WIA's range of welding machines are suited to a range of applications including maintenance, rural and construction industries. Selecting the right welding machine can be challenging, but we are here to help you make the best choice.

Four simple points to consider:

Process: What process do you need? Are you doing MIG, Stick, DC TIG, AC TIG or Plasma Cutting? Selecting a welding machine based on what process you need will help make the decision easier.

Plug: 10 Amp, 15 Amp, 25 Amp, 32 Amp, single phase (240 V) or 3 phase (415 V)? Consider how much power you need to get the job done.

Material: From steel to aluminium, selecting a welding machine that’s capable to tackle different materials will help make your decision easier.

Metal thickness: thin gauge, 6, 8, 10, or 12mm plus – choosing a machine that can tackle certain metal thicknesses is key to choosing an appropriate machine.

The right welding machine for each industry

The best welding machine for one person, isn’t necessarily the right one for another. Whether you’re doing regular fencing work on a farm or doing intricate beading work in a fabrication workshop – the welding machine you choose comes down to application and specification needs.

Multi-process welding machines for every application

No matter what industry you are in, having a multi-process welding machine can make all the difference. With light to medium fabrication in mind, the new Weldmatic range offers the flexibility to weld in different processes including MIG, Stick and TIG. For quick and easy adjustment, selected models offer an LCD screen interface with pre-set parameters, an ideal feature for less experienced operators. From the entry level Weldmatic 180 to the professional Weldmatic 500, all WIA machines come with 3 years warranty – offering the reliability and performance needed to get the job done.

Below includes a comprehensive WIA Weldmatic selection chart, making it easy to choose the right WIA multi-process machine for different welding needs (click image to enlarge and access links):

An extensive range of welding machines

WIA's extensive range of welding machines cater to specific demands of various industries and applications. Whether you are a novice or a seasoned welder, dealing with thin or thick metal, or working in a rural or construction environment, there is a welding machine that fits your requirements perfectly.

View the entire WIA equipment range.

/safety/view/vortex-hdv-papr-system

Vortex HDV PAPR System

Protecting the respiratory health of welding operators on the mine site is crucial in ensuring a safe and healthy work environment.

In recent years, there has been a growing demand for respiratory protection that not only offers increased protection but also enhances comfort and visibility.

Weldwell, a leading supplier of welding equipment, has addressed this need with its latest innovation, the Miller Vortex HDV PAPR System. Designed to take respiratory protection to the next level, the Miller Vortex HDV PAPR System offers a range of features and exclusive technologies that set it apart from other systems.

Exclusive Technology

The standout feature of the Vortex HDV PAPR System is the HDV Technology that provides high-definition clarity, giving welders a sharp and detailed view with minimal distortion. This feature makes it easier for welders to see their work with greater accuracy and efficiency.

ClearLight 2.0 technology minimises glare and optimises the light spectrum, providing a clearer, brighter and more realistic weld view.

InfoTrack technology features a memory function and allows the operator to store two favourite settings and track weld time and arc counts.

X-Mode technology is another exclusive feature and major benefit to welding operators. Designed for outdoor usage, it eliminates sunlight interference, and the lens only darkens when the welding operator strikes an arc, making it ideal for low amp TIG and out-of-position welding.

Ground-Breaking Design

The system's lightweight blower unit weighs only 1362 grams, providing long-term comfort, allowing welders to wear it for extended periods without causing strain. The Vortex HDV PAPR System provides protection against welding fumes, making it an ideal choice for welders working in confined spaces.

The six air distribution points ensure that the air is evenly distributed, providing maximum cooling and comfort, while the three air speeds allow the operator to control the volume of air to meet their work conditions.

The audible and vibrating alarm increases safety by notifying the user in noisy environments of low battery.

Included in the package are two lithium-ion batteries, one to use and another for charging, eliminating downtime when it’s time for a recharge.

Usage of the Vortex HDV PAPR System is easy, thanks to the LCD display that provides an easy-to-read screen for viewing fan speed, current time, and battery level, and a filter timer to remind the welder when it's time for it to be replaced.

With all of these features and technologies combined, the Miller Vortex HDV PAPR System provides the ultimate respiratory protection for welders, ensuring greater clarity, comfort, and safety.

The Next Step in Respiratory Protection

The Miller Vortex HDV PAPR System is a game-changer in respiratory protection for welders, providing exclusive technologies and top features that offer the next level of protection, comfort, and visibility.

Its lightweight design and industry-leading features make it a must-have for welders in the mining industry in New Zealand.

The next generation of WIA welders have landed! Built with new digital platforms and extensive features, all come with 3 years warranty and better than ever reliability and performance for the Australian Market.

For decades WIA machines have been established as reliable welding solutions for DIY, farming, construction, repair, maintenance, and fabrication applications. Today, WIA’s next generation range is set to exceed the reliability and performance standards set by its predecessors.

But there’s more, everything about WIA’s new models is new, from the new robust design, smooth silicon dials, higher level of performance, up-to-date digital technology and extensive list of features, every choice that was made was with the user top of mind.

Two new models have also been added, including a highly portable Weldarc 135 stick welder, and a Weldmatic 180 multi-process machine, which has been introduced for beginner to intermediate welders who require a 10 Amp plug. A new Weldmatic 200+ multi-process model has also been added, providing advanced LCD screen technology with pre-set parameters for quick and easy adjustment.

Every model has been completely re-developed and built with new digital technology for enhanced welding performance, precise arc waveforms, and a more stable arc control. This exciting new platform also allows for potential software upgrades to easily be made in the future. Manager Aleksandr Koshelyev says it’s exciting where we could take these machines. Simple upgrades can be developed and implemented to meet market demands quickly and easily.

Product Manager Aleksandr Koshelyev also says, when it comes to commercial welding machines, this WIA range has it all. Each machine was built to meet welders wants, needs and more.

Take the all new Weldarc 185 Stick / TIG welder for example, it has been designed with a range of improvements and new features to suit light fabrication, repair, maintenance, farming, and building and construction projects. The Weldarc 185 machine now has a higher duty cycle than previous models, meaning it will run for a longer period at 185 Amps.

Also, it comes with VRD for safety requirements and Fan on Demand™ which runs in only when the machine reaches its maximum heating point, reducing noise and the amount of dust getting into the machine. Additionally, it has digital meters for precise adjustment, and is IP23S rated for added environmental safety protection, a requirement for some mine sites.

What truly sets this machine apart is Power Factor Correction (PFC) which makes it tolerant to unconditioned power when generators are used, and tolerant to being operated on long extension leads.

Like all WIA machines, the Weldarc 185 is built with high quality components and comes with 3 years warranty (power source only), which sets the standard for machines in this category.

The new Weldarc 200 ACDC Stick/TIG welder is also packed with features. Designed for repair and maintenance, aluminium boat fabrication and motorsports fabrication, the Weldarc 200 ACDC offers precise AC TIG welding of aluminium and comes with Power Factor Correction, Fan on Demand™ and new LCD technology. 

From repair, maintenance, light-medium and heavy fabrication, WIA’s new Weldmatic multi-process range has also been fully re-designed to maximise ease of use, portability, flexibility and reliability.

All come packaged with a new improved MIG gun featuring a flexible goose neck for better positioning and new ball cable joint for more flexibility.

Lightweight, the smaller machines have a built-in wire feeder making them extremely portable. The Weldmatic 180 weighs only 11kg and the Weldmatic 200+ only 17kg, making them easy to transport between workshop and on-site locations.

For fabrication workshops, WIA offer the 3 Phase Weldmatic 350 and Weldmatic 500 multi-process machines. All come with a separate wire feeder for extra flexibility and manoeuvrability.

Ease of use is a highlight of these machines, both Weldmatic 200+ and Weldmatic 250 come with LCD screen technology and offer pre-set parameter adjustment, while the Weldmatic 180, Weldmatic 200, Weldmatic 350, Weldmatic 500, come with digital meters for more precise adjustment. Suitable for both the workshop and outdoor applications all suit gas shielded and gasless wires.

