duty cycle of 30% at 130 amps. The unit has a Dual groove option allowing quick change of drive roll. Like other models of Hobart it is also made of durable cast aluminum drive. The package has work cable, clamp, sample spools, dual gauge regulator, and gas hose, and 10 ft. power cord, contact. Hobart says though it gives industrial performance you need low skill level to operate it. That explains selector switch that can make switching guns from mig to spool gun easy.

Pro-Series MMIG125 125 Amp Fluxcore Welder Kit

Pro-Series MMIG125 125 Amp Fluxcore Welder Kit, Black

Pro-Series MMIG125 125 Amp Flux core Welder Kit is not from any brand for professionals, the brand name is pro series itself. This welder made its way in my review because of its unique features in this category. First of it is the super light feature it weighs only 10.4 pounds while gives penetration to 18 gauge.

This small welder has Thermal Overload Protection for safety. It runs on 80 amps. It enjoys 20% duty Cycle at 80 amps. Use wire size from.030 - .035. It can go with two power settings. It is easy to install and can be plug and play from standard home power settings of 120V.It can weld metal up to 3/16" or 18 Gauge with two heat settings.

This little kit is great for beginners and can weld up to 1/4 “thick steel. You can experiment with wire sizes to a bit but do not use this AC power unit in anything other than mild steel.

Best MIG Welder for the money

If you are considering to enter into the MIG welding business and make money from MIG welding as this field is appearing t be one of the easiest to earn sectors from than you are in no position to negotiate the quality with price. A beginner MIG welder can earn 15$ an hour by welding. If you already have a job and still cannot give away the idea of welding new toys for home décor, sculptures, chandeliers, tables, mobiles or car or whatever interests you than a short course on MIG welding can make you ready for the contentment of the aesthetic thirsts. A part-time sculptor and full-time teacher turned an MIG welding shop owner in Glendale, Matt Jones encourages other to take MIG welding as more than a hobby.He also conducts training classes and says Mig welding is as simple as brushing your teeth. This is the escape that you might be looking for from your mundane day job of a banker, an accountant or an engineer. After a few months of finding your way out, you know how serious you are about the welding and can choose to be a freelancer welder or continue it just as a passion. Lincoln Electric Model # K1297 AC/DC 225/125 Stick Welder is the one best value for money welder for me.

98% people in Home Depot gave it a rating of 5 stars. This is the best unit of MIG welder that uses sticks for welding. It has the option for both AC (usable at magnetized weld) and DC welding (cleaner weld). Presence of both AC and DC let it usable for welding arcs with versatile use. If you are interested in maintenance repair, fabrication, construction and other applications this MIG welder let you do it in the variety of metals like- stainless steel, steel, and cast iron. It is safe with NEMA rated, UL listed and CSA approved.

What is Welding

Welding is the process of joining metals with heat.This involves melting metal,creating arc and joining another metallic or thermoplastics component. This heating process is conducted by blowtorch, electric arc, or other means of welding.In words of books Generally welding uses another metal wire which burns from heating and a fusion is caused.When the filler metal melts and join two part it cools and the bond becomes permanent. One important note on welding is it is a hazardous job, so proper training and protection from atmospheric contamination is must. Welders need to use gloves and welding helmet, irrespective of what technique of welding is in use.

What is MIG Welding?

MIG Welding is the abbreviation of-Metal inert gas (MIG) welding or metal active gas (MAG) welding, in this welding process, an electric arc is formed between a consumable wire electrode and a metallic work piece. The electrode burns and melts through electricity and joins two metals. The atmospheric contamination created through the process needs to be shielded against. A gas shield which is created from a tank of gas associated with the welding gun does the protection job.

Advantage of MIG Welding

  • GMAW is the most common industrial welding process.
  • It provides versatility, you can use steel, aluminum other non-ferrous metal to MIG weld.
  • It does welding at a greater speed.
  • Easy to adapt.

