Welding & Soldering

The right welding and soldering equipment can open up a new range of applications for you to tackle, including everything from repairing or enhancing your car or motorcycle to soldering circuit boards or audio connectors. Choosing between the different tools available for each activity requires a thorough examination of the types of jobs you plan to undertake and the kinds of materials you will work with most frequently. With such a vast array of available options, keeping the following questions in mind as you shop will help you hone in on the right tool:

• Are you shopping for a welder or a soldering iron?
• What power source will provide the ideal performance?
• What type of welder is appropriate for what types of jobs?
• Which soldering iron tip is best for the task at hand?
• What types of materials do you work with and how thick are they?

Welders, Soldering Irons and Safety

Welders are available in either stick or wire configurations. Each type offers similar results but features different benefits for both novice and experienced users. You'll need to determine which welding processes you require for the applications and materials you work with most. Make sure the welder you choose is designed to perform the needed functions and provides as much versatility as possible. Soldering irons do not require you to sift through as many different types, but you'll need to understand what an iron's wattage level indicates as well as whether a gas or electric unit is right for you. Finally, whether you weld or solder, you'll need to adhere to some important safety guidelines to ensure proper use.

Welder Specifications: When selecting a welder, it is important to understand a little bit about its specifications. Be sure to look at the input voltage as you compare various units. Many welders use either AC or DC, though some use both. Bear in mind that DC welders use a wider range of electrodes but require their own generator, while AC units generally operate on a 220V household current. Output amperage is another important specification. It lets you know the maximum electrical current the welder can deliver. Duty cycle is a rating that indicates how many minutes out of ten a welder can produce its maximum output without overheating. For example, welders with a duty cycle rating of 60% can be operated for 6 minutes and then require 4 minutes to cool down before being used again.

• Input voltage, output amperage and duty cycle should meet anticipated use requirements
• 115V AC units are good for home repair, hobby work and other light-duty tasks
• Choose a unit with a higher duty cycle rating to handle more frequent use
• Higher voltage units allow you to weld heavier metals for more demanding jobs

Welder Types and Processes: First-time users will most likely want to use a wire welder. These tools are fairly simple to operate and offer increased portability. They feature a flux-core wire that provides a good, general-purpose welding medium. Moderate to experienced users may want to look at stick welders, which are more economical, while advanced users will appreciate the power of GTAW (also called TIG) welders, which use a tungsten electrode for high-quality, precision work. A variety of welding sticks are available, allowing you to find the perfect match for different metal types and welds. Welders may be either gas or electric, so consider which power source is most convenient when making your selection. Use the chart below to assess which welding processes might meet your needs:

Type	Description	Ideal Uses
Flux-Cored Arc Welding (FCAW)	Uses a hollow, consumable electrode filled with flux material May use gas for additional shielding	Steel Stainless steel
Gas Metal Arc Welding (GMAW)	Also known as MIG (metallic inert gas) Requires external shielding gas to protect the weld Uses automatically fed wire High welding speed for increased productivity	Steel Stainless steel Aluminum Cast iron Works with both thin and thick materials
Gas Tungsten Arc Welding (GTAW)	Also known as TIG (tungsten inert gas) Uses a nonconsumable tungsten electrode and high-frequency generator Inert gas provides shielding Creates less splatter and slag	Thin sheets of metal Foil High-quality welds Specialty alloys
Shielded Metal Arc Welding (SMAW)	Stick welding Burning creates CO2 shield Slag refines and protects Requires electrode change as stick is consumed	Steel Stainless steel Cast iron High-alloy metal
Submerged Arc Welding (SAW)	Uses a continuous-feed wire Uses flux to cover the weld Produces fewer fumes High productivity Welding should be done on flat surface	Heavy plate applications Structural steel High-speed welding of light sections

Soldering Irons: Soldering irons are ideal for more delicate tasks. When deciding which one is best suited to your needs, keep in mind that units with higher wattages don't always provide more heat. They will, however, be more effective when working on bigger joints, since lower-wattage soldering irons lose heat more quickly. Soldering irons with temperature control give you the ability to increase the temperature to heat joints more quickly. They may be powered with gas or electricity. Gas- and battery-powered units provide portability, letting you easily move from job to job. For bench use you'll probably want an iron that plugs in, since they often provide the highest-quality performance. Chisel, bevel and conical tips each offer different benefits for different tasks.

• Chisel and bevel tips handle smaller wires on low power and larger wires on high
• Conical tips are ideal for small projects in tight spaces
• Soldering smaller joints requires the use of lower wattages
• Rosin solder comes with varying amounts of lead and tin to accommodate different tasks
• Electric irons work better under windy conditions than gas-fueled models

Safety: Because they get very hot and generate sparks, welders should be operated with great care. Some units keep the wire electronically cold until the trigger is pulled, preventing flying sparks in the event of accidental contact with any surfaces prior to beginning your work. When you're working with heavy-gauge material, welders with thermostatic overload protection prevent overheating that can cause damage. Using a helmet and eye protection is vital to safe operation. Helmets with an auto-darkening lens protect you from bright flares while simultaneously providing excellent visibility. Make sure a helmet fully covers your head and neck and doesn't leave room for sparks to get in between the bottom of the helmet and the top of your shirt or apron.

• Use gloves when operating welders and soldering irons to protect hands
• Wear fireproof clothing to keep yourself safe from stray sparks
• Fans cool welders down to avoid damage to the equipment
• Use a lightweight helmet to help prevent neck strain

Features

Gas Tank: Welders with gas tanks provide a protective shield of gas, often a mixed gas or carbon dioxide, around the welding area to keep away debris and materials that might contaminate and weaken your weld.

Circuit Breakers: Look for welders with input circuit breakers and other protections that keep the wiring and motor safe if something prevents the wire from feeding through smoothly.

Helmets: Welding helmets may be solar or battery powered. Many automatically adjust the tint of the lens to offset sudden increases in brightness on the welding surface, and some do so in as little as 1/25,000 of a second to minimize discomfort.

Thermostatic Control: Soldering irons with this feature give you the ability to adjust the heat up for tougher jobs and down for more delicate tasks.

Continuous Control: Welders with continuous control enable you to make infinite minute adjustments for working with thinner materials.

Conversion Kits: Purchase a special conversion kit for your welder and expand its functionality, allowing you to handle more diverse materials and accomplish a wider range of tasks.