Voltage is necessary for driving rated current to infinite volts through the arc. It is impossible to talk about stick welding without understanding the voltage involved in the process. Therefore, it is only normal to want to know about the output voltage of a stick welder.
When an arc is struck, the open-circuit voltage of a stick welder reduces to approximately 20 – 30 volts alternating current (AC). When working with tiny rods, you can get away with an arc voltage of a little less than 20 volts, but the arc will be difficult to maintain.
Most times, it is difficult to determine the output voltage of a welding machine as it is dependent on several factors. One of these factors is the Open circuit voltage. In this article, we shall be looking at the Open circuit voltage with the output voltage of stick welding.
What is Open Circuit Voltage
Welding methods such as SMAW, TIG, MIG MAG, and FCAW require open-circuit voltage (OCV) in the range of 20 to 40 volts and current in 50 Amp to 400 Amp. Open Circuit Voltage, or no-load voltage, is the voltage (in volts) between the workpiece and the electrode. So, OCV refers to the voltage between a welding machine’s negative and positive poles while it is turned on but not yet welding.
Why Were the OCV Values Limited at a Maximum of 80 Volts?
It is common knowledge that the maximum safe voltage for a human body is 80 volts. A voltage that is higher than this can be deadly to living creatures.
Simply put, the higher the open-circuit voltage (OCV), the easier it is to strike an arc due to the larger initial voltage pressure. However, this leads to a higher risk of electric shock.
Welding power sources are designed to have a maximum OCV of 80 Volts since 80 Volts is a safe limit of electric hazard for humans. Typical OCV values for welding machines are between 50 and 80 volts. Welders benefit from an OCV of 50 to 80 volts because it allows easy arc striking and an easier weld start.
Does a Closed Circuit and an Operational Voltage Mean the Same Thing?
The voltage measured across the arc during welding, or the voltage that exists between the workpiece and the electrode holder during welding, is the closed-circuit voltage. It depends on the electrode type, polarity, arc length, and current type. The closed-circuit voltage is typically between 15 and 40 volts.
What Is the Difference Between OCV and Welding Voltage?
This is one of the most unclear aspects of welding. A beginner might confuse the welding voltage for the open-circuit voltage. However, both terms are very different.
The welding voltage is the voltage that exists between the electrode and the job (or the earth). This voltage keeps the arc between the electrode and the job you’re working on. Welding voltage is usually significantly lower than OCV. It differs depending on certain factors like the arc length.
What Is the Effect of Voltage in Stick Welding?
Understanding the impacts of voltage on a weld is critical since it helps speed up the process of troubleshooting welding faults.
The voltage has a direct influence on heat input. Heat input increases as voltage rises. Heat input is essential when welding materials with physical and mechanical properties change because of heat.
Some circumstances require a large amount of heat to reduce the cooling rate and prevent embrittlement. In other cases, little heat input is necessary to accelerate cooling and avoid sensitization cracking.
Does Voltage Affect Penetration?
Many welders and other welding professionals will tell you that penetration depends on the voltage. In other words, they imply that the higher the voltage, the deeper the penetration. This notion is incorrect.
When the voltage is set correctly, it has little influence on penetration. The lower the penetration is within this range, the higher the voltage. In the same vein, penetration reduces as the voltage increases. However, we frequently hear that to achieve deeper penetration, you must weld “hotter,” which usually implies a higher voltage
When you use a higher voltage, you create a broader bead on the material you’re welding. As the voltage increases, the energy density decreases, and penetration decreases. Keep in mind that if the voltage is too low and the arc becomes unpredictable, you will lose penetration.
The voltage’s primary goal is to provide enough energy to the arc for adequate metal transfer, whether in a short circuit, globular, or spray transfer. Your voltage should theoretically grow as your contact-tip-to-work distance increases. Still, the power supply maintains the properVoltage by altering amperage.
Frequently Asked Questions
What Does SMAW Stand For?
SMAW means Shielded metal arc welding and is also known as manual metal arc welding (MMA or MMAW), stick welding, or flux shielded arc welding. A manual arc welding procedure lays the weld with a consumable electrode covered with flux.
What Is an Electric Welding Arc’s Temperature?
One of the arc’s primary roles is to generate heat. The arc’s heat melts the base metal’s surface and the electrode’s end. The temperature of an electric arc can range from 3,000 to 20,000 degrees Celsius.
What Is an Electric Arc Welder?
Electric arc welding refers to any arc welding procedure where the electrode melts and becomes part of the weld.
What Is Inverter Welding Equipment, and How Does It Work?
Inverter welding units convert utility AC power to DC before switching (inverting) the DC power into a step-down transformer to create the necessary welding voltage or current. Typically, the switching frequency is 10 kHz or more.
What Is Arc Welding, and How Does It Work?
Arc welding is the procedure of using an electrical arc to melt the work and filler material (also known as the welding rod) for welding joints. Attaching a grounding wire to the welding material or another metal surface is the first step in arc welding. You also put an electrode lead on the material for welding.