Disadvantages of MIG Welding

  • It needs inert gas protection unlike some other welding process Shielded metal arc welding (SMAW), flux cored arc welding
  • Use of inert gas makes it pricey
  • Not a convenient mean for outdoors

How to Choose the Right MIG Welder - Ultimate Buying Guide for 2017

MIG welding is a heavy process so there are some features you need to watch out for in your welding machine and gun- It should have the provision of cooling.

Air Cooled: Air-cooled guns are those easy to operate welding machine which maintains Ambient air and shielding gas that does not let heat to hinder the process. For this purpose, the power cable contains more copper than the cable on a water-cooled gun. This prevents the cable from melting. Pros are they are friendly at outdoor locations with small diameter wires (.035, 3/64-in.). Con of such guns is they have more weight making them less flexible. Pros are –no need of independent radiator cooling system or extra hoses. Amperage ranges from-150- 600 amps.

Water Cooled: More usable at a stationary location with access to water and hose. Particularly useful if you are using helium mix to run the welding machine.Water-cooled MIG guns do the same thing as air cooled so you can choose any of them, as the purpose is to reduce heat but this offers lightweight and more flexibility. They generally last longer and serves as more energy saving.You can find them ranging from 300- to 600-amp. Because high amp and application require more cooling like it.

Push-Pull: If you need a gun which has to function far from the power source Push pull guns are great. They are capable to more than 50 feet away (preferred distance is 15-35 feet). You will find them available in gooseneck and pistol-style grip, this position makes operator contents for a special type of demand and preference.

​Spool Gun: You can do without a spool gun that will require you to push soft wires through a regular gun (good for aluminum) But for occasional welding and low amperage capacity presence of spool gun eliminates inconvenience of pushing soft wires (silicon bronze, stainless steel, small diameter, aluminum) spool by hand.

Fume Extraction Gun: Only models with 400 amps or more may have it. It will capture the at the makes and bring back to a high-vacuum fume extraction system. Adjustable extraction control and good shield from the gas flow, easy handling features are making fume extraction gun more and more popular.

High amperage=High power: A welding gun with 600 amps can support every kind of possible application, but you do not want to spend for a thing that is more than necessary. With extra amps, these guns price accelerates. If you are not required to operate on very thick metal very often than there is no point of ending up spending 3 times more on a welding gun. So before buying is sure about the maximum needs you may need to address. Also added power means more weight and bigger size, making the operation gruesome and exhausting. Depending on small to big welding need the welding gun require 100-150 amp, 200-300 amp, 400-500 amp, 600 amps. Some other features that may guarantee more durability and good value for money are-

  • POWER PIN - A strong power pin. This will guarantee no kinking and improve the flow of power.
  • PLUG-Multiple plug option - it is good to have as this offers more flexibility.
  • POWER CABLE - The power cable should not be too light or too large (that may cause a clutter on the floor). A light one will make welding performance substandard.
  • LINER - Liners are responsible to keep the gas inside and a weak liner may cause leaks, so choose one with the coating or extensive jacketing. Also, it must comply with the diameter size.
  • NECK - Choose an MIG gun with the flexible neck, if possible than one with a rotatable neck. Also, a neck of hard plastic or metal is preferred to that with a soft armored neck.
  • TRIGGER - A trigger should be serviceable. So choose one which has the strong trigger and can be replaced easily if breaks.
  • HANDLE - When considering handle-choose lightweight, comfortable and one that meets amp/duty cycle rating needs. This is something works great if small in size. Plus if the gun has an option with a ventilated handle that will allow more productivity and less heat than you know you need to look for no more option for the handle.

How to Arc Weld

Arc welding is a process to join metal by electrodes. All the welding processes that use an electric arc as the source of heat belong to Arc welding category. So you need to position the tip of the rod close to the surface, the tip should be against the metal so that when you pull it back an arc is created between the electrode tip and the welded metal. Another feature of Arc welding is the use of a fillet. Arc welding may also produce a slag, which covers molten metal and protect from oxidation. After joining metal when it cools down and solidified, a metallurgical bond is created, which is identical to the one with the core metal. This was the traditional Arc welding done by consumable variables.There also exist a no consumable arc processes. Where welding is done by melting the base metal only, the result is termed as an autogenous weld. If filler metal is not usually required in such process. However, if a filler is required in a no consumable process, it is fed to the gun manually or by spool gun.