The new Cutmatic 45 has also been re-designed with a new robust design, improved duty cycle, Power Factor Correction and an upgraded water and air filter design. Weighing only 1kg it’s highly portable and offers precise and effortless cutting for fabrication, on-site maintenance and automotive repair applications.

WIA’s exciting next generation of welding machines are available now Australia-wide. 

If you want to weld your best, weld with the best – Weld with WIA.

Contact your local stockiest and get yours today.

Here’s What You Should Know About Weldability of Filler Metals

Original article courtesy of Hobart Filler Metals - hobartbrothers.com

It’s true that not all materials can be welded, at least without cracking, and some may be easier or more difficult to weld than others. That’s where the idea of weldability comes in to play — and it can have slightly different meanings depending on the context.

Informally, the industry refers to weldability as a material’s ability to be welded or joined. The American Welding Society (AWS) defines it as “The relative ease with which a material may be welded to meet an applicable standard.”[1]

Weldability can also be considered as it relates to filler metals and their characteristics. That is, how well do the products perform?

A filler metal with high/good weldability makes it easy to repeatedly make passing and quality welds, even for welding operators who may be less skilled. Filler metals with low/poor weldability typically require more skill, time and attention to achieve the same results and may also require more time for cleanup or rework.

Evaluating weldability

An easy way to evaluate the weldability of a filler metal is to rank it based on key criteria. If you are looking for a new filler metal, want to assess your current one or are looking to benchmark competitive products, this evaluation can help. Set up a scale with criteria on the opposite ends of the spectrum and touchpoints in between. Think good, better and best.

Arc stability – This can be ranked from extremely erratic to extremely smooth or consistent.

Slag removal – Consider ranking welding slag removal from very difficult to very easy.

Spatter level – Look at how heavy or light the amount of spatter is.

Bead appearance – Evaluate whether it is unacceptable all the way to excellent.

Overall appeal – This ranking is more subjective, but it helps determine how much the welding operator likes how the wire runs — from unacceptable to excellent.

When evaluating filler metals for their weldability, use those with similar AWS classifications and welding parameters to be sure you are establishing a true comparison. The exception would be comparing solid to metal-cored wire if you are looking for a potential conversion to increase productivity.

The benefits

What’s the purpose or benefit of assessing weldability? Simply stated: quality and productivity. Having a filler metal with high weldability, that operates smoothly with little manipulation, offers consistency. It also makes training new welding operators faster. That leads to less rework and more parts out the door.

So, when it comes to weldability, ask yourself: How much easier does this filler metal make my job?

View the Hobart welding wire range today:

[1] AWS A3.0:2020, Standard Welding Terms and Definitions

Best Practices for Welding Wire Spool Selection and Set-Up

Original article courtesy of Hobart Filler Metals - hobartbrothers.com

Filler metal packaging, such as spools, may seem like an inconsequential part of the welding operation — a simple way to deliver the welding wire to the joint. However, the type and size of spool a company selects can have a significant impact on productivity, quality and cost.

Not only is it important to make the right selection for the application, but it’s also critical to set up the welding wire spool properly to prevent problems related to poor wire feeding. Such issues can be far-reaching and lead to extra costs for replacing welding consumables as well as downtime for troubleshooting. With labor already accounting for around 85% of the total cost of a welding operation, maintaining arc-on time is key to being efficient and profitable.

How to choose welding wire spools

The specific type of welding wire spools varies by filler metal manufacturer; however, there are typically three options: steel, plastic and fiberboard.

Each of these spools includes a hub that mounts on the wire feeder by way of a spindle assembly. Depending on the filler metal manufacturer and the type of wire being used — solid, metal-cored or flux-cored — spool weights for industrial applications generally range from 33 to 60 pounds, but can be as light as 12 pounds. These ranges are true for steel wire; aluminum wires have different standard packages. Typically, heavier weights of welding wire are packaged on fiberboard spools due to their sturdy structure.

There are several factors that determine the right welding spool for the application. In some cases, the decision may be made based on what is available for a given wire type and size. In other instances, sustainability may be a factor. For companies committed to implementing and maintaining recycling initiatives, a plastic or steel spool may be preferred over a fiberboard spool. 

Portability and productivity can also have major impacts on spool selection — particularly when choosing a specific weight of welding spool. If the welding will take place in a stationary location, using a bench-style feeder, it is often beneficial to purchase a larger spool to minimize downtime for changeover. If the operation requires the welding operator to change locations, a smaller spool is better to simplify portability. In this case the spool would be added to a suitcase-style feeder.

Step-by-step setup

Proper welding spool setup for MIG or flux-cored is key to preventing unnecessary downtime for troubleshooting or fixing problems. Incorrect setup can lead to such issues as poor wire feeding, bird-nesting (a tangle of wire in the drive rolls), burnback (the wire fusing in the contact tip) and wire stuttering that leads to poor arc stability.

As a matter of best practice, follow these steps for setting up a spool on a bench-style feeder.

1. Holding the spool from below (rather than by the rim), place it on the spool assembly, aligning the hole on the spool with the dowel on the wire feeder. This helps maintain the wire tension on the feeder. If it isn’t preset, set the hub tension on the spool to ensure it doesn’t unwind when welding stops.
2. Be sure to account for the inlet guide angle to determine the direction the wire should feed. If the guide is at an angle, the wire should feed from over the top of the spool. If the gun is flat, the wire needs to feed from underneath the spool. Proper wire direction helps prevent drive roll slippage, excess wear on inlet guides and possible bird-nesting. Put the retaining clip in place to secure the spool.
3. Open the drive rolls via the knob on the wire feeder, and be sure to have the correct ones for the type of wire being used. Typically, gas- and self-shielded flux-cored wires, and metal-cored wires use V-knurled drive rolls. Solid wires pair with V-groove drive rolls. Aluminum wires use U-groove drive rolls.
4. If the spool of wire is new, snip the short, bent end of the wire that has been secured to the spool so the wire is straight. Take care to keep a good hold on the wire so that it doesn’t unspool. Feed the wire through the first inlet guide, the first set of drive rolls, the intermediate guide through to the second set of drive rolls and into the power pin at the back of the MIG gun. As with the drive rolls, be sure to have the correct type and size of inlet guide. Use plastic guides for aluminum wire and steel guides for other styles of wire. Inlet guides usually come with drive rolls and are designed to be slightly larger than the diameter of wire.
5. Close the feeder housing on the wire feeder and set the drive roll tension by turning the knob on the wire feeder. A good rule of thumb is to set the tension until it is one half turn past the wire slipping. Avoid overtightening the drive rolls, as this can deform the wire and lead to mechanical wear of the contact tip, arc wander and other feeding issues.
6. Jog the wire until it feeds through the length of the MIG gun. Place the contact tip over the wire and tighten. Then add the nozzle. Test the drive roll tension by feeding the wire into a gloved hand while curling the wire into a small ball. The wire should feed smoothly without slipping.

Storing spools

In addition to selecting the most appropriate spool and setting it up properly, it’s important to protect the welding wire on it through proper storage. After purchasing a new spool, keep it in its original, intact package and store in a cool, dry area. This helps prevent moisture pickup that could introduce hydrogen into the weld, potentially leading to hydrogen-induced cracking, porosity and other weld discontinuities and defects. If possible, remove the spool after welding and place it in its original package. If that is not feasible, it’s best to cover the spool while it is still on the wire feeder.

And, as with any aspect of the welding operation, contact a trusted filler metal manufacturer or welding distributor with any questions about welding spools or other filler metal packaging.

What is the right shielding gas to use? What position does a particular filler metal weld in? These and other questions are likely able to be answered by consulting a filler metal data sheet.

