Multiprocess Welders and Types of Welding They Perform

Welding is a method to join two or more thermoplastic or metal pieces with the application of heat and pressure in adequate amount. It softens the materials and fixes them together as a unit. Different welding machines or welders help users to weld different machine parts, iron fittings, automobile equipment, etc. The functioning of most of these welders is limited, as they can perform only a specific process. However, some welders can perform multiple processes. These sophisticated machines can handle all sorts of processes like Stick, TIG, MIG, Air Carbon and Flux-Cored Arc Gouging and more. Let’s get to know a little bit more about them.

Capabilities of multiprocess welders

Different service providers offer their own version of these welding machines with functionalities that separate them from the rest. Some common capabilities to look for in these machines include appropriate AC auxiliary power, usually 2000 watts, remote control facility, availability in multiple configurations, such as 4Pak and 6Pak, and so on.

Additionally, some essential features to consider while purchasing or renting any of these welders include arc force, hot start, continuous output control, lightweight, compact & portable, availability of digital meters for preset welding output and adjustable arc control.

Multiple processes

Processes that these welders perform can include:

Gas Metal Arc Welding (GMAW)

Also known as Metal Inert Gas (MIG) welding, this method is most appropriate for fusing aluminum, mild steel, stainless steel, and similar materials. It is a regular welding method in fabrication shops.

Gas Tungsten Arc Welding (GTAW)

Also known as Tungsten Inert Gas (TIG) welding, it requires the operator to perform the welding task manually. It is useful in ensuring superior standard of finish, without perform the grinding or sanding work for cleaning.

Shielded Metal Arc Welding (SMAW)

Also known as stick or arc welding, this method is suitable for welding heavy metals with size 4mm and more. It is one of the most basic of all the welding modes, and is apt for construction, repair, and manufacturing processes.

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What’s a Good Choice-- Plasma Cutting or Oxy-fuel?

Steel service centers and fabricators looking towards purchasing a new machine often ask this question-- Plasma Cutting or Oxy-fuel? The other frequently posed question is: should a particular part be cut with plasma or oxy-fuel? The confusion is limited to those working with mild steel as oxy-fuel fails to cut an aluminum or stainless plate; and the answer to the debate depends on various factors-- thickness, location, alloy, variety of work, cost, power resources, etc.

Comparing Plasma vs. Oxy-fuel -- Cutting Speed

Based singularly on cutting speed, plasma serves to be faster than an oxy-fuel torch, to an extent of 2.75 inches. The act of using two oxy-fuel torches makes the speed drop back to a thickness of 2 inches. In the comparison of a single plasma torch versus 4 oxy-fuel torches, oxy-fuel wins when it is at 1-1/8 inch and thicker. This shows that:

• A one inch cut-off with respect to plasma holds true if the parts are being cut with at least 4 different oxy-fuel torches at the same time;
• Plasma ranks higher on speed on anything that’s less than 3/4 inch thick, also with 4 oxy-fuel torches versus 260 Amps.

Comparison of Oxy-Fuel and Plasma-- Cost-Per-Inch

After taking all the costs associated with the two processes:

• Plasma: nozzles, shields, retainers, electrodes, baffles, oxygen, electricity, compressed air and torch coolant;
• Oxy-fuel: fuel gas, internal/external nozzles, and oxygen;

studies have shown that an oxy-fuel torch proves less expensive (per inch) than 450 Amp plasma; this is true for anything that’s above 2-5/8 inch of thickness. Cutting with 4 oxy-fuel torches is far less expensive (per inch) until a thickness of 3/4 inch.

Comparing Oxy-Fuel vs. Plasma--Cost-per-Part

When different part-sizes (with varying numbers of pierces) were considered for cost-per-hour of overhead and labor, the cross-over point of a 450Amp plasma vs. an oxy-fuel torch was found to be just a little less than 3” thick. However, if the plasma speed was doubled, the results were different. 

Conclusion

For deciding whether a part should use a burning machine or a plasma cutter:

• Use plasma for all instances that have a production piercing capacity of 2 inches thickness.
• Use oxy-fuel for  those materials that can be chain cut or are more than 1 inch thick (with 1 or 2 pierces), and are capable of being cut with a minimum of 4 oxy-fuel torches. Else, use plasma.

