How to select a Mig Welder for your application.

With so many choices of welding machines on the market today , how does a novice welding operator choose what he or she needs ? There are a couple of key questions that can guide you thru the process and narrow down your selection to make a choice a little easier. Ask yourself the following:

1. Which arc welding process best suits my needs ?

Beginners will usually turn to a wire feeder or a stick process , but which is the best one for your particular application  ? Wire feed welding ( also referred to as MIG welding ) offers a number of benefits . First it provides higher productivity effencies over stick since a wire is fed in a continious process and you dont have to constatly change electrode rods as you are welding. Second , wire welding has a lower skill level requirement and can be pickup more readily . With stick , you have to coordinate your hand movements for feeding the electrode rod into the weld puddle, while with wire welding you you just press the trigger and weld . Although there may be some applications where stick might be a better selection , most beginners should look toward wire welding when making their first welding machine purchase .

2. Which wire process is best for me?

Now that you've chosen wiree welding over stick, the next desision is to choose the type of wire welding you will perform the majority of the time.  The catagory breaks down into two: Gas Metal Arc Welding ( commonly called MIG ) and flux-cored wire welding. MIG is the best choice when cosmetic appearance is an issue since it provides lower splatter levels . In addition , MIG can weld a wider range of materials , including thinner materials and different types such as stainless and aluminum, Since a bottle of shielding gas is necessary with MIG process it might not be the most attractive option it portability and convenience is a factor. The Millermatic Passport comes to mind as it is a 45 lb self contained MIG welder with an internal cylinder that makes cattying one item very attractive. The Passport is also a 120 volt and a 230 volt MIG welder that weights 45 lbs.

On the other hand , flux-cored wire welding is the optimal choice for outdoor procedured since an external shielding gas is not required with the flux built right into the wire to shield the weld. This procedure us most suitable for thicker materials where weld apprarance may not be as critical. Flux can be used to weld mild steel and stainless steel. , so if you are looking to weld aluminum or more exotic metals this process may be too limiting for you.  Flux welding is not recommended for auto body repair .

Most industrial products sold thru a welding distributor would be equipped to handle both processes . Miller sells all of their mig welders and feeders to handle both processes. The Millermatic 140, Millermatic 180, Millermatic 210 , millermatic 212, millermatic 251, millermatic 252 , Millermatic DVI-2, millermatic Passport, Suitcase feeders  12VS and 12 RC are all equipped for flux and solid wire. All of these are equipped with contactor and gas solenoid, most with a regulator and gas hose.

3 . What is the thickness of material that will most frequently be welded ?

As a rule of thumb , it is recommended to use a MIG process on materials that are 24 gauge to 1/2" . Flux from 20 gauge and up.

The material thickness that you most often weld will not only determine the process that you choose , it will also determine the voltage of the unit you need. For instance, if you plan to weld over 3/16 " material the majority of the time using a MIG process , it is recommended that you invest in a 230 volt system . If youo need a dual voltage system than consider the Millermatic DVI-2 which has both 120 volt and 230 volt capabliities for sheetmetal up to 3/8 " mild steel. The higher amperage range of this machine can better handle your welding needs in a single pass and you wont have top waste time with a second or third pass that may not even penetrate the base metal.

If most of your welding will be preformed on materials less than 1/8 " thisk a 115 volt MIG is probably your best bet for economic reasons. For flus -cored welding a 115 volt machine generally allows you to weld materials up to 1/$" thick. A 115 volt unit is less expensive and will suit your needs . When choosing a machine look also at the apmerage rating of the machine you dont want to overburden a machine by continuously welding at an amperage higher that what is recommended . The Millermatic 140 is a great choice.

4. What input power is available?

Another key question is to ask yourself is what input power do you have available . For instance , if you will be doing most of your welding in your home or garage . you may only have access to a 115 volt input power source , this will limit your selection to a 115 volt wire feered . If you have access to a 230 volt power in your home , garage or shop you need to see if you have the capability in your breaker box for a 30 to 50 amp breaker, depending upon which model you choose. Usually you take the manufacturers input amps and multiply that by  1.5 and get you fuse size. For instance , a machine with a rated input amperage of 17 amps need a 25.5 amp breaker .

5. What's your budget?

There are a number of technology features that set one compact feeder apart from another. For example with both 1 115 volt and a 230 volt machine  you can purchase either a tapped or a continuous control model. . Tapped control basically offers you 3 to 7 discrete voltage settings. With a continuous control , you have a continuous range of settings that can provide for fine adjustments where a finer heat control helps to achieve an aesthetically pleasing weld-this fine control is is typically more expensive than a tapped control but will benefit those welding a lot of thinner sheet metals . In the last few years Miller has put a process in their mig welders called Smooth Start and Active Start to improve the starting properties of the arc to give s better and smoother starting.

6. What's included in the package?

Not all compact wire feeders offer the same accessories in their package. Pay careful attention to what is included. For instance Miller and Hobart models of wire feeders /Mig welders come complete with a hose, regulator and eve a sample spool of wire( select models come with an instructional video) . The only extra item you need to purchase to be ready is a tank of gas. Most mig welders use Argon/CO2 mix ( 75-25) or CO2. For stainless steel and aluminum use Argon.