Original article courtesy of Hobart Filler Metals - hobartbrothers.com

And while there is no industry standard for what manufacturers include on filler metal data sheets, these documents are valuable for understanding the proper usage of welding wires and stick electrodes. Referencing them can help welders ensure they are employing the correct welding parameters to gain high weld quality and productivity — and avoiding costly downtime.

Referencing filler metal data sheets can help welders ensure they are employing the correct welding parameters to gain high weld quality and productivity — and avoiding costly downtime.

Welding operators should make it a best practice to consult filler metal data sheets prior to welding with a new wire or electrode. There are common questions that can be answered with a quick consultation.

These documents can also be of great value to welding engineers who are responsible for weld design and the development of welding procedures, plus quality control managers who need to ensure welders complete the welds correctly.

Filler metal data sheets are readily available on manufacturer’s websites and sometimes shipped in product packages.

So, what details do they provide?

Key information for welding engineers

Welding engineers are responsible for establishing weld and joint design, as well as welding parameters for an application. Filler metal data sheets are an excellent resource to gain insight into the properties and characteristics of a filler metal to help achieve the best results. Welding engineers can also consult Certificates of Conformance, which provide filler metal testing information based on material thickness and type.

While welding engineers need to look at all the information provided by a filler metal data sheet, there are several key components they should consider, including:

American Welding Society (AWS) classifications: Every filler metal must be tested to confirm it meets the mechanical and chemical properties set forth by AWS to bear a specific classification. This classification is typically included as reference at the top of a filler metal data sheet and can guide welding engineers as they specify a filler metal for a particular weld design.

Typical weld metal chemistry (chem pad): Filler metal manufacturers provide details about the level of elements — such as carbon, manganese, sulphur and phosphorus — created by their welding wires and stick electrodes in the welds. The levels are based on the use of a specific shielding gas or shielding gas mixture and compared to the AWS spec. This chem pad is important to welding engineers because the chemistry of the filler metal needs to be compatible with the base material to provide the best results. In some cases, they may want a filler metal with higher or lower levels of a particular element. For example, higher levels of nickel are desired in critical applications requiring good impact toughness at low temperatures to lessen the risk of cracking.

High amounts of sulphur and phosphorus can cause hot cracking, so it is good to keep these low to help reduce the chance of the weld cracking during solidification.

Typical diffusible hydrogen: Through a gas chromatography test, manufacturers can determine the level of diffusible hydrogen in a filler metal. They report this on the data sheet in the form of ml of hydrogen per 100 grams of weldment based on a shielding gas or shielding gas mixture. This data is valuable since lower hydrogen levels also help minimize hydrogen-induced cracking.

Mechanical properties: Data sheets provide welding tensile strength and yield strength, expressed in pounds per square inch (psi) and megapascal (MPa). These values are based on testing of weld samples created with the filler metal. This testing also provides elongation properties in percentages to indicate ductility. All three must fall within the AWS specification for the filler metal classification so welding engineers are assured the product will be strong and ductile enough for the application.

Typical Charpy V-notch impact values: Charpy V-notch testing provides welding engineers with the impact toughness a filler metal will provide in a completed weld at a specific temperature. Impact toughness is how much rapid impact a weld can manage before cracking occurs. These values, expressed in foot-pounds and joules on the filler metal data sheet, explain the amount of impact a weld can withstand at 0, -20- and -40-degrees Fahrenheit, for example.

Charpy V-notch testing (the equipment shown here) provides welding engineers with the impact toughness a filler metal will provide in a completed weld at a specific temperature.

The basics for welders

Filler metal data sheets can commonly be found posted near a weld cell as reference for welders. Some important information that is relevant to welders, and also referenced by welding engineers during weld design planning, include:

Welding positions: Filler metals are designed for welding in all positions (including vertical up and overhead) or flat and horizontal positions. Filler metal data sheets indicate the product’s usability with graphics or they will have the positions written out.

Welders can consult the filler metal data sheet for the recommended amperage, volts and wire feed speed according to the welding position they will use.

Shielding gas: Filler metals, such as solid, metal-cored and gas-shielded flux-cored wires, require an external shielding gas to protect the molten weld pool from atmospheric contaminants. Some wires are formulated for welding with 100% carbon dioxide (CO2), while others can be welded with both 100% CO2 and a combination of CO2 with an argon balance or even a mixture of argon and oxygen. Filler metal data sheets provide this information; it is important for welders to pay attention to the designated shielding gas, as it directly impacts the arc characteristics and weldability of a filler metal. Filler metal data sheets also provide shielding gas flow recommendations.

Type of current: Gaining the best welding performance requires the use of the correct polarity for a given filler metal. Filler metal data sheets will indicate whether a welding wire needs to operate on direct current electrode negative (DCEN or straight polarity), in which the lead connects to the negative terminal on a power source and the workpiece connects to the positive terminal, or direct current electrode positive (DCEP or reverse polarity). For DCEP, the welder uses the opposite connections — the lead connects to the positive power source terminal and the workpiece to the negative. For stick electrodes, the sheet will explain if the product can be used for alternating current (AC) welding, along with direct current (DC).

Filler metal data sheets provide recommendations for set up and welding parameters to best operate the welding wire or stick electrode.

Storage and reconditioning: All filler metals need to be stored in a dry, enclosed environment in their original, intact packaging until ready for use. Stick electrodes, however, have additional considerations when it comes to keeping them in top shape. Ideally, they should be stored in an oven at a recommended temperature to minimize moisture pick up and help ensure a low hydrogen weld deposit that is less prone to cracking. Filler metal data sheets will provide the temperature ranges for storage. The document will also state the reconditioning parameters, should the stick electrode be exposed to the atmosphere for an extended period of time. For example, a stick electrode may need to be reconditioned at 500 to 800 degrees Fahrenheit for one to two hours prior to being used.

Putting the filler metal to work

Having information about the characteristics, weldability, properties and care of a filler metal is important — but the product also has to be put to proper use. Filler metal data sheets provide recommendations for set up and welding parameters to best operate the welding wire or stick electrode. This information is a starting point. Welders and welding engineers may determine that slightly higher or lower parameters work best for the application.

Based on wire diameter — most wires range from 0.035 to 5/64 inches — welders can consult the filler metal data sheet for the recommended amperage, volts and wire feed speed according to the welding position they will use it. Corresponding to these welding parameters, most filler metal data sheets offer a suggested contact-tip-to-work distance in inches and millimeters, along with the achievable deposition rates (pounds/hour) that welders can gain when following these parameters (give or take adjustments to amperage, etc.). These guidelines are based on testing the filler metal with either 100% CO2 or a mixed shielding gas, which will be specified on the data sheet.

Combining the correct operating parameters with the welding procedures for the application, including pre-heat and interpass temperature is important to achieving success. Filler metal data sheets do not provide details on these temperatures, as they will vary according to the material and the material thickness. However, many filler metal manufacturers offer technical support and can help determine the best temperatures to follow, answer any questions about the filler metal’s properties or expand on details provided by the filler metal data sheet.

With the easing of restrictions in Napier, we are currently back to normal hours of service. 

From everyone at Weldwell, we wish you safety and good health during this time and thank you for your ongoing support. 

When it comes to welding a range of different metals of varying shapes and thicknesses, Miller TIG welding machines are reputed to be among the best in the business.

The road transport equipment building industry is dependent on high quality welding machines and highly skilled welders to produce trailers and tankers of a standard that the market demands.

It’s for this reason, among others, that Weldwell offers the American-designed and built-to-last Miller Dynasty and Maxstar range of TIG Stick welding machines.

“Essentially, it comes down to quality – both in the product build and operational performance,” says Mathew Hefferan, Business Development Specialist, when asked what sets the Miller range apart from the competition.

“Every component used to build these machines is of the highest quality, which is why they produce such quality weld results and have a reputation among those who use them for being reliable and consistent.”

Mathew adds that a road tanker manufacturer that uses Miller TIG machines comments that they produce excellent results when welding the stainless-steel fittings that are integral to the builds.

