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Those that are committed to learning how to stick weld, and that want to get started quickly will likely look in the local newspaper or even online for a good used stick welder. This is not a bad idea, but for some, the improper selection of a welder will be what kills their long term love affair of welding. Most will likely find a nearly new AC “buzz” box stick welder. These are great little welding machines, but probably not the best to learn welding.

A few days of stick welding will usually be all a person needs to know if they wish to pursuit the art further. Not everyone that tries it will like it or be cut out for it, that’s for sure. However people armed with a few tips and a little knowledge are more likely to stay with it than others. If you are thinking about learning to weld, the stick( or to use the more correct term SMAW) process is one of the most versatile processes. It’s excellent for teaching general technique and is a widely employed form of welding.

Setting up a plasma cutter is fairly straight forward, with connections, fittings, and wiring. There's not much to it for most people. However, plasma cutter settings to make a proper cut is another issue entirely. A lot of people have called me seeking advice on exact settings and hard and fast rules of plasma cutting. Unfortunately there are few unbendable rules related to plasma cutting. Any plasma cutter will make some sort of cut operated at maximum amps on the thinnest metal.

A lot of effort should be focused on keeping the settings correct on the plasma cutter to maximize torch life. Few people when plasma cutting worry about the duty cycle of the plasma cutter or the torch. A torch or plasma cutter rated for 60% duty cycle can only cut for 6 minutes out of 10 at the maximum rated welding duty cycle. Anything over this and the torch and the unit will over heat.

Improper torch manipulation will result in not only damaged welding consumables, but possibly result in damage to the torch itself from blow back of sparks and dross. Keeping the torch at the right angle and distance from the work piece is essential. When establishing a cut, starting off edge and moving into the metal is the best and least problematic way of starting a cut, with little or no blow back. However, at times a pierce cut is sometimes required.

One of the problems associated with plasma consumable life is related directly to technique. One of the most frequently abused features of a plasma cutter that results in marked reduction in consumable life is the over use or misuse of the pilot arc. The pilot arc is the arc that is generated when the trigger is held, without it being in close proximity to the metal. The pilot arc is used to help generate continuity between the work piece and the torch.

One of the problems encountered when plasma cutters are coupled to oil-less type compressors is their size limitations. Most oil-less compressors provide less than 5 cfm output. This is less than ideal for operation with most air compressors, and during a middle of a cut, your plasma can “starve” for air, creating problems with burned up consumables and torches. This also results, as you would imagine, in poor quality and inconsistent cuts.

One of the signs of moisture in your line is (as we stated in our last blog) is consumable wear. But tell-tale signs of moisture are evident long before the consumable decides to unceremoniously blow out. Take a close look at your consumable. Is it dark and sooty looking, or is it shiny and clean, except the very tip where the arc discharges? Is the hole in the tip of cup (the outer consumable part) oblong or rapidly wearing, in just a few cuts? These are quick signs to look for to help you determine if too much water is getting to your consumables.

Recent events have turned my thoughts again toward plasma cutting issues the last few days. One of the common issues I have had to deal with working for Everlast is consumable wear. No, it’s not due to lack of good design or poor quality. It’s largely due to neglecting to follow a few basic steps to ensure maximum life from the consumable. One of the primary issues that most people most people face is chronic problems with moisture in their air lines. Honestly, most people have this issue sooner or later, either from forgetfulness or outright neglect.

Wanting a welder but not sure if you have the wiring capability to handle a full size welder? Are you considering a smaller welder just so you can use it on 120V? It used to be that 120V welders were largely ridiculed because of the limited capability of the welder. Now, with the technological improvements and the advent of inverter welders, it does not seem that far fetched to find a 120V welder even in commercial facilities. Output and duty cycles have risen. 120V welders now hold a large market share due to those facts.