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welding power supply wikipedia jump to content main menu main menu move to sidebar hide navigation main page contents current events random article about wikipedia contact us contribute help learn to edit community portal recent changes upload file special pages search search appearance donate create account log in personal tools donate create account log in contents move to sidebar hide top 1 classification 2 power supply designs toggle power supply designs subsection 2 1 transformer 2 2 generator and alternator 2 3 inverter 2 4 other types 3 references 4 external links toggle the table of contents welding power supply 17 languages العربية čeština deutsch español eesti français עברית हिन्दी hrvatski bahasa indonesia italiano 日本語 한국어 nederlands polski русский 中文 edit links article talk english read edit view history tools tools move to sidebar hide actions read edit view history general what links here related changes upload file permanent link page information cite this page get shortened url switch to legacy parser print export download as pdf printable version in other projects wikimedia commons wikidata item appearance move to sidebar hide from wikipedia the free encyclopedia piece of equipment used to weld this article has multiple issues please help improve it or discuss these issues on the talk page learn how and when to remove these messages this article includes a list of general references but lacks sufficient corresponding inline citations please help improve this article by introducing more precise citations june 2015 learn how and when to remove this message this article is written like a personal reflection personal essay or argumentative essay that states a wikipedia editor s personal feelings or presents an original argument about a topic please help improve it by rewriting it in an encyclopedic style may 2014 learn how and when to remove this message this article needs more citations please help improve this article by adding citations to reliable sources unsourced material may be challenged and removed find sources welding power supply news newspapers books scholar jstor march 2013 learn how and when to remove this message learn how and when to remove this message welding power supply alternating current coated electrode welding machine a welding power supply is a device that provides or modulates an electric current to perform arc welding 1 there are multiple arc welding processes ranging from shielded metal arc welding smaw to inert shielding gas like gas metal arc welding gmaw or gas tungsten arc welding gtaw welding power supplies primarily serve as devices that allow a welder to exercise control over whether current is alternating current ac or direct current dc as well as the amount of current and voltage power supplies for welding processes that use shielding gas also offer connections for gas and methods to control gas flow the operator can set these factors to within the parameters as needed by the metal type thickness and technique to be used the majority of welding power supplies do not generate power instead functioning as controllable transformers that allow the operator to adjust electrical properties as needed however in some welding applications notably smaw used in areas isolated from power grids welding power supplies are used that combine the functions of electrical generation and current modulation into a single mobile unit mounted on a vehicle or towed trailer classification edit welding machines are usually classified as constant current cc or constant voltage cv a constant current machine varies its output voltage to maintain a steady current while a constant voltage machine will fluctuate its output current to maintain a set voltage shielded metal arc welding and gas tungsten arc welding will use a constant current source and gas metal arc welding and flux cored arc welding typically use constant voltage sources but constant current is also possible with a voltage sensing wire feeder constant current sources are used for welding operation which are performed manually like shielded metal arc welding or gas tungsten arc welding being manual processes the arc length is not constant throughout the operation this is attributed to the fact that it requires very high amount of skill to keep the hand at exactly same position above the workpiece throughout the welding using a constant current source makes sure that even if the arc length changes which causes a change in arc voltage the welding current is not changed by much and the heat input into the weld zone remains more or less constant throughout operation the nature of the cv machine is required by gas metal arc welding and flux cored arc welding because the welder is not able to control the arc length manually citation needed if a welder were to attempt to use a cv machine for a shielded metal arc welding smaw task the small fluctuations in the arc distance would cause significant fluctuations in the machine s current output with a cc machine the welder can count on a fixed number of amps reaching the material regardless of how short or long the electric arc gets power supply designs edit the welding power supplies most commonly seen can be categorized within the following types transformer edit a transformer style welding power supply converts the moderate voltage and moderate current electricity from the utility mains typically 230 or 115 vac into a high current and low voltage supply typically between 17 and 45 open circuit volts and 55 to 590 amperes a rectifier converts the ac into dc on more expensive machines this design typically allows the welder to select the output current by variously moving a primary winding closer or farther from a secondary winding moving a magnetic shunt in and out of the core of the transformer using a series saturating reactor with a variable saturating technique in series with the secondary current output or by simply permitting the welder to select the output voltage from a set of taps on the transformer s secondary winding these transformer style machines are typically the least expensive the trade off for the reduced expense is that pure transformer designs are often bulky and massive because they operate at the utility mains frequency of 50 or 60 hz such low frequency transformers must have a high magnetizing