“They describe the Miller machines as among the best on the market for achieving the consistent quality welds that are required for these expensive fittings,” he says.

The Miller TIG welding machines have a broad range of features including Auto-Line Power Management Technology – a key feature that’s exclusive to the Dynasty and Maxstar TIG Range.

This ensures smooth and consistent welding power with multi-voltage input, with the Auto-Line circuit boosting primary power to a higher and more constant voltage. Even if the incoming voltage varies widely, the circuit will ensure a rock-steady welding arc.

This feature provides a number of benefits including better weld quality from uninterrupted production, location flexibility, fewer amps, electrical efficiency and more welding output on the primary power.

“With Auto-Line, end users have the benefit of being able to use the welding machine in a workshop or out on a site with single- or three-phase input,” Mathew explains. “It’s also generator-compatible, so it can be used in remote areas where generator power is the only option.”

Other unique features of these welding machines include the wireless foot control which removes leads from the floor, ensuring a much safer working environment. Also, the TIG can run on either an air-cooled or liquid-cooled system.

Standout features of both Dynasty and Maxstar 210DX models include:

• Auto-Line technology – allows for any input voltage control (240-480 V) with no manual linking
• Blue Lighting high frequency arc starter for non-contact arc initiation. This provides more consistent arc starts.
• Pulse – pulsing can increase puddle agitation, arc stability and travel speeds while reducing heat input and distortion.
• DIG control – allows the arc characteristics to be changed for specific applications and electrodes.
• Sleep timer – this conserves electricity by powering down the machine if it has been idle for a certain time.
• Stick-stuck – this detects if the electrode is stuck to the part and turns the welding output off to safely remove the electrode.
• Hot start – adaptive control provides positive arc starts without sticking.
• Fan-on-Demand – variable speed fan adjusts to match the cooling requirements.
• Wind tunnel technology – protects internal parts from airborne contaminants.
• Pro-Set technology – provides a starting point for new welders by giving them pre-set parameters and controls.

While the Arc and TIG welding machines share many features and are both considered premium products of their respective classes, they are suited to different applications.

The Dynasty 210DX is an AC/DC TIG welding machine that can weld aluminium. It is ideal for precision fabrication and maintenance jobs split between a workshop and site.

Meanwhile, the Maxstar 210DX is a DC TIG that is appropriate for welding exotic materials and steel, including stainless steel, copper and titanium.

The main differentiating feature that the Dynasty machine boasts – and one that is also exclusive to Miller – is its four AC wave formations. These are:

• Advanced squarewave – which provides fast freezing puddle, deep penetration and fast travel speeds.
• Soft squarewave – this enables a soft, buttery arc with maximum puddle control and good wetting action.
• Sine wave – is for customers who prefer a traditional arc with quiet and good wetting.
• Triangular wave – this reduces the heat input and is good on thin aluminium. It allows fast travel speeds.

As Mathew points out, these Miller welding machines are premium products that are widely considered to be the most advanced of their kind on the New Zealand market. They also have a reportedly unparalleled three-year warranty which includes parts and labour.

“Reliability is key,” Mathew reiterates. “We supply companies that are involved in defence-type contract work and we find they always come back to the Miller brand because it is reliable and consistent. Likewise, we have a lot of customers in the transport and automotive sectors and the features that these welding machines provide allow them to achieve quality weld results on a consistent basis.”

Also available in the Dynasty/Maxstar range is the Dynasty 280DX, Dynasty 400 and Maxstar 400.

Promotion Period has now ended.

Get a free WIA Duffle Bag and WIA Blue Helmet when you purchase a Weldmatic 200i, 250i, Weldarc 200i AC/DC, 200i DC or Cutmatic 45, or a free WIA Duffle Bag and Miller Digital Elite Graphic Helmet when you purchase a Weldmatic 350i or 500i.

Bonus items will be provided by WIA Distributors with machine purchases.

For more information on the products in this promotion click the below links:

Weldmatic 200i
Weldmatic 250i
Weldmatic 350i
Weldmatic 500i
Weldarc 200i AC/DC
Weldarc 200i DC
Cutmatic 45

Terms and Conditions:
Offer is available from 1 October – 30 November, 2020 while bonus stocks last. Purchase a Weldmatic 200i, 250i, Weldarc 200i AC/DC, 200i DC or Cutmatic 45 machine from an authorised distributor and receive a free WIA duffle bag and WIA Blue Helmet (P/N: MHELBLUE235620), or purchase a Weldmatic 350i or 500i from an authorised WIA distributor and receive a free WIA duffle bag and Miller Digital Elite™ Helmet in either the Inferno, Stars and Stripes or Vintage Roadster graphic, based on availability. (P/N: Inferno - MHELGRAPDIGI, Stars and Stripes: MHELGRAPDIGSS, Vintage Roadster: MHELGRAPDIGVR).

For more information, contact our customer support team on 0800 WELDWELL.

The most popular welder generator is now even better.

When operating an engine driven welder or using power from a welder/generator out in the field, operators are often faced with a dilemma: Do you leave the machine running in between the tasks and risk wasting fuel, or do you turn it on and off each time at the cost of losing efficiency?

The remote start/stop feature in the new Miller Bobcat 260 welder/generator resolves that issue.

The model, which is now available in New Zealand through Weldwell NZ, can be turned on or off with a remote control, allowing the operators to work noise-free when they no longer need the welder or the power source. It also offers considerable fuel savings, so the machine can run longer with each tank refill.

Fuhai Liu, Product and Sales Manager – End Markets Oceania says the remote control option in the new Bobcat 260 is a unique feature for a welder/generator of its caliber.

“For a low-budget, commercial model, the Miller Bobcat 260 was already jam-packed with great features. It’s one of the most popular models in this class of welders across the Weldwell branch network. The remote control feature adds even more efficiency and convenience to an already very successful product,” says Fuhai. 

One of the key markets where the Miller Bobcat 260 is extensively used is in the farming and agricultural sector, according to Fuhai.

“When working on a farm, access to a power source is not always readily available. An engine driven welder/generator like the Bobcat 260 is a handy machine for conducting simple welding and repair jobs or to use as a stand-alone generator for different applications. 

“Fuel savings are particularly important when you are working on a farm. Apart from the obvious benefit of saving on fuel costs, going back to the storage to get the fuel to refill the welder’s tank can be a time-consuming task on a large farm. By easily turning off the machine when it’s not needed, you can extend the refill interval. A large 45-litre capacity fuel tank enables long runtimes with this machine.”

The remote start/stop feature is available on both the diesel and petrol models of the Miller Bobcat 260.

Matthew Hefferan, Business Development Specialist, says there’s no right or wrong when it comes to the choice between buying a petrol or a diesel model.

“It all depends on your preferences. The diesel model is slightly more expensive than the petrol model, which explains why most people prefer to buy the petrol-fuelled machine. That said, there could be long-term cost benefits if you invest on the diesel-run model.”

Overheating is not a concern with the Miller Bobcat 260 as the model features the signature reversed generator airflow feature of the Miller range, according to Matthew.

“Quite often, engine driven welders are fitted at the back of a utility vehicle or on top of a trailer, surrounded by toolboxes or other barriers that can limit the airflow. The exclusive engine and generator packaging design in the Miller machine ensures that the engine is rotated towards the front to create efficient airflow.”

The Miller Bobcat 260 is capable of being adopted for multiple welding processes, including stick, MIG, flux-cored, DC and AC TIG, air carbon arc and even air plasma cutting and gouging with optional WIA Cutmatic 45 models.

However, Matthew says the machine’s most common uses, particularly in the agricultural sector, are for stick welding and power supply.

“When using the Bobcat 260 as a stand-alone power generator, users can rest assured that the reading on the machine is a true reading and not inflated. The Accu-Rated™ feature in the Bobcat 260 ensures that 11,000 watts of usable peak power is delivered for a minimum of 30 seconds to facilitate plasma cutting.”

