Most welding professionals now have a preference for the welding machines they use. While some prefer transformer welding, others prefer inverter welding machines. But, for a new welder who has just started, the choice may seem complicated or uneasy. Most experts suggest you go with the machine suitable for the project you are working on. In this article, you will find all the details about the inverter welders and transformer welders to make an informative decision while choosing.
Transformer Welders
What Is a Transformer Welder
A transformer welder comes with a transformer inside the welding machine that converts the high-voltage current pulse to AC from DC. It transforms the 208 to 600 volts DC pulse to a continuous AC flow of 15 to 55 amperes. The machine can transform DC to AC by moving the winding core closer or away from the secondary winding. On top of that, it shifts the magnetic shunt inside the machine core, transforming the current output.
Quick History Of The Transformer
Modern transformer welders are usually seen in the heavy metal industry, where stationary workplaces are set up. Due to their hefty size, these welding machines are challenging to move around and are most suitable for indoor use only. It was first introduced in the welding field in the 1900s. The early prototype model was not stable for completing intricate tasks. After the 1920s to 1930s, engineers were able to create a stable arc inside the machine, leading to faster adoption. Arc welding became more prominent during WWII, and transformer welders grew in prominence during that time. Even today, engineers are trying to improve welding machines.
How Does a Transformer Welder Work?
The transformer welding machine uses a simple “step-down transformer” mechanism that transforms a high-voltage, low-amperage current into alternating low-voltage and high-amperage current. For example, a 220 volt 30 A current will be transformed into 45 Volt and 220-400 A current flow after it passes through the transformer welder. Many transformer elders have AC outputs. But some machines have added rectifiers that allow you also to get clean DC output. A transformer welder machine has the following parts- Primary core- It is a copper coil winding that is connected to the primary input voltage. And the main power supply Secondary coil– The secondary coil is connected to the welding leads. It is less dense than the primary coil and reverses the input voltage and amperage to transform the current flow into a low voltage high amperage one. Core– It is a core that concentrates the magnetic field of the primary coil and moves it towards the secondary coil.
Advantages Of Transformer Welders
It has been in use for 100 years. It is a reliable and simple machine that comes without complicated digital elements. It is easier to handle and repair.
Disadvantages Of Transformer Welders
Their heavy and bulky size makes them unsuitable for moving workstations Welding may take longer time to complete as it is not easy to manoeuvre. Low-duty cycle for portable machines. The arc control function is limited. Are not stable enough compared to inverter welders. Can be expensive in case of price and maintenance.
Inverter Welders
What Is An Inverter Welder
An inverter welding machine uses solid-state electrode parts to improve the quality of the electric current conversion. It increases the input current frequency and comes with digital controls and a display to control all the welding settings, including frequency, arc cone width, input and output amperage etc.
How Does An Inverter Welder Work?
Inverter welders convert the AC to a low voltage, high amperage output suitable for welding. For example, you can convert a 200 Volt AC into 20 Volt DC. Since it uses electronic parts, the machine can work significantly faster, nearly one-millionth of a second. It allows better power supply control, making the machine more compact and advanced.
What Is IGBT Technology?
IGBT Technology, which stands for Insulated Gate Bipolar Transistors, is a semiconductor-based technology that can switch AC to DC faster. It has three terminals that can synthesise complex current pulses into clean and clear DC output. The bipolar transistor comes with three insulated terminal gates. On top of that, it combines a control input with a MOS structure and a bipolar power transistor to a comprehensive output switch.
Advantage Of Inverter Welders
A compact machine that is easy to manoeuvre and easy to handle Comes with advanced features of arc control. These machines are highly efficient and offer better arc stability The longer duty cycle makes welding faster A machine can even perform complicated eliding projects Needs a lower-rated circuit breaker to function Is less expensive
Disadvantages Of Inverter Welders
The inverter welders have a lower life expectancy, and repair may be challenging. It is not robust like the transformer welders. It is not suitable for all electrodes. You will have to find different machines for different electrodes.
Inverter Vs. Transformer Welders – Which is better?
