Welding power sources
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Frequently asked questions
What does duty cycle mean on a welding machine?
Duty cycle is the percentage of a 10-minute period a machine can weld continuously at a given current without overheating, per IEC 60974-1. For example, 60% at 250 A means 6 minutes welding and 4 minutes rest at that current. At lower current the duty cycle increases.
Inverter or transformer welder: which fits better?
Inverters are light, energy-efficient, give a stable arc and often combine several processes. Transformer machines are bulky but simple and tolerate dust and voltage fluctuation well. Where mains supply is unstable, check the inverter's permitted input voltage range.
How does single-phase vs three-phase supply affect machine choice?
High-current machines, typically from about 250 A for MIG/MAG, mostly run on 380 V three-phase. Single-phase 220 V machines suit light repair but limit welding current and cause voltage drop on long supply cables. Check breaker rating and cable size before installing.
What features does a TIG machine need for aluminum?
TIG welding aluminum needs an AC/DC machine, because alternating current breaks up the surface aluminum oxide. Modern machines let you adjust AC balance and frequency to control cleaning and penetration. DC-only machines suit steel and stainless but do not weld aluminum well.
Can a MIG machine run flux-cored wire?
Most MIG/MAG machines can run flux-cored wire with the right drive rolls and polarity for the wire type. Self-shielded flux-cored wire usually needs DC electrode negative, unlike solid wire on DC electrode positive. Knurled drive rolls feed flux-cored wire without crushing it.
How is welding cable size chosen for current?
Welding cable size is chosen by welding current and total length of the lead and return cables. Undersized or overly long cable causes voltage drop, a weak arc and hot cables. For example, 35 mm2 cable typically serves about 200 A over short runs, while longer runs need a larger section.
Can a welding machine run on a generator?
Inverter welders can run on a generator, but the generator needs spare capacity and stable voltage, or the electronics may be damaged. Generator rating is usually about 1.5 to 2 times the welder's input power. Choose a welder with a wide input voltage range for site work.
Where should the work clamp be placed?
Clamp the work lead to the workpiece as close to the weld as practical, on clean bare metal. Welding current passing through bearings, cylinders or electronics can damage them. A loose clamp or dirty surface causes clamp heating and an unstable arc.