The Miller Bobcat 260 follows the footsteps of its predecessor model, the long-running Miller Bobcat 250. In addition to the enhanced user-friendliness of the new model, it also offers an extra 10 amps of power.

“The Miller Bobcat 260 is very easy to set-up and use. There are no digital interfaces, as most customers in the agricultural sector prefer the manual front panel. To use the machine for stick welding, all you need to do is to choose the stick welding option on the front panel, choose the type of electrode you want to use, set the amperage, and you are ready to weld.”

Click for more information on the Miller Bobcat 260

Weldwell electrodes - Locally Manufactured since 1967. Weldwell joins a long list of Kiwi names heralded for their ingenuity.

At Weldwell we source and use only the best-quality raw materials, and as a result our arc welding electrodes provide the highest quality welding performance and continue to be the go-to electrode in New Zealand for those reasons.

We have strict manufacturing processes are in place to support consistent product quality and reliability. From receiving incoming raw materials to converting those materials into arc welding electrodes, packing and storing them, as well as delivering them to distributors throughout New Zealand and overseas, quality assurance is implemented at every stage.  

This quality management system complies to the International Organization for Standardization i.e. ISO 9001:2015. Moreover, our Weldwell structural electrodes carry approvals from different registrar and classification societies, such as Lloyd’s Register International, Bureau Veritas, American Bureau of Shipping and Det Norske Veritas.

We guarantees with confidence that Weldwell arc welding electrodes meet or exceed minimum compliance for increasingly stringent and robust industry standards.

“As demand changes we have the capacity to change what product we manufacture at short notice, not wait for 3 months for new product to arrive,” says Weldwell regional sales manager – Upper North Island, Kerry Williamson.

That's because Weldwell electrodes are locally manufactured, right here in New Zealand, flexibility and availability is second to none.

“You can’t beat the convenience and reliability of grabbing a packet of Weldwell electrodes and heading back on-site to start or finish a job”.

“Knowing that the next packet you use will have exactly the same quality and usability as the last one, gives customers the confidence that they will get the job done right the first time!”

Weldwell electrodes have played a major role in building and construction sector, and maintaining New Zealand’s infrastructure over the course of the last 53 years.

“Power generation plants, bridges, refineries, have all used our electrodes due to their consistent quality and operator appeal,” Kerry says. 

Welding Industries of Australia (WIA) has introduced the new Weldarc 200i DC welding machine, which is designed to meet all of the requirements of professional TIG welders.

The WIA Weldarc machines have been long-established as reliable units that are well-suited to light industrial and construction maintenance work. This is due to the portability of the machines.

WIA’s Equipment Development Engineer Willem Corbett says the new Weldarc 200i DC, while still portable at 21 kilograms, is a much more sophisticated machine compared to the compact DC TIG/Stick models offered by WIA – which include the Weldarc 185i and the Weldarc 145i.

While the former two Weldarc models primarily targeted the stick welding applications, with the option for Lift TIG welding, the new Weldarc 200i DC is primarily designed for TIG welding, featuring a 200 Amp DC TIG capability, while still retaining a 170 Amp stick welder capability. This means the machine is also perfectly suited for professional stick welding applications.

According to Willem, Arc Start for DC TIG on the Weldarc 200i DC can be either with the High Frequency (HF) Pulse non-contact starting method, or the Lift Arc method. “Both options ensure minimum electrical interference during Arc Start, while HF also eliminates the risk of tungsten electrode contamination,” he says.

“The HF Pulse non-contact method is one of the key features of the new Weldarc 200i DC machine. During the arc start process, pre gas flow is provided through an integrated gas valve, the HF Pulse start then ignites the arc without any risk of tungsten contamination. The Lift Arc method also eliminates scratch starting and tungsten electrode damage.”

In the stick welding mode, the Weldarc 200i DC has a built-in “Hot Start” feature, allowing the machine to deliver a peak of current when striking the arc.

It is quite common for welders to build certain modules in the workshop and then carry out outdoor welding for installations on the project site. Willem says the transition from indoor workspace to outdoor work is very easy with the Weldarc 200i DC.

“Being a single phase machine, the Weldarc 200i DC can easily be taken to the site and plugged in to continue welding on site. The built-in Power Factor Correction (PFC) feature also makes the machine tolerant to unconditioned power when generators are used, and tolerant to being operated on long extension leads.”

The Weldarc 200i DC has an IP23S rating, which as Willem explains, means the machine is designed to be tolerant to outdoor environment.

“The IP23S rating means the machine is protected against water sprays and some level of atmospheric humidity. But we do not recommend using the machine for welding in the rain or in very wet environments,” he clarifies.

Safety is another key consideration in the design of the Weldarc 200i DC machine, as Willem explains.

The Weldarc 200i DC comes with an optional built-in Voltage Reduction Device (VRD), which reduces the Open Circuit Voltage (OCV) to a safe level. The VRD operates in accordance with AS1674.2 CAT C requirements.

“The machine also has thermal overload shut down to prevent overheating. The on-demand fan option further reduces ambient noise and prevents dirt and dust from entering the welding machine,” he explains.

The new professional Weldarc 200i DC machine by WIA comes with a three-year unlimited New Zealand-wide warranty, which covers both parts and labour.

“The latest WIA addition to the TIG/Stick welders range incorporates all of the latest technologies and features for professional welders. When you buy any Weldarc machine, you’re buying reliability and performance,” Willem concludes.

Click for more information on the WIA Weldarc 200i DC

The new Weldarc machines: Upgraded for New Zealand worksites

In response to direct feedback from the field, new versions of the popular WIA Weldarc 140i and 180i TIG and Stick machines have been released to the New Zealand market with bigger outputs and improved safety features.

The Welding Industries of Australia (WIA) Weldarc machines have been long-established as reliable units that are well-suited to light industrial and construction maintenance work. This is due to the portability of the machines.

Industry expert Willem Corbett says the new Weldarc machines have been manufactured to meet specific industry requests.

“These are designed specifically for worksites. We test and trial everything in the field but also readily take customer feedback on board to improve our products, which is definitely the case with the Weldarc 145i and 185i machines,” explains the WIA product engineer. “For example, the new machines have a fan on demand feature which will significantly reduce the amount of contaminants that will blow through a machine in a dusty environment. This feature has come as a result of direct feedback from our customers.”

Another key feature of the new Weldarc 145i and 185i machines is the digital display.

“This will give you an accurate visual of your weld set up,” says Willem. “Once the operator has put in their settings, the visual remains on the screen for the entirety of the weld.”

The new Weldarc releases remain a great fit for general maintenance applications because of their small size and light weight. The 145i will comfortably run a 3.2mm welding electrode, while the 185i will comfortably run a 4mm welding electrode.

“The 145i will run from a 10 amp socket and the 185i will run off a standard 15 amp socket,” says Willem. “But the main reason why these machines are so popular for construction site maintenance or light fabrication work is because they are easy to be mobile with."

The Weldarc 145i and 185i are both compact and light, totalling 4.1kg and 5.5kg respectively. Both the 145i and 185i includes optional Voltage Reduction Device (VRD) which delivers added safety for onsite work and is compliant with the New Zealand standards AS 60974.1 and AS1674.2 CAT C. The VRD is disabled but if required can be enabled by a WIA service agent. 

“The fan on demand feature is energy saving but the real benefit here is that it prevents dust from getting into the machine and causing problems,” says Willem. “At WIA we’re always listening to our customers and wanting to improve our products. The Weldarc machines are fantastic portable welding machines, really suitable for maintenance or installation work."

"WIA already had a good product, but we’re driven by our field experience. By implementing customer feedback we’ve managed to improve the product and deliver a safer option for our clients.”

Click for more information on the WIA Weldarc 145i

Click for more information on the WIA Weldarc 185i

Stick welding can be a hard process to learn as there is an array of issues that could cause problems. But don’t despair. There are techniques that can make the process easier.