Hope this helps you find answers to the age old question. Do post your logic or comments speaking of your own experiences.

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Welding Efficiency Analysis Program from Red-d-Arc

Are you worried about hidden costs eating into your bottom line figures? The smartly conceived Welding Efficiency Analysis program by Red-d-Arc provides a comprehensive analysis of your welding operations along with insightful comparisons with your peers. Get an estimate of your position in the industry with their free Welding Efficiency Analysis services and reach higher levels of efficiency—the right way.

Metal Fabrication

With years of experience in handling the most formidable problems addressing the welding industry, Red-d-Arc goes a long way in helping customers figure out and reign in the various costs that negatively impact the returns on their welding operations. This program helps in:

• A thorough analysis of welding processes including the comparative usage of various consumables.
• Offering a comparison of how your operations compare with that of peers and other bench marked operations of the industry.
• Prioritizing and quantifying improvement opportunities and so forth.

Unleash and Eliminate the Hidden Costs of Welding Class

Welding Efficiency Analysis services show that most welding operations end up striking an arc (actually welding) merely 9 minutes in each hour. This results in most operations wasting a large quantity of the MIG consumables and shielding gas purchased by them. Red-d-Arc unleashes these hidden costs and helps fabricators and manufacturers gain awareness about their operational problems and key welding metrics.

Way Forward

So, what are you waiting for? Just invest three-and-a-half days of your time in the Welding Efficiency Analysis program and Red-d-Arc pays you back many times over. Specifically conceptualized and programmed for department heads, business owners, shop foremen, as well as those presiding as decision makers, the modules of this program succeed in getting at least 20 percent more from your operating costs, along with bringing about much required improvements in your overall performance and quality of operations.

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Red-D-Arc’s National Rental Equipment & Assets Management Services

With Red-D-Arc’s National Accounts program, business organizations spanning across the US can address the many challenges put forth by their rental equipment requirements. Whether it is about leveraging the advantages of special pricing or getting immediate access to the specialized equipment or services of national account specialists, Red-D-Arc is a partner that can be trusted to deliver the best possible results for your needs.

National Accounts Program—its Many Advantages

Red-D-Arc takes pride in offering weld automation, rental welders, and specialty products through over 70 authorized service centers located all across the world. With over 3,700 weld positioning/ automation products, 60,000 welders, and 1,600 natural gas, diesel, and bi-fuel-powered generators to their credit, the company is geared to cater to your service and rental requirements.

National Account Specialists

All national account customers of the company are under the custody, control and care of a dedicated team of professionally trained National Account specialists.

Special Pricing

Their standardized pricing or special price-percentage discounts which are applicable to customers across diverse operating geographies help to put this program ahead of their competition.

National Accounts Hotline

The National Accounts Hotline offers a single-point-of-contact for all national account customers and helps them manage their service and equipment procurement needs.

Get in touch with Red-D-Arc to learn more about their National Rental Equipment & Asset Management Services today!

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Products & Services Offered By Red-D-Arc

Red-D-Arc is the largest provider of welding and welding-related rental products and services in North America with over 60,000 units in their fleet. Started in 1955, Red-D-Arc became an Airgas company in 1995 and currently offers rental welding-equipment through over 70 service centers in the United States, Canada, Mexico, the United Kingdom, Europe, and the Middle East, as well as through Airgas Construction Stores, and a dealer network that includes the Caribbean, Puerto Rico, Trinidad, Kazakhstan, and Australia.

Tools Available On Rent/Sale

Welders – Red-D-Arc offers an assortment of welding equipment for different purposes and requirements. Their range of rental welding machines includes Gas, Diesel, LPG, Automatic and Multi Operator welders.

Welding Automation – Red-D-Arc offers a full line of welding positioners, manipulators, turning rolls, fit up bed rollers, weld monitors, sub arc welders and automatic wire feeders.

Generators & Specialty Equipment – They also supply engine driven generators, power distribution panels, light towers, compressors, electrode ovens, gas cylinder cases, flux holder ovens, oxyfuel cutting equipment, pipe bevelers, plasma cutters and smoke extractors.