How to MIG Weld Steel

To start with the topic, I would like to clarify that-All MIG welding is arc welding but all arc welding is not MIG welding. MIG (Metal Inert Gas) is another type of Arc welding; other forms of Arc welding may take the form of- TIG (Tungsten Inert Gas), and SMAW (Shielded Metal Arc Welding). However, MIG welding is a very age-old process and remain almost same till its first use in 1940.

The mechanism & process- MIG welding uses electricity, a planned short circuit is created between a continuously fed anode (+ the wire-fed) and a cathode ( - the metal that is welded). Heat makes the melting and joining possible. Same time inert gases create a protection for the operator against the contaminated atmosphere also creates non-reactive gas that helps melting process.

The heat produced by the short circuit, along with a non-reactive (hence inert) gas locally melts the metal and allows them to mix together.

Types of MIG Welding

MIG welding is same in all types only difference is created by the use of the material you choose as spool and the inert gases it may produce. These spools can be made of - stainless steel, carbon steel, aluminum, magnesium, copper, nickel, silicon bronze and other alloys. Gases used to melt and also as shielding purpose are-Co2, argon, oxygen, acetylene.

What is the Best MIG Welder for home use

The humongous variety of MIG welder in the market can easily confuse you about the choice of the best one. Well, the answer is tricky. Some are really good for professional and some are must have for a beginner. Some are fast some produce less spatter. Some are inexpensive but gas cost high while other are expensive with a low operation cost.

Like –multi-purposeful, easy to use, good for both beginner and professional. I choose LONGEVITY Mig Weld 140 because the welder is easy to learn and operate and very easily portable. Just plug and play anywhere. So whether you are using it at home or in the shop it will help you achieve the desired result. Most home users need a welder that can handle exotic materials LONGEVITY Mig weld 140 - 140 Amp Mig Welder gives you that benefit. The consumables you need to operate a home welder should be easily available, for LONGEVITY Mig weld 140 - 140 Amp Mig Welder this trait is applicable you will get the consumable in local stores, Again It can work on gas or via flux-cycle gasless welding. It can run on a standard 110-volt power cord the wire comes with the package, and it can hold up to an 11 lbs .comes with wire. Making it perfect for use in the home, shop, or on any professional repair call-out in the field. It has a convenient carrying handle built-in which works on all exotic metals and good for beginners or professionals.

What are the different types of welding?

Some popular welding technique and their mean of fuel are listed below, it shows how welding has evolved over ages and so many options are there-

Name

Fuel

Protected from atmospheric
contamination by

Oxy-fuel welding / oxyacetylene welding.

Gases and oxygen

Oxygen

Shielded metal arc welding (SMAW) /stick welding /electric welding.

Electrode holder holds the electrode

Gas tungsten arc welding (GTAW) / TIG uses tungsten electrode to produce the weld.
The weld area by a gas such as.

A non-consumable tungsten, inert gas.

Inert shielding by argon or helium.

Gas metal arc welding (GMAW) / MIG welding

Metal more specifically wire,

Inert gas-argon, carbon dioxide (CO2)

Flux-cored arc welding (FCAW)
– almost identical to MIG welding except it uses a; it can be used with or

Special tubular wire filled with flux

May or may not need shielding (of gas) depending on the filler.

Submerged arc welding (SAW)

Automatically fed consumable electrode

Covered by granular fusible flux

Electro slag welding (ESW) –vertical
or close to vertical position.

Electricity

Electric resistance welding (ERW)

Heat is formed from electrical resistance of the material

What welding is used for?

The most economical way through which one can joint metals permanently and efficiently is -Welding. Every year 50% of USA’s gross national product is achieved by welding. This scientific process needs many variables to make the function flawless.

Some welding cases spark whereas other may not. Some welding is suitable only in indoor condition whereas some other can be conducted under water. Maintenance, repair, production, servicing all industries need welding to a great extent. It is required in sculpture making to steel foundries, refining plants, and smelting.

