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A transformer-style welding power supply converts the moderate voltage and moderate current electricity from the utility mains (typically 230 or 115 VAC) into a high current and low voltage supply, typically between 17 and 45 (open-circuit) volts and 55 to 590 amperes. A rectifier converts the AC into DC on more expensive machines.
Because the power normally supplied to the welding machine is high-voltage alternating current, the welding transformer is used to reduce the voltage and increase the current. As a result, instead of 220 V at 50 A , for example, the power supplied by the transformer is around 17–45 V at currents up to 600 A.
Arc welding power supplies can deliver either direct (DC) or alternating (AC) current to the work, while consumable or non-consumable electrodes are used. The welding area is usually protected by some type of shielding gas (e.g. an inert gas), vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated.
Power transformer overexcitation condition caused by decreased frequency; flux (green), iron core's magnetic characteristics (red) and magnetizing current (blue). Operation of a transformer at its designed voltage but at a higher frequency than intended will lead to reduced magnetizing current.
The basic spot welder consists of a power supply, an energy storage unit (e.g., a capacitor bank), a switch, a welding transformer, and the welding electrodes. The energy storage element allows the welder to deliver high instantaneous power levels. If the power demands are not high, then the energy storage element isn't needed.
Spot welding is a resistance welding method used to join two or more overlapping metal sheets, studs, projections, electrical wiring hangers, some heat exchanger fins, and some tubing. Usually power sources and welding equipment are sized to the specific thickness and material being welded together.
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