Eco-Friendly Media Blasting

Blast Cleaning Equipment – Red-D-Arc also offers a choice of Cold Jet dry ice blasting and Farrow media blasting equipment, used for advanced surface preparation and industrial cleaning projects.

Power Generation – Red-D-Arc is one of the leading power generation rental and service providers in the southwest U.S. They have the expertise and equipment to keep oilfield power generation equipment running 24 hours a day, 7 days a week, 365 days a year.

Lease Program - Red-D-Arc’s WelderLogistics operating lease program provides the benefits of equipment ownership while delivering additional cost and operational advantages. A cost effective option to acquire a core fleet of welding equipment.

National Accounts - Red-D-Arc offers a National Accounts Programs, partnering with large organizations which do business across the United States. They offer special pricing and dedicated professional support to their partners.

Used Equipment Sales – Red-D-Arc has the world’s largest inventory of professionally maintained used welding and welding related equipment available for sale. Red-D-Arc equipment is renowned for its durability and reliability and their master technicians meticulously maintain all equipment in on ongoing basis.

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Advantages and Range of Rental Welding Equipment

If you are planning a home remodeling or construction project in the near future, or if you are a builder or contractor, there is a good chance you’ll need access to a welding machine. Welding is a common requirement during building construction and reconstruction ventures.

Benefits of Rental Welding Equipment

Economical Option – Renting is certainly more economical than buying. You do not have to pay the full price. The vendors only ask for a nominal security deposit, which is refundable, and the rent for their equipment, which is typically very affordable.

Avoid Transportation Cost – There are times when contractors avoid projects from distant cities due to the significant transportation cost of equipment, including welding machines. With rental services, they can book their desired tool on site, to be delivered by the vendor, at the given address, on the given date.

Range of Welding Tools

Gas Engine-Driven Welders

Gas Engine – A welding process which gets its mechanical energy from a gas powered engine. Gas engine welders are portable, are available in different capacities, amperage, wattage, and AD/DC work requirements.

LPG Engine-Driven Welders

LPG Engine – LPG (liquefied petroleum gas) engine-driven welders are capable of high quality multi-process welding. Fuel efficient, portable DC and/or AC welding machines which also provide auxiliary power.

Diesel Engine-Driven Welders

Diesel Engine – Diesel engine-driven welders and generators also offer multi-process welding capabilities and auxiliary power output. These portable machines are built for the toughest welding situations.

MIG Wire Feeder Welders

Wire Feeders – Built specifically to offer versatility and portability, several semiautomatic and automatic wire feeder options are available for use in field construction, field fabrication, and shipyards.

Aside from the above options, there are a diverse range of multi process welders, advanced process welders, automatic wire feeders, and stud welders that can be purchased or hired on rent.

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Choosing the Right Welding Equipment

MIG Welding Machines

Determining the right type of welding equipment can be a daunting task due to the wide range available welding equipment in the market. However, the first step is to consider the size of your project. This will allow you to narrow down on the type of equipment you need. For example, for light repair work on aluminum, steel, stainless steel and sheet metal up to 3/16 inch thick a 130-amp TIG or MIG unit may suit your needs best. For heavier repair work and fabrication jobs choose amperage of around 200 amps with a duty cycle of 40% or more. Duty cycle is one of the important factors, which is the number minutes a welder can operate out of a 10-minute cycle. For example, a machine with 200 amps AC and 40 percent duty cycle can weld 200 amps continuously for 4 minutes.

Duty cycle and amperage

Duty cycle and amperage are inversely proportional where the duty cycle increases when the amperage is reduced. Thick metals require more amperage than thin metals. Therefore, it is essential to consider both factors prior to choosing welding equipment. Depending on your needs, you may want to consider renting welding equipment. Red-D-Arc has an extensive selection of welding equipment ranging from gas, LPG and diesel engine welders to advanced process welders, and more. These machines are available at affordable prices. With decades of experience, Red-D-Arc has the potential to help contractors choose the right type of equipment and generate great savings.

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