Welding ranks high among industrial processes and involves more sciences and variables than those involved in any other industrial process. Following chart shows broader classification of sectors that contribute to Gross domestic production through welding in the year 2000.

Automotive Sector

510,658

6%

Aircraft/Aerospace Sector

141,897

2%

Electronics/Medical Sector

435,400

5%

Light Industrial Manufacturing Sector

227,796

2%

Heavy Industrial Manufacturing Sector

147,030

2%

Construction Sector

363,889

4%

Capitalized Repair & Maintenance Sector

1,281,051

14%

Targeted In a research Study on 2000’s
part of FY national gross domestic product

3,107,721

34%

Welding Processes

Welding process can transform steel and other thermoplastics to different shapes, join them to other similar metal, create and change the original metal to anything a welder can think of.The process of welding follow some basic mechanism-using heat to melt lethal, creating arc through electrode, creating the shield and inert gases and so on. However, the process has evolved for years and gave birth to many new twigs. Like

  • Mig welding
  • Gas Metal Arc Welding
  • Flux-Cored Arc Welding
  • TIG Welding
  • MIG/Flux-Cored Welders or Multi-function

Gas Metal Arc Welding

This is another name of MIG welding. In MIG welding you combine two pieces of metal with creating arc through electrode and wire filler. In Gas metal Arc welding this process is shielded by gas, both gas and electrode heats up so that the two metals can be joined.

Flux-Cored Arc Welding

Another name of Arc welding is Shielded Metal Arc welding, or ‘Stick’. The most basic process of welding of all welding types. Flux-cored Arc Welding evolved as an alternative to shield welding. It is same as MIG or GMAW process, except in FCAW a special tubular wire filled that is covered with flux is used. So it can function without shielded gas ( the type of filler decides whether to use or not gas). Stick welding can be used for manufacturing, construction and repair work. Advantage of Flux-Cored Arc Welding is fast, portable, inexpensive (no gas cost) and easy to learn. Hence the main disadvantage is final product is not as good looking as that from a mig welding.

Tig welding

Like Mig welding electrode is used in the metal arc to join another metal, however, in TIG welding instead of soft wires as spool welders use long welding rods, they feed them slowly into the weld puddle (TIG).

Advantage of TIG Welding: It is safer, consume less power suitable for thin sheets- ie- kitchen sinks, tool boxes, pipe welding (with more powerful welding gun)

Disadvantage of TIG Welding:  Slow in process then MIG Welding

MIG/Flux-Cored Welders or Multi-function

Now a day’s multi-functional welding machines are available in the market. They offer multiple functions in exchange for a higher price. You can have a single welding machine with all-in-one welding features like- MIG/Flux-Cored welding. Welders with the need of both light and heavy welding works can buy these. These can range from 125 amp to 300 amp and more.

Thermal Overload Protection and the Duty Cycle

Duty cycle is a specification of welding equipment-It tells how long within a 10 minute period, during which a welder can safely produce welding current. It is mentioned in the manual and it can be easily calculated too. For example, for a 150 amp. Welder with a 40% duty cycle, the machine must be given time to cool down after 6 minutes continuous use.

If you are wondering what happens if duty cycle period formula is not maintained than here is the answer-It is by forced shut downed if the heat goes beyond a limit. Thermal overload protection protects your welding machine when it is over heated. Generally when heat exceeds duty cycle the motor gets too warm and Thermal Overload Protection shuts down the system also let the cool down occur and do not allow power to in even if welder tries to switch it on.

The Metal thickness and size of wire weld

Enough said about the different welding techniques and available machines, let us concentrate on the process. Many faces problem when joining two different thicknesses of materials together. The gas metal arc welding (GMAW) process has used four modes to transfer metal from the electrode to the piece you are working. Which model to choose depends on-?