Known as CLAMS – Current setting, Length of arc, Angle of electrode, Manipulation of electrode and Speed of travel – these procedures are straightforward to learn, will improve the weld and ensure the job is completed properly.

However, before laying down these techniques, the surface has to be prepared properly, which includes making sure that the workspace is clean. It also means that the surface of the metal being welded must be grit-, dirt- and rust-free. If it is not, the weld will probably crack, which means the job will be ruined and the only option will be to start again.

Positioning of the body is a key consideration, too, as well as keeping clear of the smoke produced by the weld and having a good view of the weld puddle.
 

Current Setting

The selected electrode will determine whether a machine should be set up in AC, DC negative or DC positive. It is best to select the amperage being used based on the electrode, welding position and visual inspection of the finished weld. If the finished weld is poor, then one of these settings could be the problem. It is important to adjust the welder by 5 to 10 amps at a time, until a suitable setting is found.

If the amperage is too low, the electrode will start sticking when striking an arc. If the amperage is set too high, glitches can appear that include the puddle being excessively fluid, the electrode charring when half of it is gone and an arc sounding louder than it should. Excessive heat can also have a negative affect the electrode’s flux abilities.
 

Length of Arc

A good rule of thumb is that a correct arc length will not exceed the diameter of the core of the electrode. Using a long arc seems natural because it helps the user see the arc and puddle. However, the user should position themselves so they have a better view of the arc. If a user’s body is put in the correct position, it not only gives a good view of the puddle it also helps to manipulate the electrode correctly.
 

Angle of Travel

It is best to hold the electrode perpendicular to the joint being welded. This allows the user to tilt the top in the direction of travel about 5 to 15 degrees. For welding vertical up, use the forehand technique whereby the top of the electrode it tilted up to 15 degrees away from the direction of travel.
 

Manipulation of Electrode

Each welder should develop his or her own style by practicing and also looking at other peoples’ techniques. Any material thinner than 6mm means that weaving the electrode is unnecessary because the bead will be wider than needed. In many instances a straight bead is all that’s required.

With thicker material, a welder can create a wider bead by moving the electrode side to side. This creates a continuous series of partially overlapping circles in a “Z,” semi-circle or stutter-step pattern. It is important to remember that the aforementioned side-to-side motion should be limited to twice the diameter of the electrode core. To cover a wider area, make multiple passes or use “stringer beads”.

If welding vertical up, the focus should be on welding the sides of the joint, because the middle will take care of itself. Remember, when moving across the middle of a joint it is done at a pace that allows the weld puddle to catch up. Then pause at the sides to allow a solid tie-in to the side wall.

If welds look like they have overlapped, then the user has gone forward too fast and didn’t hold on the sides as long as necessary.
 

Speed of Travel

Finally, there is the speed of travel. This is a key ingredient to getting the correct weld. Your travel speed should allow you to keep the arc in the leading one-third of the weld pool.

If you travel too fast, then penetration decreases, which affects the integrity of the weld. It can underfill, which is when the outside of the weld is recessed. If the user is travelling to slow, it produces a convex bead with little penetration. It looks like the weld is sitting on the surface of the metal and has not joined the two pieces together

Date: 15/01/2020

Eight tips for creating a good weld

It’s important to know the basic principles to creating a safe, strong and clean weld.

To help we've put together our top eight tips to create a good weld.

1. Safety

Make sure you have the correct safety equipment, including gloves, a fire-resistant jacket and a helmet.

Designed for the welder who wants protection, performance and comfort at an affordable price, Weldwell offer WIA's Blue auto-darkening helmet which makes it easier for welders to remain safe.

2. Select a process

MIG, Flux Cored, Stick and TIG? Don’t get confused by all the different terms.

Wire welding uses spools of wire fed through a gun, and the constant feed of wire minimises starts and stops. It’s fast, more economical and better suited to welding thin sheet metal.

There are two types of wire welding:

1. MIG (metal inert gas): MIG welding relies on a constant stream of shielding gas to protect the weld from contamination. The limitations to MIG welding are that it can be difficult to use outdoors, and you have to cart around the gas bottle.

2. Flux-cored: Flux-cored welding uses wire that is specifically designed for use with or without shielding gas depending upon the wire being used. Self-shielded wires that can run without the use of gas are suited to outdoor work.

Stick (SMAW)

The best choice for quick repairs. It’s easy to set up and it uses a stick electrode like the Weldwell PH16TC, so you don’t need a wire feeder. Stick is slower than MIG welding, but often more forgiving when working with dirty or rusty metal. Stick is not recommended for thin sheet metal welding.

Tungsten Inert Gas (TIG)

TIG welding is preferred for architectural or automotive work where the weld has to look good. It’s also a good way to weld thin and sheet metal and achieve a seamless look. TIG is the hardest to learn, but it’s not out of your grasp if you put the effort into it. TIG machines can weld a variety of metals, however if you want to specifically TIG weld aluminium then the a machine with AC/DC capabilities is required, for example the WIA Weldarc 200i AC/DC machine.

If your work requires using a range of different processes, Weldwell offers various multi-process machines including the Weldmatic 200i, 250i, 350i or 500i.

3. Select the right machine for your weld

There is no single welding process that suits all applications, so you’ll need to choose one that best matches your welding application.

During the selection process the following factors should be considered:

• type of material being welded
• thickness of the material
• the welding position
• type of welding power source and the amount of current available

4. Ensure your material is clean

Make sure all the materials are clean. Any oil, rust, paint or mill scale can cause contamination and will result in a poor weld. Before you start the welding process, brush all your equipment, surfaces and materials down to ensure everything is clean.

5. Select the correct settings

Having the correct settings on your welding machine will place a huge impact on the quality of your weld. Every WIA machine comes with information that will enable you to determine the optimum settings for your weld.

6. Maintain the correct stick out

When MIG welding, it’s important to maintain the correct CTWD contact tip to work distance. If your CTWD is too close, you will find excessive tip wear and if the CTWD is too far, you will experience a reduction in amperage. Both issues will result in a poor weld.

The optimum CTWD for a 0.9mm wire is 10 to 16mm and for a 1.2mm wire is 16 to 19mm.

7. Adjust your machine for every weld

Check your reference chart and adjust your wfs and voltage to suit. Make several practice welds on some scrap metal to ensure you are happy and comfortable with the settings.

8. Practice, practice, practice!

Practice makes perfect. The more welding you do, the better you will become.

Date: 15/01/2020

Like every other welding process, flux cored welding comes with some challenges, but with some know-how and a bit of practice, you can prevent some of the common problems and gain the weld quality you need.

To help we’ve put together some tips associated with common undercutting, lack of fusion, slag inclusions and penetration problems.

Undercutting

The problem

Undercutting causes a weaker area at the toe of the weld and often leads to cracking.

The solution

Use the proper welding current and voltage and adjust to the right gun angle.

Maintain a travel speed that allows the weld metal to fill the melted-out areas of the base metal completely or if you are using a weaving technique, pause at each side of the weld bead.

Lack of fusion

The problem

Failure of the weld metal to fuse completely with the base metal.

Solution

Obtain the correct angle - place the stringer bead in its proper location at the joint, adjust the work angle or widen the groove to access the bottom during welding as needed.

Keep the arc on the trailing edge of the welding puddle and maintain a gun angle drag of 15 - 45 degrees. If using a weaving technique, momentarily hold the arc on the groove sidewalls when welding.

Increase your voltage range and/or adjust the wire feed speed as necessary to obtain complete fusion. If you feel that the wire is getting ahead of the work puddle, simple adjustments, such as increasing travel speed or using a higher welding current can prevent problems.

Clean the surface of the base metal prior to welding to remove contaminants to prevent lack of fusion.

Slag Inclusions

Slag inclusions occur when the slag generated by the molten flux in the wire’s core becomes trapped inside of the weld. There are four major causes of slag inclusions.

Incorrect weld bead placement

Provide enough space in the weld joint for additional passes, particularly on joints requiring multiple passes.

