Welding question

[rallydiesel]

What type of welding set-up would be best if I wanted something for light fabrication (downpipe, manifolds) and body work (seam reinforcing). I would like to be able to weld aluminum and steels. From what I have read, stick welding would probably be the way to go? Does this require inert gas cylinders or is the flux gas on the electrode?

[Pat Dolan]

There are essentially three main divisions:  SMAW (Shielded metal arc = "stick"), GMAW (Gas Metal Arc = i.e. "wire")  and GTAW (Gas Tungsten Arc = "Tig" - the old acronym for "tungsten inert gas", but the gas is not always inert, thus the new acronym).

SMAW is the flux coated electrode that is used on a lot of steel applications, but electrodes small enough to do body sheet metal are not at the corner store, and machines that are low enough power to do that have terrible welding charactaristics.  Also, you COULD do aluminum that way, but electrodes are very expensive, and quite mickey-mouse (my appologies to the ghost of Walt).  Also, to do the different materials, you need an AC-DC power source, not on the low end of the cost range.

GMAW wire feeders are the ones that use the bottles of shielding gas, and are the most common in shops today.  You can buy very inexpensive ones that use small wire and can easily do seam welding on body sheet metal, and work on maybe 1/8" on the high end (single pass).  A bigger machine will usually turn down quite well, and cost a lot more, but will do a lot more (and better).  These are DC only machines if dedicated to steel.  If you want to do aluminum with wire, you need a different power source that will do so, and they start to get a bit pricey.

GTAW uses a power source that will generally do SMAW as well, AC and DC, plus superimpose a high frequency, low amp, high volt current on top.  However, they seldom will acommodate a wire feeder.  You can do EXTREMELY fine work with the "tig" welder (especially one of the new, digital square wave HF units), and control is fantastic, but the rate of deposition is very low (unless you have a monster water cooled torch and big power supply).

As you might now be surmising, no one welding machine will do everything.  There are wire feeders that will work well on both steel and aluminum, but count on spending $6 or $7 grand for a good setup.
If you really want to do everything, you pretty much need one set up for steel wire, one for aluminum wire (or one of the fancy units that will do both well) and a separate one for SMAW and GTAW.

[zukgod1]

Pick up a nice 220 volt mig with the gas hookups. This would be the least expensive option and give ya the most versatility in welding.

Dan

[935racer]

I'd have to recommend tig, it will do stick as well, but if you want to do manifolds and good Al welding your going to want a good tig machine. If you can do without manifold and just want to do some body work,downpipes, chassis braces etc a good 220v mig like a miller 175/180 would be perfect.

[jimfoo]

I only have a 120v MIG (GMAW) and when using a spool gun, it welds aluminum just fine. I did preheat the slightly thicker sheet I welded onto my radiator to mount it. You do need different gasses for steel and aluminum however, or just use argon and loose penetration on steel, unless you use flux cored wire for the steel. If you get one, buy the best you can afford however. I would have liked a larger one, but don't have 220v.

[blkboostedtruck]

Pat Dolan,
they do have multy process machines out now on the market! you just buy the different attachments and gas bottels and you can weld in all process! Miller welders i know have them!
I plan on selling both my welders someday and buying one unit saving valuable room in my garage! I used one a while back that required TIG welding in the field and i was the only ironworker in the field that knew how to TIG that company did not want to lay me off at the end of the job!  
but they had no more work close to my home!
but at least i got to try one out!
thanks Duane

[Pat Dolan]

Pat Dolan,
they do have multy process machines out now on the market! you just buy the different attachments and gas bottels and you can weld in all process! Miller welders i know have them!
I plan on selling both my welders someday and buying one unit saving valuable room in my garage!

Duane:

I have been waiting for their prices to come down (haven't looked for a while) but I think they are out of the price range of the OP.  I have the same concern (space), but now have three welding machines in three different buildings, so all is not lost.

[blkboostedtruck]

Pat Dolan,
they do have multy process machines out now on the market! you just buy the different attachments and gas bottels and you can weld in all process! Miller welders i know have them!
I plan on selling both my welders someday and buying one unit saving valuable room in my garage!

Duane:

I have been waiting for their prices to come down (haven't looked for a while) but I think they are out of the price range of the OP.  I have the same concern (space), but now have three welding machines in three different buildings, so all is not lost.

 yep i know what you mean they are expensive! I'm hopin to run accross a used one that has everything or a recon. till then i can only dream?
thanks Duane

[Op-Ivy]

Get gas. Worth it in the end!