  • The welding process,
  • The welding power supply,
  • The consumable,

Depending on the mode you choose following variables change-

  • the amount and type of welding current,
  • the electrode chemistry
  • electrode surface,
  • electrode diameter,
  • shielding gas,
  • choice of filler metal used

Generally, the rule of thumb is to use more dense wire and more amperage for thicker material. A very thick material may be welded by .035 but most welding can be conducted with .030 size of the wire. Well, every good brand has manual specifying what metal thickness needs which wire brand this specification may vary a bit. Here are some of the examples.

Alloy-Aluminum on spray arc transfer

Metal thickness

Amperage Range

Wire Size & Wire Feed Speed

Shielding Gas & Voltage
Range:

1/8” or 3.2 mm

110-130

.035" (0.9 mm) at 350-400 ipm
3/64" (1.2 mm) at 240-270 ipm

Argon (AL): 21-22 Volts

3/16” or 4.8 mm

140-150

.035" (0.9 mm) at 425-450 ipm
3/64" (1.2 mm) at 300-325 ipm

Argon (AL): 23-24 Volts

1/4” or 6.4 mm

180-210

3/64" (1.2 mm) at 350-375 ipm
1/16" (1.6 mm) at 170-185

Argon (AL): 24-25 Volts

7.16 “ or 11.1 mm

280

1/16" (1.6 mm) at 240-270 ipm

Argon (AL): 28-29 Volts

1.5“ or 12.7 mm

300

1/16" (1.6 mm) at 290-300 ipm

Argon (AL): 29-30 Volts

Reference - miller welds

Short circuit transfer

In short-circuit transfer, the electrode will touch the work along with a short circuit, making the metal to transfer and join. In each second it happens at a rate of 20 to more than 200 times. Some important characteristics of the short-circuit transfer are-

  • It requires low energy.
  • Can be used on less thick material of ¼ inch or less,
  • You can use it in all positions
  • Needs smaller-diameter electrodes, such as 0.023, 0.030, 0.035, 0.040, and 0.045
  • If it is used in excessive amount with high welding current, it may result to excessive spatter

Alloy-Steel on Short circuit transfer

Metal thickness

Amperage Range

Wire Size & Wire Feed Speed

Shielding Gas & Voltage
Range:

1/8” or 3.2 mm

140-150

.035" (0.9 mm) at 280-300 ipm
.045" (1.1 mm) at 140-150 ipm

CO2 21-22 Volts 75% Argon/25%
CO2: 18-19 Volts

3/16” or 4.8 mm

160-170

.035" (0.9 mm) at 320-340 ipm
.045" (1.1 mm) at 160-175 ipm

CO2 21-22 Volts 75% Argon/25%
CO2: 18-19 Volts

1/4” or 6.4 mm

180-190

.035" (0.9 mm) at 360-380 ipm

CO2 23-24 Volts 75% Argon/25%
CO2: 21-22 Volts

5.16 “ or 7.9 mm

200-210

.035" (0.9 mm) at 400-420 ipm
.045" (1.1 mm) at 210-220 ipm

CO2 23-24 Volts75% Argon/25%
CO2: 21-22 Volts

Reference - miller welds

Spray arc transfer

A spray of tiny molten droplets is made across the arc. Once the arc is established it will be on until the end. Some important characteristics of the spray arc transfer areSpray transfer will be smaller than the diameter of the wire. Needs relatively high voltage and wire feed speeds? It produces little spatterMost useful on thick metals in the flat and horizontal positions.

Alloy-Steel on spray arc transfer

Metal thickness

Amperage Range

Wire Size & Wire Feed Speed

Shielding Gas & Voltage
Range:

1/8” or 3.2 mm

160-170

.035" (0.9 mm) at 320-340 ipm
.045" (1.1 mm) at 160-175 ipm

98% Argon/2% O2:
23-24 Volts

3/16” or 4.8 mm

180-190

.035" (0.9 mm) at 360-380 ipm
.045" (1.1 mm) at 185-195 ipm

98% Argon/2% O2:
24-25 Volts

1/4” or 6.4 mm

200-210

.035" (0.9 mm) at 400-420 ipm
.045" (1.1 mm) at 210-220 ipm

98% Argon/2% O2:
24-25 Volts

3.8 “ or 9.5 mm

300

.045" (1.1 mm) at 375 ipm

98% Argon/2% O2:
26 -27 Volts

Reference - miller welds

Globular transfer

Globular transfer is named the process where weld metal transfers through the arc in large droplets, usually larger than that requires the large diameter of the electrode. This mode is applied only on carbon steel and uses 100 percent CO2 as shielding gas.