Travel angle

Maintain the correct travel angle and travel speed. In flat, horizontal, and overhead positions your drag angle should be between 15 - 45 degrees. In the vertical up position, your drag angle should be between 5 - 15 degrees. If you still experience slag inclusions increase your drag angle slightly. Maintain a steady travel speed; if you travel too slowly, the weld puddle will get ahead of the arc and create slag inclusions.

Incorrect weld heat input

Maintain proper weld heat input, too low of a welding heat input can cause slag inclusions. Use the manufacturer’s recommended parameters for a given wire diameter. If slag inclusions still occur, increase the voltage until the inclusions cease.

Contaminants

Clean thoroughly between weld passes, removing any slag with a chipping hammer, wire brush or grinding before beginning your next weld pass.

Excessive or Lack of Penetration

The problem

Excessive penetration occurs when the weld metal melts through the base metal and hangs underneath the weld. It often results from too much heat.

The solution

Select a lower voltage range, reduce the wire feed speed and increase travel speed.

Selecting a higher wire feed speed, a higher voltage range and/or reducing travel speed can prevent problems like lack of penetration.

Prepare the joint to permit access to the bottom of the groove while also maintaining proper welding wire extension and arc characteristics.

Using these valuable tips should result in good welding technique, and your ability to prevent these problems—or identify and correct them quickly without sacrificing time or quality.

Flux Cored Arc Welding (FCAW) has been a viable welding process for structural steel erection, heavy equipment repair, bridge construction and other similar applications for many years.

They offer high deposition rates, excellent chemical and mechanical properties, and the weldability needed for these jobs.

Like other welding process, flux cored welding comes with some challenges, but with some know-how and a bit of practice you can prevent common problems and gain the weld quality you need.

To help we’ve put together some tips associated with common wire feeding, porosity and worm tracking problems.

Wire Feeding - Burnback

The problem

The wire melts into a ball at the end of the contact tip which is most often the result of too slow of a wire feed speed and/or holding the welding gun too close to the workpiece.

Solution

Use the correct feed speed for your application and maintain a distance from the contact tip to the workpiece of no further than132mm

Wire Feeding - Birdnesting

The problem

A tangle of wire that halts the wire from being fed.

Solutions

Use knurled , drive rolls in your wire feeder. FCAW wire is much softer, if you use the incorrect drive roll, it can easily compress the wire.

Set the drive roll tension correctly - release the tension on the drive rolls then increase the tension while feeding the wire into the palm of your welding glove, then continue to increase the tension one half turn past wire slippage.

Check for liner blockages. If there’s a blockage replace the liner. Always trim the liner (using the correct tools).

Check that the liner doesn’t have any burrs or sharp edges and always use the correct size liner for your diameter of welding wire.

Porosity

The problem

Porosity occurs when gas becomes trapped in the weld metal and can appear at any specific point on the weld or along its full length.

Solutions

Remove any rust, grease, paint, coatings, oil, moisture and dirt from the base metal prior to welding.

Use a filler metal with added deoxidisers, it helps weld through such contaminants, but pre-cleaning is still required.

Always maintain an appropriate electrode extension or stick-out. As a rule the wire should extend no more than 32mm beyond the contact tip.

Worm tracking

The problem

Worm tracking leaves marks on the surface of the weld bead which is caused by gas the flux in the core of the wire creates.

The Solution

Follow the voltage parameters recommended by the filler metal manufacturer for the specific diameter of welding wire. If worm tracking does occur reduce your voltage by increments of one half volt until you eliminate the problem.

Using these valuable tips should result in good welding technique and your ability to prevent these problems—or identify and correct them quickly without sacrificing time or quality.

The latest auto-darkening lens technology from Miller, ClearLight Lens Technology, improves visibility by letting a greater range to colours through.

Selecting the right welding helmet plays an integral part in welding operator safety and comfort, and can also assist in improving efficiency, productivity, and weld quality.

An important consideration when selecting the right welding helmet for your application is the type and quality of lens used in the helmet.

At the most basic level, a welding lens is certified to protect you from the ultraviolet (UV) and infrared rays of the welding arc. In addition to protecting from harmful rays, an auto-darkening lens uses optical (and sometimes electromagnetic) sensors to change from a “light” state to a “dark” state when an arc is struck. Recently, new technologies have led to improvements for auto-darkening welding lenses.

The latest auto-darkening lens technology from Miller — ClearLight Lens Technology — improves visibility by allowing a larger range of colours to come through the lens — giving you a clearer view of the weld pool and surrounding workpiece while welding. Helmets with this new lens technology are also designed to reduce eye strain when you’re not welding, enabling you to leave your helmet down during pre-weld setup or when finishing work; leading to greater efficiency and continuous protection.

Safety & Productivity Benefits

Injuries in a welding environment most commonly occur when welders aren’t welding and your helmet in the up position. ClearLight Lens Technology, reduces eye strain by providing greater clarity and a brighter light state, giving you the capability to keep the helmet down when performing non-welding tasks, like grinding or cleaning. In the past, it was necessary to raise the helmet up for a clear line of sight.

In addition to the safety benefits of using the ClearLight Lens Technology provides, the improvements deliver added benefits that can assist productivity improvements.

When you can clearly see the weld pool and surrounding workpiece, it can lead to higher-quality welds and less rework — saving time and money. ClearLight Lens Technology makes it easier for you to do your job, potentially leading to increased output.

Seeing more Colours

ClearLight Lens Technology allows more wavelengths along the colour spectrum to come through the welding filter and auto-darkening lens.

Where previous filter technology prevented some colours from passing through — which resulted in the operator seeing an artificial yellow, green, or blue tint — ClearLight Lens Technology allows colours commonly emitted during welding to pass through the lens filter, providing a more colour-neutral lens.

The image below illustrates the improved lens technology, showing transmittance percentage (y-axis) along the wavelength light scale (x-axis). The green line shows the colour band resulting from traditional lens technology, while the blue line shows the wide-band filter from the ClearLight Lens Technology. The display is a good representation of the additional colours that you can see when welding with ClearLight Lens Technology.

Even when not welding, you’ll benefit from ClearLight Lens Technology. The heightened contrast in colours makes it easier to see outlying items when in between welds –leading to increased helmet down time.

A brighter light state

ClearLight Lens Technology provides a brighter light state. Light state refers to the state of the lens when it is not darkened for welding and is measured on a numeric scale that represents how much light is being filtered out. This scale typically runs from shade 4 to 13 for welding helmets. The higher the number, the more light is being filtered out and the darker the lens. For example, a shade 13 would be a darkened lens for high-amperage welding.

ClearLight Lens Technology is a three on the numeric scale, achieving a brighter light start, meaning you have a brighter view when wearing a Miller Digital Elite or Infinity helmet while welding or working.

The brighter light state from the ClearLight Lens Technology provides numerous benefits, reducing the number of times you remove your helmet, as well as how often you raise your helmet to the up position. In addition, a brighter light state can reduce eye strain – an important comfort and safety factor, especially when welding over extended periods of time.

Additional Factors to consider

When it comes to choosing the right helmet, there are additional factors to consider apart from ClearLight Lens Technology. A helmet that is correctly balanced is just as critical its weight, since both reduced weight and improved balance reduce neck strain and improve comfort. It can also help increase productivity by allowing for more arc-on time.

Headgear technology that utilises flexible materials provides a more secure fit and conforms to your unique head shape and size, improving comfort and efficiency – minimising irritation or pressure points that lead to headaches.

Choose a helmet that goes beyond basic

ClearLight Lens Technology provides you with a clearer view of your work — a key feature that helps avoid costly mistakes and rework by making it easier to see the weld pool. ClearLight Lens Technology can also reduce the potential for eye strain – making it more comfortable for you to keep the helmet down.

When selecting a welding helmet, consider available lens technologies like ClearLight Lens Technology. Investing in a helmet capable of providing a brighter light state and a wider range of colours can help improve safety, compliance, productivity, and operator comfort in the welding operation.

