If you have been buying a new welding wire (MIG and flux cored) welding machine, or are considering adding a TIG machine to your metal processing library, you may encounter the latest innovation in molten metal-a multi-process welding machine.

As the name suggests, these all-in-one machines allow you to use three different welding processes (rod, wire or DC TIG) in one package. There are also multi-task machines, such as plasma cutting in addition to bar welding and TIG welding, or only bar welding and TIG capacity, or three welding processes paired with generators.

Buying an all-in-one machine can become very confusing. For simplicity, this article will focus on the machines that provide bar welding, wire welding and DC TIG welding.

Have some new technologies been discovered recently to make multi-process welding machines possible? Not really. 

It is true that improvements in inverter technology (making the welding machine more powerful and durable) have helped, although some multi-process welding machines do not use inverters; they insist on using traditional transformers to complete the work.

The reason for the multi-process boom is the consumer market's demand for a single welding machine, which can perform multiple welding processes in one package. Eventually, the demand for all-in-one welding machines has flourished, so that today you can also choose from the industrial version of the machine.

Otherwise, the combination welder uses the same power source as the single-process welder. The difference from multi-process welders is that they have additional sockets and corresponding cables to accommodate multiple uses.

In order to give critical attention to these new welders, "Successful Farming" magazine partnered with ESAB (one of the first companies to launch a multi-process welder on the market) and worked with James, a dairy producer in Rochester, Indiana. Fred provided a horizontal welder.

The test device is the Rebel EMP 215ic. The table at the bottom of this article lists multi-process welders with similar capacities and prices.

Fred is interested in trying this machine because he wants a welding machine that can perform TIG welding.

“I have a lot of stainless steel (such as bulk tanks and wash basins) in the dairy plant that need to be repaired, and I cannot handle them with a MIG welder,” he explained. "This is a DC TIG machine that does not allow welding of aluminum, although I can get a spool welding gun, which allows me to use it to weld aluminum."

None of the welding machines compared in the table provide DC and AC (alternating current) TIG. More advanced models do offer two models, for example, ESAB's Rebel 205ic retails for $2,999.

"What impressed me with this welder was that it was easy to switch from MIG welding to TIG welding," Fred points out. "At first, I had to use the operator manual to make sure everything was plugged in correctly. After I switched a few times, I could easily make changes in just a few minutes."

In addition, it is easy to switch Rebel from a 120-volt power supply to a 230-volt power supply. "I basically changed the wires, and I'm happy to go."

What is more challenging for Fred is learning to use the welder's TIG function. "Regardless of the welder-multiple or single processes, this is correct. When doing TIG welding, I use both hands-one hand to hold the tungsten electrode gun, the other hand to feed the filler rod into the weld-and feet The pedal is used to adjust the amount of voltage supplied to the welding gun," Fred explained. "However, Rebel does provide the ability to do TIG welding without a foot pedal (Isab calls it Lift Arc). But I want to use the foot pedal for more control."

The lifting arc is realized by Rebel's advanced control, and Fred feels that it is really shiny during the MIG welding process. ESAB calls it sMIG (Smart MIG), which automatically adjusts the welder according to your technology, "allows you to simply set the welder to the metal thickness in MIG mode," Fred explained. "After four seconds of welding, the machine will automatically adjust the wire speed and current intensity to match your technique. It really improves my welding results. For example, if I change from thinner metal to thicker metal, I don’t have to Worry about making manual adjustments yourself. Welders do this automatically."

The machine setup is very simple, because all adjustments are made on the LCD screen, not through the dial.    

The core question Fred was asked to consider was whether the multi-process welder was worth the price. "Welders like this allow me to take equipment to farms or fields under windy conditions for flux-cored welding, stick welding of thick metal to tools, or perform TIG welding in a barn," he pointed out.

If you strictly do welding housework in the store, and have a relatively new MIG device, and only want to do TIG welding, then it may be better to buy a dedicated TIG welding machine. 

One final note about multi-process welders. 

For example, the industry offers more powerful all-in-one devices that can melt ½ inch thick and thicker metals during MIG welding. However, the price of these machines quickly climbed to over US$3,000. 

An example of this type of machine is the Idealarc DC 400 Amp welding machine from Lincoln, which, in addition to a 400 Ampere rated output (100% duty cycle), also offers bar welding, wire and TIG welding, and arc gouging. The retail price of this unit is US$6,745. 

205 amps at 25% duty cycle

210 amps, 40% duty cycle

170 amps, 20% duty cycle

200 amps at 25% duty cycle

200 amps, 20% duty cycle

* Please be sure to check the equipment that comes with the welding machine when shopping. For example, Isa, Lincoln, and Miller welders are equipped with MIG welding torches and cables, TIG torches and cables, rod electrode holders and cables, gas regulators, grounding cables and clamps, drive rollers and contact tips. This is not the case with other welders.

"The fungi that cause tar spots, like many pathogens that cause our common diseases, overwinter in the remains of infected crops," explains... Read more

© 2021 Meredith Corporation. all rights reserved.

All https://www.barchart.com/solutions/ are provided by Barchart Solutions.

Futures: delayed by at least 10 minutes. The information is provided "as is" for reference only and not for trading purposes or advice. To view all transaction delays and terms of use, please refer to https://www.barchart.com/solutions/terms.