  • For weld in the flat and horizontal positions
  • droplet size is larger than an electrode
  • difficult to control in the vertical and overhead positions
  • Generates the most spatter
  • When higher currents is combined with CO2 shielding and a buried arc, spatter is reduced.

Pulse-Spray Transfer

Another mode is called pulse-spray transfer mode, where the power supply moves between high spray current and low background current, it is used to lower heat input and reduce distortion, good to use when high travel speeds not achievable.

Which Is the Best Welder Brand?

Best welder brands are something people search in Google quite often. Reason is plain and simple when you invest so much money into equipment you want to be sure of

  • Quality
  • Good value of money
  • After sale support
  • Reliability

Based on this entire category the welder manufacturers have made money through the years. Still there are some named as best brand.

  • Miller (Also known as Hobart)
  • Lincoln (Sold under different names in the US and beyond).
  • Fronius (globally Distributed)
  • Kemppi
  • Everlast
  • EWM (Sell in UK and europe)
  • CK Worldwide
  • ESAB (have many brands)
  • Eastwood
  • AHP

Best MIG Welder under 1000

Hobart 500553 Handler is a 21V P0M is a powerhouse with a price slightly less than 1000$. It is a great catch in this price super easy to use and setup. It is full of easy control features like-

  • It has Multi-Voltage Plug that means you can use it either 115V or 230V
  • It adjusts its power source to the mode in a way that not external control is required.
  • In case of mild steel, it can weld 24 gauges up to 3/8 inch.
  • It has a strong metal body
  • This is a very powerful welder with 210 amp capacity
  • It comes with all necessary accessories
  • The MIG welder has the durable cast aluminum drive system.
  • It has a Built-in gas solenoid valve makes balancing super easy
  • The dual-gauge regulator for easy gauge control too.

Best Small MIG welder

Definition of small is subjective When you are in need to work with diverse set of metals and powerful welder but you do not want to use a cart you look on the internet for a small welder in that sense than you will surely love Lincoln Electric Easy MIG 180 Flux-Core/MIG Welder.

Lincoln Electric Easy MIG 180 Flux-Core/MIG Welder

  • It works on- steel, stainless and aluminum.
  • This can function on both gas-free flux core welding and gas-shielded MIG welding.
  • The wire feed speed control has 50–500 IPM wire compatibility.
  • It has a fully adjustable drive system.
  • It has an aluminum made body is and equips user with a rigid drive that aids wire alignment.

Pro-Series MMIG125 125 Amp Flux core

By small if you mean a lightweight small sized MIG welder then go for-Pro-Series MMIG125 125 Amp Flux core Welder Kit.

  • It weighs only 10.4 pounds
  • This small welder has safety features like-Thermal Overload Protection
  • It runs on only 80 amp
  • It has option to with two power settings
  • It is compatible with standard home power settings of 120V
  • This small welder is great for home users and can weld upto 1/4 “thick steel.

Best MIG welder under 500

Buying a Hobart in less than 500 is not a dream, yes this top brand have a line of welders under 500 for beginners, hobbyist. Hobart 500568 Handler 130 Welding Equipment is one of them.

  • It is a 115V welder even with this less power it can handle 1/4”.
  • It has EZ-Mode feature this makes it very easy to handle, all you need is to adjust a single knob for the thickness of the mild steel rest is done by the machine
  • The package comes with self-shielded flux-cored wire-meaning more money is saved.
  • It has a built-in gas valve, so it is very much suitable for solid wire welding applications.
  • Works with steel, Hobart 500568 Handler 130 can Welds 24 gauge up to 3/16 inch steel.
  • It has a built-in wire feeder, the feeder has a quick-release drive roll tension lever. Making easy wire release so that a spool gun is not needed
  • Even at this low price it has a Proven Self-resetting thermal overload and motor protection,
  • It does not need a spool gun as the meaning wire will be released frequently without much effort.
  • It can weld 1/16" and 1/8" steel, also it is powerful enough to weld 1/4”steel

Best MIG Welder for Beginners

Beginner welders are made by many big names. It was hard to choose anyone all are quite compatible, yet Viper MIG 180amp MIG Welder by Razor Weld welds won as the best welders for beginners because it has the entire easy feature, multiple usable options at a low price.