inductance to avoid wasteful shunt currents the transformer may also have significant leakage inductance for short circuit protection in the event of a welding rod becoming stuck to the workpiece the leakage inductance may be variable so the operator can set the output current generator and alternator edit welding power supplies may also use generators or alternators to convert mechanical energy into electrical energy modern designs are usually driven by an internal combustion engine but older machines may use an electric motor to drive an alternator or generator in this configuration the utility power is converted first into mechanical energy then back into electrical energy to achieve the step down effect similar to a transformer because the output of the generator can be direct current or even a higher frequency ac these older machines can produce dc from ac without any need for rectifiers of any type or can also be used for implementing formerly used variations on so called heliarc most often now called tig welders where the need for a higher frequency add on module box is avoided by the alternator simply producing higher frequency ac current directly inverter edit since the advent of high power semiconductors such as the insulated gate bipolar transistor igbt it is now possible to build a switched mode power supply capable of coping with the high loads of arc welding these designs are known as inverter welding units they generally first rectify the utility ac power to dc then they switch invert the dc power into a stepdown transformer to produce the desired welding voltage or current the switching frequency is typically 10 khz or higher although the high switching frequency requires sophisticated components and circuits it drastically reduces the bulk of the step down transformer as the mass of magnetic components transformers and inductors that is required for achieving a given power level goes down rapidly as the operating switching frequency is increased the inverter circuitry can also provide features such as power control and overload protection the high frequency inverter based welding machines are typically more efficient and provide better control of variable functional parameters than non inverter welding machines the igbts in an inverter based machine are controlled by a microcontroller so the electrical characteristics of the welding power can be changed by software in real time even on a cycle by cycle basis rather than making changes slowly over hundreds if not thousands of cycles typically the controller software will implement features such as pulsing the welding current providing variable ratios and current densities through a welding cycle enabling swept or stepped variable frequencies and providing timing as needed for implementing automatic spot welding all of these features would be prohibitively expensive to design into a transformer based machine but require only program memory space in a software controlled inverter machine similarly it is possible to add new features to a software controlled inverter machine if needed through a software update rather than through having to buy a more modern welder other types edit additional types of welders also exist besides the types using transformers motor generator and inverters for example laser welders also exist and they require an entirely different type of welding power supply design that does not fall into any of the types of welding power supplies discussed previously likewise spot welders require a different type of welding power supply typically containing elaborate timing circuits and large capacitor banks that are not commonly found with any other types of welding power supplies references edit larry jeffus 27 january 2011 welding and metal fabrication cengage learning pp 232 isbn 978 1 133 41655 5 larry jeffus lawrence bower 12 february 2009 welding skills processes and practices for entry level welders cengage learning pp 21 isbn 978 1 111 78207 8 nasir ahmed 2005 new developments in advanced welding crc press pp 245 isbn 978 1 85573 970 3 external links edit miller electric news release on igbt technology for welding inverters 8 april 2003 archived 2 june 2008 at the wayback machine frank g armao inverter based welding power supplies for welding aluminum the lincoln electric company lincoln electric tutorial on inverter based welding machines how does an inverter welder work v t e metalworking v t e welding arc welding atomic hydrogen athydo ahw electrogas egw flash flux cored fcaw gas metal microwire mig gmaw gas tungsten heliarc tig gtaw plasma paw shielded metal stick mma smaw submerged saw other processes electric resistance erw electron beam ebw electroslag esw exothermic forge friction friction stir fsw friction stud laser beam lbw laser hybrid magnetic pulse oxyacetylene oaw spot rsw ultrasonic upset equipment electrode filler metal helmet power supply robot shielding gas related terms heat affected zone photokeratitis residual stress weldability casting fabrication forming jewellery machining metallurgy smithing tools and terminology welding retrieved from https en wikipedia org w index php title welding_power_supply oldid 1297021888 categories arc welding power supplies hidden categories articles with short description short description matches wikidata articles lacking in text citations from june 2015 all articles lacking in text citations wikipedia articles with style issues from may 2014 all articles with style issues articles needing additional references from march 2013 all articles needing additional references articles with multiple maintenance issues articles using infobox templates with no data rows all articles with unsourced statements articles with unsourced statements from june 2020 webarchive template wayback links this page was last edited on 23 june 2025 at 18 43 utc page was rendered with parsoid text is available under the creative commons attribution sharealike 4 0 license additional terms may apply by using this site you agree to the terms of use and privacy policy wikipedia is a registered trademark of the wikimedia foundation inc a non profit organization privacy policy about wikipedia disclaimers contact wikipedia legal safety contacts code of conduct developers statistics cookie statement mobile view search search toggle the table of contents welding power supply 17 languages add topic