What’s the Best Welding Output for Your Job?

One of the most popular questions we get asked is, “What’s the best welding output for my job?” This is a difficult question, as different welding applications need different welding outputs.

As such, we’ve broken it down into the most common welding scenarios and what’s the best welding output for them.

WELDING APPLICATIONS

1. Metal Fabrication: For metal fabrication, we recommend 1-6 amps per foot of welding, depending on the application. A typical metal fabrication shop will weld between 50 and 150 feet a day, so it’s really based on the type of application and how many times the welding will occur during the project. This can be a huge number if you have very complex applications.

For example, if you have a large ship hull with a lot of complex shapes, you’d want to use high amps to get good penetration and a smooth finish. In the case of metal fabrication shops that do a lot of work with stainless steel, the higher amperage welding provides better welding speeds and good penetration.

2. Manufacturing: For manufacturing, we recommend 2-6 amps per foot of welding. This is mostly used when welding steel but can apply to stainless steel if you have multiple passes required.

3. Heat Treating: We recommend about 4 amps per foot of welding for heat treating, but this can vary depending on the application.

4. General Maintenance: Experts recommend about 6 amps per foot of welding for general maintenance.

5. Repair: For repair welding, we recommend 6-12 amps per foot of welding. This is mostly used when welding stainless steel or aluminum and thin welding sheets of steel.

6. Fabrication: For fabricating, we recommend about 10 amps per foot of welding. This is typically used for thicker pieces and to minimize distortion.

7. Hot Work: We recommend about 16 amps per foot of welding for hot work. This is used when welding stainless steel and aluminum and welding thicker plates of steel.

8. Spot Welding: For spot welding, we recommend about 20 amps per foot of welding. This is the highest current setting for a typical welding gun.

What Welding Output To Use?

For metal fabrication, welds will typically range from 1-8 amps per foot, depending on the thickness of the plate and the type of joint. Welds should be performed at no less than 1 amp per foot and no more than 8 amps per foot. It’s recommended that you start with the low end and work your way up from there.

In the case of heat treating, welds will typically be around 2 amps per foot. As you get to thicker areas, you can increase the current to 3 amps per foot. However, this can lead to spatter and distorted joints. So again, starting at the lower end and increasing as needed can help keep welding safe.

For manufacturing, welds will typically be around 3-10 amps per foot. Welds should be performed at no less than 3 amps per foot and no more than 10 amps per foot.

For heat treating, welds will be around 5 amps per foot. You can increase the current in thicker areas.

For general maintenance, welds will be around 6-20 amps per foot. Welds should be performed at no less than 6 amps per foot and no more than 20 amps per foot.

For repair welding, welds will be around 10-50 amps per foot. Welds should be performed at no less than 10 amps per foot and no more than 50 amps per foot.

For fabrication, welds will be around 10-200 amps per foot. Welds should be performed at no less than 10 amps per foot and no more than 200 amps per foot.

For hot work, welds will be around 25-150 amps per foot. There should be no less than 25 amps per foot of welding and no more than 150 amps per foot of welding.

For spot welding, welds will be around 50-400 amps per foot. Welds should perform at no less than 50 amps per foot and no more than 400 amps per foot.

When using welding equipment, you must follow the machine’s instructions to ensure you’re in the right mode for the application.

Welding Process and Amperage Selection

Most of us are familiar with welding processes that we use in our homes and at work. We might have even done a bit of welding in the past. However, we may not know exactly what welding is. Welding is a process of joining pieces of metal together by using heat and filler material. There are different types of welds, and a person must understand the different types of welds before he or she does the welding process.

There are three main types of welding:

1. Metal-arc

2. Gas metal arc

3. Shielded metal arc

Each type has a different amperage range, and the wrong welding method can damage the welded components.

The three main types of welding are used when welding metals and plastics. In the metal-arc welding process, there is an electric arc created between two electrodes that contain filler material. When the current passes through the filler material, it heats the filler, fusing it into place. The filler material is usually a combination of metals, but the filler could also be plastic, ceramic, and composite materials.

Gas Metal Arc Welding

The gas metal arc welding process uses a plasma of gases to produce the electric arc between the electrodes. The filler material is metal or a composite material, such as fiberglass and carbon fiber.

Shielded Metal Arc Welding

The shielded metal arc welding process is where the filler material is added after the electrical arc is created. With this welding process, a non-conductive shield is placed over the welding area to prevent the filler material from being melted into the substrate.

Pro Tip: Using the correct welding method is very important when welding. When welding, make sure that you have the right amperage and type of welding machine. If you are welding in your home, you may want to consider getting gas or electric welder instead of a MIG welder.

With a MIG welder, the filler material is placed on the tip of the electrode wire, which is attached to the welding machine. With a gas or electric welder, the filler material is added directly into the molten metal and does not need the help of the electrode.

Welding with the right amperage, type of welding machine, and the correct welding process will greatly reduce the chances of damaging the components being welded. Make sure you read the welding machine’s manual before starting the process.