1. Performance
In the case of performance, the inverter welders perform slightly better. The transformer elders offer a decent arc like the inverter welders. But, the inverter welders can modify the arc and prevent voltage fluctuations, arc blow, and other issues. Such functions are not available to the transformer welding machines. On top of that inverter, welders are highly efficient. You can adjust the bead’s width, bead size, and thickness as per the requirements. These machines are also reliable in case of constant voltage and arc stability.
2. Reliability & Life Expectancy
Even though the inverter welders are more advanced, the transformer welders are winners in this aspect. The modern transformer welding machine is more reliable. But that does not mean you cannot use the inverter ones, which are more reliable if you want to go for advanced welding projects. The life expectancy of a transformer welding machine is longer than that of an inverter welding machine. You will find transformer welders of more than 40 years still in service, which is quite impressive!
3. Costs
In the case of the cost, both machines perform quite similarly. Modern inverter machines are relatively inexpensive compared to transformer ones. On top of that, the inverter welder machines also come with a warranty to serve you better. Often the cost depends on the machine model including its features and the manufacturing brand. So you will always find a transformer welder or even an inverter welder that suits your budget. The main thing is that the companies are slowly decreasing the production of transformer welders.
4. Welding Environments
Both machines require different working environments. If you are looking for heavy-duty eliding in dusty and humid areas, transformer welding machines are the best choice. Besides that, these machines are ideal for stationary workstations. The earlier transformer welders did not come with the Voltage reduction device or VRD to keep the voltage at a safe limit. Its inclusion in modern machines has made modern transformer welders an ideal choice for humid environments. On the contrary, the inverter welding machines are the most suitable for moving workstations or where you need to move around with the welding machines. So, you need to choose the machine depending on your working environment.
5. Energy
The inverter welding machines are energy efficient. It offers 93% power output compared to a transformer welder’s 60% power output. Hence, go for inverter models if you need more energy without spending a lot. On top of that, inverter welding machines also support 110 V home outlets and can be used anywhere you want.
6. Portability & Weight
The transformer welders are known for their bulky and heavyweight shape. That makes them difficult to mob around. Hence, these machines are generally used in stationary welding workshops. On the contrary, inverter-based transformers are smaller, compact, and can be moved around easily without any help. Hence, you can use them easily without many worries.
7. Duty Cycle
The transformer welders usually come with a larger core that emits a lot of heat due to the electric resistance of the coils. But, these are difficult to cool. Hence, these machines have shorter duty cycles. On the other hand, even though the inverter machines generate a lot of heat due to the PCB board, these can quickly cool down due to the inclusion of fan systems. On top of that, these machines are also smaller in size and dissipate heat faster. Hence, their duty cycles are longer compared to the transformer machines.
8. On a Generator
In the case of the performance of a generator, both machines fare well. But you need the right generator to supply the transformer’s required current. Generally, a generator with a Total Harmonic Distortion or THD level lower than 6% is recommended. Transformer welders are more vulnerable to damages related to unpredictable voltage surges. On the contrary, modern inverter welding machines have a safety mechanism to get some protection from sudden voltage surges. On the other hand, many modern inverter welding machines come with high-voltage capacitors to prevent similar damages. You can also buy these.
9. Features
In the case of features, the inverter welders are the sure-shot winner. Their digital features allow you to choose advanced functions, including bead size, bead thickness, selection of waveforms etc. On the contrary, the transfer welders only allow a simple sine wave.
10. Known Problems
While inverter welders are reasonable, their main issue is the E6010 electrode compatibility. Only a few inverter electrodes can be used with this electrode. If you want to use inverter welders, you need to use a machine with a higher OCV that is compatible with this specific electrode. On the other hand, transformer welders are compatible with most electrodes. But, these machines are stationary, and you may need to use longer cables to connect these to the power outlet if your workstation is away from the PowerPoint.
Conclusion
The inverter welders are more modern and mobile, alongside some advanced features. But, the transformer welders are bulkier in size. On the contrary, you can use transformer welders for heavy-duty work in a dusty and humid environment, which is impossible for inverter machines. But, you must choose the machine depending on the project requirements and your preference. You can use this artwork as a guide to finding the most suitable welder for your welding work. Source: Inverter Vs Transformer Welders Comment * Name * Email * Website
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