Article

Multi Process Welder, New Trend in Welding Machine Industry

Jan 29, 2023

Multi Process Welder

Introduction

Multi-process welders are an excellent investment for anyone who wants to increase their welding capabilities and get more done in less time. These versatile machines allow you to switch between welding processes without having to switch machines, saving you both time and money. In this article, we will provide a comprehensive overview of multi-process welders and their benefits.

Multi process welder is a new trend in manufacturing welding welders which have proved to be more economic instead of buying single welder for each welding mode. In this blog, we will go deeply with the multi process welder to know which is better to work with single process welder or with multi process welder and what is the best multi process welder.

What is the multi process welder?

Multi process welder is the one which can be used to weld with different welding modes including DC stick/MMA, MIG flux cored/FCAW, MIG Gas welding/GMAW, Lift TIG welding, etc. and also, it can be used to weld with wide range of welding wire sizes where the welder is manufactured to provide the suitable voltage and amperage for this range of wire sizes.

What a multi-process welder is and how it differs from single-process welders

A multi process welder is a welding machine that is capable of performing multiple welding processes, such as MIG, TIG, Stick, and flux-cored welding, using a single machine. This means that instead of having to purchase and maintain multiple welding machines for different welding processes, a welder can use a single multi-process welder to perform various types of welding.

In contrast, single-process welders are designed to perform only one type of welding process. For example, a MIG welder can only perform MIG welding, and a TIG welder can only perform TIG welding. If a welder needs to perform multiple types of welding, they would need to purchase and maintain separate welding machines for each process.

Will multi-process welder become a popular choice for welder?

Multi process welders are a new trend by which you can get one welding machine that can be used in welding by multiple modes. This technology is recently used in factories and workshops in which the welders need to work with more than one welding mode like the case of piping work in which the root of joints is welded by using TIG welding and filling and cap passes are welded with using stick welding mode or MMA in addition to supports and steel structure welding on which piping lay down in which welding may be done by stick welding or flux cored arc welding FCAW or Gas metal arc welding GMAW, so you need one multi process welder to adapt all these needs instead of buying single process welder for each welding mode.

Also, in the field of cars manufacturing, the process of manufacturing needs many modes of welding including resistance spot welding, resistance seam welding and stick welding and all of these modes are achieved by only one multi process welder that is why it becomes more efficient for this type of work.

Is the multi process welder expensive?

The answer is yes as this welder combines the features of many single process welders in one welder, that is why it becomes more expensive than the single process welders.

For example, Arccaptain Official offers the stick welder ARCCAPTAIN ARC160 for 139$ and the TIG welder TIG200 for 299$ which are lower expensive than the multi process welder like MIG 200 . That is why, if your work only needs one welding mode, there is no need to buy a multi process welder but if your work needs a combination of many welding modes, the multi process welder is the right choice.

The pros and cons of multi process welder

Each welder, whether single process one or multi process one, has advantages and disadvantages but the most important thing is to select the welder which fits your needs. The multi process welder has the following pros and cons:

Pros

Cons
  • Versatility: the multi process welder can work with multiple welding modes, so there is no need to set up each single process welder separately.
  • Lower cost for multi welding modes needs as compared to the cost of buying multiple single process  welders.
  • Light weight where although it combines multiple processes, it has a relatively light weight near to that of single process welders.

  • Convenience: Multi-process welders are typically compact and portable, making them easy to transport to different job sites.

  • Synergic welders in which the welding parameters are adjusted automatically as per the wire size used and also, they have manual adjustments.
  • Higher cost for single welding mode as compared with the cost of singular welders.
  • Limited power and duty cycle where although it combines many processes, each process cannot reach the power and duty cycle of single process ones.
  • High repair cost as this type of machines is made up of many high technological parts which cost a lot to repair or replace them.

So, you have to think well and to determine your needs precisely to select the welder that fits your needs.

Is it difficult to manufacture multi process welder?

The multi process welder is a piece of art like computer which contains high technological parts and components that is why the manufacture of such welder is a complex process to get a welder that can adapt with many welding modes.

Can multi process welder integrate plasma cutter？

Multi process welder can integrate plasma cutter and commonly the welder can adapt TIG and Stick welding modes accompanied with plasma cutter but this is not preferable choice as the plasma cutter will turn your welder to lousy welder due to the high power and duty cycle needed. If you are welding some intermittent works like welding by the week end, you can get this multi process welder but if you are continuously welding and cutting, the multi process welder with plasma cutter is not the right choice and it is preferably to get one separate welder for plasma cutting.

What do you have to check before buying a multi process welder?

