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For applications that need even more flexibility, even more strands are used (welding cables are the usual example, but also any application that needs to move wire in tight areas). One example is a 2/0 wire made from 5,292 strands of No. 36 gauge wire. The strands are organized by first creating a bundle of 7 strands.
Electrodes are available in straight lengths and coils. Their diameters may be 1.6, 2.0, 2.4, 3, 4.0, 4.8, and 6.4 mm. The approximate value of currents to weld with 1.6, 3.2 and 6.4 mm diameter electrodes are 150–350, 250–800 and 650–1350 amps respectively.
C-50 (50% argon/50% CO 2) is used for short arc welding of pipes, C-40 (60% argon/40% CO 2) is used for some flux-cored arc welding cases. Better weld penetration than C-25. C-25 (75% argon/25% CO 2) is commonly used by hobbyists and in small-scale production. Limited to short circuit and globular transfer welding.
The voltage needed for welding depends on the resistance of the material to be welded, the sheet thickness and desired size of the nugget. When welding a common combination like 1.0 + 1.0 mm sheet steel, the voltage between the electrodes is only about 1.5 V at the start of the weld but can fall as low as 1 V at the end of the weld.
Electric resistance welding (ERW) is a welding process in which metal parts in contact are permanently joined by heating them with an electric current, melting the metal at the joint. [1] Electric resistance welding is widely used, for example, in manufacture of steel pipe and in assembly of bodies for automobiles. [2]
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