With so many different welding helmets available, selecting a helmet isn’t always easy. If you’re a professional welder and serious about welding protection, performance and comfort, there are a few things to look for.

Not all welding helmets are the same and it’s important to consider differences in weight, switching speeds, the number of arc sensors, the quality of the lens and of course comfort.

The Miller Digital Elite series are premium helmets, designed for industrial welding applications and suitable for a variety of welding applications, including MIG, Stick, TIG, plasma cutting, flux cored and pulse welding.

Suitable for all stages of welding, the Digital Elite offers variable shade control and four modes:

• Weld – For all welding applications
• Cut – For plasma, laser, gas welding and cutting applications
• Grind – For preparation and clean up
• X-Mode – Electromagnetic arc sensing technology

Exclusive to Miller’s Digital Elite series, X-Mode ensures that the lens will only darken when an arc is struck. If you weld outdoors at low currents, in areas effected by low hanging fluorescent or strobe lights, or in positions that can obstruct the lens, X-Mode is the answer. No more flickering!

When it comes to headgear, the Digital Elite offers a lightweight solution with multiple settings, allowing operators to achieve the best fit and comfort. Weighing only 510g, the helmet is lighter than others and can be worn for longer periods, keeping fatigue to a minimum.

With 4 arc sensors the Digital Elite helmet provides continuous arc sensing for the most demanding applications.

Fitted with an auto-darkening lens the Digital Elite helmet provides visibility even when welding has stopped. When inactive the lens is usually set to shade 3 or 4, which is relatively easy to see through; then when an arc is struck, the lens automatically darkens lightning fast - 1/20,000 of a second, to shade 8 to 13. After welding, the dark to clear state speed of the lens can be easily adjusted from 0.1 sec to 1.0 for maximum control when welding.

For a better view the Digital Elite helmet comes with a built-in magnifying lens provision, allowing you a much closer view of what you’re working on.

Battery powered with solar assist, the helmet also offers an exceptionally long life before charging is required. Delivering up to 3000 hours of interruption free welding.

Tested in Australia the Miller Digital Elite helmet complies with New Zealand standards AS/NZS 1338.1 (Auto-Darkening) and AS/NZS 1337.1 B (High Impact).

Manufactured with quality and longevity the Digital Elite comes with a 3 year warranty (Auto-Darkening lens only) for peace of mind.

If you’re serious about welding protection, visit your nearest stockist and take a serious look at the Miller Digital Elite Auto-Darkening helmet.

For more information on the Digital Elite helmet click here.

Promo Ended - Redemptions Closed 31.10.19

Weldwell are offering end users a BONUS Miller Digital Elite welding helmet with the purchase of selected WIA Weldmatic and Weldarc machines.

Valid for purchases made between 1 August – 30 September 2019.

The offer is by redemption only via the Weldwell website. All claims must be submitted along with valid proof of purchase by 31 October 2019. See offer details below.

Bonus Miller Digital Elite helmet when you purchase a WIA Weldmatic 200i, 250i, 350i, 500i and Weldarc 200i AC/DC .

To receive your bonus Miller Digital Elite helmet, you must have purchased a selected WIA Weldmatic or Weldarc machine from an authorised distributor during the promotion period 1 August – 30 September 2019 and complete and submit the redemption form by the 31 October 2019.

To claim your bonus product, have your proof of purchase and serial number ready – then complete the redemption form – it’s that easy.

For more information on the products included in this promotion, click the links below.

Miller Digital Elite Helmet

Weldmatic 200i

Weldmatic 250i

Weldmatic 350i

Weldmatic 500i

Weldarc 200i AC/DC

Terms & Conditions:

Offers apply during Promotion Period only: 1 July – 30 September 2019. This offer is open to New Zealand residents who purchase a Weldmatic 200i, 250i, 350i, 500i and Weldarc 200i AC/DC from an authorised Weldwell distributor, during the Promotion Period 1 August – 30 September 2019. One bonus Miller Digital Elite™ helmet (part number: MHEL257213) will be provided for each machine purchased. Not applicable with any other promotional or advertised offer. This offer is available by redemption only. All claims must be submitted along with a valid proof of purchase by 31 October 2019. Please allow approximately 4 weeks for delivery of the bonus helmet. Miller Digital Elite™ Helmet is valued at $495.  Bonus helmet is not available to Weldwell Distributors.

For more information contact our customer supprt on 0800 WELDWELL.

As New Zealand’s leading welding supply company and the country’s only manufacturer of arc welding electrodes, Weldwell is pleased to announce an exciting and intuitive new website making it easier for welders of all levels to find exactly what they need, whether it’s welding equipment, filler metals, safety products or accessories, all at the touch of a button.

We’ve been providing innovative welding products and solutions in New Zealand more than 50 years, and our new website offers easy access to the latest technology from our partners around the world including products from leading brands such as WIA, Miller, Hobart and Bernard.

To complement our new look Weldwell logo, we’ve added several new features to the website including more products and dedicated pages for our most popular products, as well as case studies and more in-depth information on NZ welders’ favourite brands, welding resources and news.

You can now find warranty information and claims online, as well as an easy Where-to-Buy feature with information on local distributors anywhere from the Bay of Islands in the north, to Invercargill in the south and how to find them using Google Maps.

All the information you’ll need on our range of welding equipment, filler metals, safety products or accessories is now easy to access with our full range of Specifications and Data sheets available online and easily downloadable. We’ve also created an easy to use electrode selection chart to help you select the right electrode for your application.

Plus, we’ve kept all the information you’ve come to rely from the old website such as MSDS information and test certificates for your favourite Weldwell products.

So whether you’re welding for the first time or you already run a substantial welding operation, Weldwell’s new website can point you to the right solution for the job, be it in the Oil and Gas, Manufacturing Structural, Agriculture, Forestry, Mining, Transport or Marine industry.

Choose the right Electrode for your application

Looking for the right electrode and not sure where to start?

All NEW to Weldwell - We’ve put together a selection chart to help you pick the right electrode for your application.

Click to view the Weldwell Electrode Selection Chart

When it comes to welding, choosing the right machine for the job is just as important as your technique. The type of welder you purchase should be suited to the specific functions you need it for, because there is no such thing as a “one size fits all” welding machine.

Weighing the pros and cons of the different welding processes and the projects you are most likely going to use your welder for is essential to making your selection.

There is no single welding process suitable for all welding situations. What’s important is understanding which process is best suited to your application.

The most common welding processes include:

• Gas Metal Arc Welding (GMAW) often referred to as Metal Inert Gas (MIG),
• Gas Tungsten Arc Welding (GTAW) often referred to as Tungsten Inert Gas (TIG),
• Flux-Cored Arc Welding ((FCAW),
• Manual Metal Arc Welding (MMAW) often referred to as ‘Stick’ welding;

Each of which has its own set of benefits and limitations. There are several factors that must be considered to determine which welding machine will be the most appropriate for your needs, including:

• Type of material being welded
• Thickness of material
• Required weld metallurgy
• Welding position
• Available power supply, for example, single phase or three phase
• Amount of available current
• Time requirements

The below table provides a comparison of the different welding processes and what metals they work with:

Apart from the type of process and metals you want to weld, it’s also important to consider the required welding current and amount of weld time; important when determining the duty cycle of the machine.

Another aspect to consider is the varying amperage and power requirements of the machine. For example, will the user always weld with high current or only occasionally? Additionally, there are other expenses to consider such as the cost of gas verses using gasless for MIG or using stick. If you are looking to purchase a machine, take the time to outline what you will use it for and come to Weldwell. We can go through the different options with you and help you make the right choice.

The WIA range of welding equipment includes a large variety of machines from single and three phase MIG welders, Arc and TIG machines and multi-process welding solutions.

View the WIA inverter welding machine range.

Call our Customer Support Team on 0800 WELDWELL for more information