Accident Waiting to Happen Limitations of 120 Volt Welders

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Transcript

00:00Do you need a weld off of a 240 volt outlet or are 120 volt welders just fine?

00:07This is a question that I have had a lot on the channel and the truth is the answer is kind of

00:15complicated and it depends a lot on the different processes you're running so we're gonna look at

00:20some examples with MIG, TIG, and STICK. Now with any process you're really limited on your amperage

00:28output when you're welding on 120 volts. So we're gonna start looking at MIG welding here

00:33and this is some 1 8th inch thick material and generally speaking 1 8th inch is kind of the

00:38crossover point. So using the Revolution 2500 it's a dual voltage machine and I have it plugged in

00:44to 120 volts now and I've set it on MIG and it's limiting the maximum output here because of the

00:54120 volt input and it's recommending an eighth of an inch. Now I'm welding this coupon together here

01:02and as I do that there's really no difference when I'm welding on these 1 8th inch coupons being on

01:09120 volts and that's really the crossover point where there's no real change. Now when you get

01:17thicker than that, not that you can't weld thicker material with 120 volts, but you are gonna have

01:23to vary your technique a little bit compared to 240 volts where you're gonna have more amperage

01:29available. And you'll also be limited a little bit on just how much strength you can get even if you

01:35run multiple passes. But let's take a look here at this 1 8th inch thick material as kind of a point

01:42of which there's really no distinguishable difference. It's a little wobbly there on my bead but certainly

01:49acceptable for most things. I'm gonna use a fillet weld brake test and that's where I weld one side

01:55and then bend the root open and you know this is kind of a garage type variant of it. There's a little

02:02more to an actual fillet weld brake test. But anyway here I'm able to bend my material clear over and so

02:11this is you know clearly a sound acceptable joint. But let's try some thicker material here, some

02:18quarter-inch thick material. Now normally when I weld quarter-inch thick material I'd be using a

02:24larger diameter wire with a lot more amperage. But since I'm limited on the amount of power I can get

02:31out of this 120 volt outlet, I'm using the same settings as 1 8th of an inch and just a little bit

02:37of weaving or kind of some loop-de-loop type manipulation. I don't really like doing this

02:43and I can see that it's running in pretty cold. I'll give this another shot in a minute without a

02:49camera in the way which will go a little better but I just want to show you what you can get from

02:54this. And so when I look at the final results to me it looks pretty cold. Now there are a lot of

03:02products that I dare say have welds that are worse than this that hold up. It's stronger than you'd

03:07think but definitely not up to my standards here. Now it's holding up pretty well to the the big hammer

03:15and I'm gonna need to move over to the hydraulic press to be able to open this up. Now you can see

03:22it starting to open already. Now on a fillet weld brake test anything quarter-inch thick and over when

03:29you just have a single pass like this is gonna break. It's not generally gonna bend over like the

03:34eighth inch did and so that doesn't mean that it fails but it lets you see inside the joint if

03:40there's any discontinuities and if it got into the root. And you can see that for most of the joint

03:46it really didn't get down and consume the root of that joint and it was really just on the face of that

03:53mill scale. Now I'm using the same settings here and you might notice there's a push angle instead.

03:59That's not really the big difference. The bigger difference is I can see a little better to stay

04:03on the leading edge of the puddle and that weld looks a lot better. Once again those same settings

04:08I used on that eighth inch thick material but I can tell already how much stronger this is because

04:13it's deforming. So with the right technique notice the edge on that top plate has been consumed all

04:21the way along there so it's not straight anymore. That's kind of one of the big things to look for if

04:27you try this test yourself to see that you got clear down to the bottom. So I feel really good

04:33about this as a single pass but it is sensitive to the technique. And again this was over the mill

04:40scale. I would remove the mill scale on a product I was welding. However I want to look at kind of

04:47worst case. So I've plugged this into 240 volts which lets me crank the wire speed which also controls

04:53your amperage by the way on wire feed welding if you're not familiar with how those work. But I'm

04:59going to set it at 480 inches per minute which is going to be somewhere around 150 amps. If I were

05:06running 035 wire which I would on quarter inch generally then it would be higher but I don't

05:11want to change too many variables at once here. So I'm just running that 030. That's why I'm getting so

05:16much spatter on it. It's because I'm really pushing the amperage beyond what that 030 wire should take.

05:23So let's break this one open here and take a look and see. Now inside this one it's very similar

05:32to the one that I ran previous to it. Now there's a little bit of delamination on the material which

05:40isn't a problem with the weld but generally speaking it was a sound weld and it's a lot less

05:48sensitive to the technique. I've changed over to stick welding here and I have this set at 95 amps.

05:54This machine will run up to 110 amps on 120 volts which is really on the high end but 95 is usually

06:01a max and that's enough to run a 3 32nd 7 inch 7018. Now if you can't get that high of an amperage you can run

06:09a 3 32nd 7 inch 6013 and the great thing about stick welding is that the thickness of material doesn't

06:18play in too much to your amperage. It's mostly the diameter and type of electrode that you're running

06:24so you can weld as thick as you want to with a 3 32nd 7 inch 60 or 70 18 here and just running

06:33multiple passes. So you can see it penetrated in to the root. I wouldn't have minded a little

06:39bit more penetration but it's certainly by most people's standards at an acceptable level. So that

06:47is going to be a good option if you want to weld thicker material on 120 volts is to use smaller

06:54electrodes with stick. Now let's look at TIG welding and particularly aluminum TIG welding. See on steel and

07:00stainless steel with TIG you can weld most things on 120 volts but with aluminum it takes a lot more

07:10heat. It's generally more depending on your joint. So here on an outside corner joint on some 1 8th inch

07:17thick material this machine will run up to 150 amps on TIG and I have the machine maxed out but I'm only

07:24about you know two-thirds of the way down on the pedal for that outside corner joint. When I put it in a T-joint

07:30configuration like this it takes a lot more heat. Now of course with the camera right there I'm gonna dip my

07:39tungsten right off the bat but we'll just roll with it for the sake of demonstration. It's running a lot slower than

07:47I'd need to and I am at full pedal here. So I really like to have my machine set closer to 170 amps when

07:54I'm welding an inside corner or a T-joint like this on aluminum TIG and I'm limited to 150 here and some

08:03machines would be limited to a lower amount if they didn't have as good of a power factor efficiency.

08:08So this is really kind of the limit in my mind welding 1 8th inch thick material with a 120 volt

08:17machine on aluminum TIG. I think you could do a little more especially with some preheat. However

08:24if I was doing more on the regular I'd want a 240 volt machine. So just to summarize when you're

08:31MIG welding I think 1 8th of an inch if you're doing much thicker than that regularly I'd want a 240 volt

08:37machine myself because I think it's just much more robust but you can get away with a bit thicker

08:43if you have good technique. Stick welding you're going to be limited to small diameter electrodes

08:48but you can really weld as thick as you want with like a 3 32nds of an inch 7018 running multiple passes

08:54but it's going to take you a while on thicker stuff. On TIG for steel and stainless steel you're

09:01going to be in pretty good shape to run you know some small beads and multiple passes but when it

09:07comes to aluminum I wouldn't plan on doing a whole lot thicker than 1 8th of an inch with a 120 volt

09:15machine. You can get away with a bit if you use some preheat but I wouldn't do it on the regular.

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09:49and thanks again for tuning in. We'll see you next time.

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