There are some few steps to check before buying your multi process welder:

  • What are your work needs? : you have to think about your work needs whether your work needs more than one welding process or not and whether your work is continuous work or intermittent work as this will give you indications to whether you need multi process welder or not and also what is the suitable duty cycle and efficiency needed as continuous work requires higher duty cycle welder.
  • Number of integrated welding modes: you have to check that your welder fits your required welding modes or it will be useless to buy an expensive welder that does not fulfill all your needs.
  • Welder duty cycle: as you know, the duty cycle expresses the time that the machine can continuously work out of 10 minutes, so the higher the duty cycle, the longer the time that the machine can work continuously which also have positive impact on machine life time especially for the continuous type of work like the case of welding shops which work on daily basis.
  • Welder weight: machine weight and portability are very important features that enable you to not only use the welder indoors in workshops or factories but also for outdoor work.
  • Synergetic and manual settings: the synergetic settings are very useful for learners and beginners as they can create professional welds like experienced professionals by inputting the wire size, material and shielding gas used, the machine will automatically adjust the welding parameters to produce sound welds.
  • The required input power: you have to check your workshop or the place where you are going to work that the input power needs of the welder are available like voltage whether the welder need 220 V or 380 V.
  • Data display: you have to check the ease and availability of welding parameters display during welding to be sure of using the right ranges.
  • Accessories: each welding modes requires special accessories like in stick welding, the welder needs electrode holder, in the case of TIG welding, the welder need TIG torch with shielding gas cylinders, in the case of spot welding, it needs the spot-welding electrodes and so on. So, be sure of the availability of all the required accessories to fit all the integrated welding modes in your welder.
  • Start and end features: be sure that your welder contains the start and end features like easy arc start, adaptive crater, pre-flow and post-flow in TIG welding, arc force, hot start, anti-stick Machine in stick welding, burn-back adjustment in MIG welding.
  • Guarantee: you have to check the guarantee time on your welder against manufacturing defects to keep value for your money.
  • Strict quality control: you have to check that your welder has passed various authoritative Laboratory tests in simulating extremely harsh environments before leaving the factory that conform to the high standards.
  • Safety issues: check that your welder contains more protection functions like VRD, over current/over voltage/over current/over load/overheating protection function. 
  • After sale services: check the availability of after sale services like repair, periodic maintenance and spare parts.

    • ARCCAPTAIN MIG200  is one of the most efficient, durable and powerful multi process welders with synergetic features that can be used also with aluminum MIG welding.

    This multi process welder have the following features which make this welder a unique one:

  • 6 in 1 welder: This multi process welder combines 6 different welding modes including gasless flux cored FCAW, gas metal arc GMAW, stick weld, Lift TIG weld, Spot weld and Spool Gun weld.
  • Synergetic Setting & Manual Setting:  By choosing the wire size, material and shielding gas, the welding parameters are adjusted automatically through this feature and this is very helpful especially for beginners. The manual control of wire feed speeds also enables you to create perfect welds matching professional standards.
  • LED Digital Display:  you can easily and clearly read the welding parameters  through the digital display.
  • Light Weight |Ultra-Portable: the light weight enables you to work in any place due to the light weight feature.
  • Burn-back adjustment: this feature reduces the deterioration of welding contact tip by the molten weld metal.
  • Extra Driver Roller Giveaway including V groove, U groove, V- Knurld Drive Roll.
    •

    Choosing the Right Multi-Process Welder

    When choosing a multi-process welder, it's important to consider your specific welding needs. Consider the welding processes you need to perform, the materials you will be working with, and the thickness of the materials. Look for a machine that is powerful enough to handle your welding needs but also fits within your budget.

    Can a beginner use a multi-process welder?

    Yes, beginners can use a multi-process welder, but it may take some time to become familiar with the different processes and settings. It's important to read the manufacturer's instructions and seek the advice of a welding professional if you are unsure about how to use the machine.

    What types of materials can be welded with a multi-process welder?

    Multi-process welders can be used to weld a variety of materials, including mild steel, stainless steel, aluminum, and copper.

    Can I use a multi-process welder for industrial applications?

    Yes, multi-process welders are suitable for industrial applications, but it's important to choose a machine with the appropriate power and duty cycle for your needs.

    How do I maintain my multi-process welder?

    Proper maintenance is important for ensuring the longevity and performance of your multi-process welder. This includes regular cleaning, inspecting and replacing worn or damaged parts, and following the manufacturer's recommendations for storage and usage.

    Conclusion

    A multi-process welder is an essential tool for any welder who wants to get more done in less time. By investing in a multi-process welder, you can save time, money, and improve the quality of your welds. Consider your welding needs and choose the right machine for you, and you'll be able to take on any welding project with ease.

    About the author

    Benjamin Mina is from Egypt, He had bachelor degree of science BSc in materials and metallurgical engineering since 2007 from Suez canal university in Egypt and He had an international welding engineer certification IWE since 2009 as a partnership between the central metallurgical research and development institute - Egypt (IIW - Approved Training Body) and SZA-SchweiBtechnische Zentralanstalt - Austria (IIW - Authorized National Body) and recently he got the master degree of science in metallurgical engineering MSc from Cairo university. He have long experience in welding and materials engineering which is gained as per my work as welding engineer and non-destructive testing specialist in the construction field in constructing new oil and gas, refinery and power station projects in addition to shutdowns and maintenance work for running oil plants and pipelines.

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