  • It does MIG, flux core and stick welding.
  • Customer care of Razor world is top notch they are never late to respond to your any query which is much-needed support for beginners.
  • It does not need any downtime, even after burning 5 pounds of sticks you are still ready to weld without break.
  • It has dual voltage option giving it flexibility.
  • A full year warranty comes handy.
  • Have very good performance- it can give a 1/8" penetration.

Best MIG Welder for Aluminum

LOTOS is a company with the high reputation of providing affordable welders. LOTOS MIG175 175AMP MIG Welder is the one the manufacturer specially designed for aluminum welding. We know an MIG welder can do steel, mild steel, stainless steel easily but when it comes to the question of aluminum-You need a very strong welder, the best result you can get if you use a spool gun and have power as AC.

  • Lotos 175AMP MIG Welder comes with a Spool Gun.
  • It has Argon Regulator which will ease the balance of gas while welding.
  • It uses durable transformer technology and
  • It has the overload protection too.

It is best for aluminum welding but you can also weld other common metals with it.

What is the difference between MIG and TIG welder?

The major difference between MIG and TIG welding are -

MIG Welding (metal inert gas)

TIG Welding (tungsten inert gas)

It has ceaseless needs of feeding wire.

It does not need continuous feeding, a long
welding rod once feeder runs a long time.

The process of MIG welding is easy to learn.

It is an advance stage require more time to adapt.

Useful for applying on thinner metal.

Useful on thick metal.

Needs less power.

Needs high power electricity.

It welds fast.

Welding technique is delicate and needs time.

Which MIG Welder to Buy for Best Use

2017 Everlast PowerMIG 200 is the one powerhouse we chose to be best right now in the market. It has digital IGBT Inverter so it will not be passing electricity when you let go off the switch-meaning power saving. It is a 200amp MIG welder which can do stick /Mig/Flux core welding. It has arc force control which allows for power balancing much more than when normal welder does, during long and short distant arc welding. It can weld up to a maximum of 7/16" in a single pass. In multiple pass, it can weld up to 3/4" in 240V. It allows for multiple voltages running 120-240.It can be used for both home projects and extensive professional without having to change the power settings during welding for the difference in arc distance. Considering easy setup and all the added advantage it is also very reasonably priced.

Which Gas for MIG Welding

The role of gas in welding can be surprisingly influential. Choice of right gas can help you achieve-

  • Weld penetration
  • Arc stability
  • Mechanical properties of the finished weld
  • Also, influence on the transfer process one selects.

Before choosing the gas the purpose of welding is need to be set. If welding on a home decor thing as an experiment than spending a lot of gas may not be a sensible choice. Following things should be taken into consideration-

  • The cost of the gas for shielding,
  • Quality and use of finished weld properties,
  • preparation and post-weld cleanup,
  • the base material,
  • Weld transfer process and your productivity goals all need to be taken into account when selecting a shielding gas.

4 most useful gases in welding are-

Argon

A mixture of argon (75%-95%) with CO2 (5%-25%) can create a weld that has benefits of both the gas and produces good arc stability. For aluminum, magnesium or titanium you may need 100% argon though

Pros

Cons

Easy puddle control

Thick penetration not possible

Less spatter

More expensive

Can be used in spray transfer process

Limited to spray transfer process and
short circuit process

Looks good after weld

Narrow penetration-good for and fillet welds.

Helium

Helium works best on non-ferrous metals, but it can be used on stainless steel too.It needs a blend of (25%-75%) Argon to produce results that may vary in terms penetration, bead profile and travel speed.