Redefining Multiprocess Welders

Until the development of the newest generation of “3-in-1” inverter-based MIG-Stick-TIG welding systems, fabricators had to compromise on one or more aspects of their operation. Not anymore.

Fabricators, mobile contractors and maintenance personnel bring a “can do” attitude to work. Whether someone comes to them with a long-run contract, one-off part fabrication, unique project or welding repair need, they find a way to get the job done. When necessity forces flexibility, a multiprocess welder is the logical equipment choice.

However, until the development of the newest generation of “3-in-1” inverter-based MIG-Stick-TIG welding systems — such as the Thermal Arc® Fabricator® 252i — fabricators had to compromise on one or more aspects of their operation.

MULTIPROCESS: DEFINED
When fabricators refer to a “multiprocess welder,” they typically mean a welder that has outputs for both Constant Current process (Stick and TIG) and Constant Voltage processes (MIG and flux cored).

In the mid- and late-90s, all of the major welding equipment manufacturers introduced multiprocess CC/CV inverters that delivered excellent arc characteristics and arc performance in all processes. The breakthrough came with the development of high-speed power switching transistors (IGBTs) and micro-controllers that could create, adjust and optimize the welding output thousands of times per second.

The smallest of these inverters typically provides a 300 amp output (at 60 percent duty cycle), weighs 70 lb to 80 lb and are about the size of a large carry-on suitcase. However, they also require a separate wire feeder, which itself weighs 25 lb to 40 lb. While more portable than the 400 lb behemoths they replaced, operators still have to manage separate components.

There’s also the cost. A power source, wire feeder and mobile cart lists for approximately $6,000. Shops that can’t afford that much typically purchase two or more separate units over a period of time. Options include an “all-in-one” style 250 amp MIG welder (with an approximate list price of $2,700) and a separate Stick/TIG welder (approximately $2,400 for a 200 amp TIG/Stick inverter or 250 amp conventional Stick welder).

MULTIPROCESS: REDEFINED
Assessing the above situation, Victor Technologies (St. Louis, MO) saw the need for an inverter that combined multiprocess benefits in a package better suited to meet the demands of light- to medium-duty fabricators:

(1) A fully integrated design. The Fabricator 252i features a built-in feeder that accommodates 4 in, 8 in and 12 in diameter (44 lb) wire spools. Its front-panel controls and connections enable switching between the MIG, TIG or Stick processes in seconds.

(2) Portability and power. The Fabricator 252i has an output of 5 amps to 300 amps (250 amps at 40 percent duty cycle, the industry’s standard rating for this class of welders). Its dimensions (H 17.32 in x W 10.23 in x D 23.62 in) are similar to a 250 amp MIG-only welder, but it weighs just 66 lb, which is 140 lb lighter.

(3) Affordability. With a base MSRP of $2,509, the Fabricator 252i costs slightly less than a 250 amp MIG-only unit. A “deluxe system” (power source, TIG torch, spool gun and two-cylinder cart) has an MSRP of $3,839.