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Joined: Oct 2002
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I read the thread on selecting a wire feed welder. I really appreciated the comments about gas versus wire w/ flux. I am also considering buying one, and wonder what everyone thinks about buying the 135 amp 110 volt models versus the 220 volt 175 amp?


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I have a Millermatic 135 110 Volt unit and have been very pleased. Great for body work and lighter welding----maybe up to 3/16". For heavier would Rx a 220 unit.

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I used my 220V welder quite a bit this last weekend on light guage steel (I narrowed up some light weight pallet racking) and it worked very nice with the .035 wire and low current. The last time I used it I was welding up 1/4" steel plate for grate frames just before I poured my shop floor. It is nice to just be a couple clicks on the current setting away from laying into some thick metal vs welding a seam in 12 guage sheet metal. I am using CO2+Argon mix with solid wire on a Sears Craftsman welder made by Miller. It is the equivalent to a Millermatic 250 I believe. smile

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Ok, lets get a little technical here. 110 AC has a single wave that goes back and forth. The MIG has a transformer that converts it to DC. 220 AC has two waves that are transformed into DC. Being the two waves intersect as they go back and forth they have this average that is more constant. Thus, the 220 welder is a more controled welder. It will not be as effected by dirty metal and will provide a better weld. If you really want an awsome welder, go three phase, then you have three waves that have a much more constant intersect. You can weld through just about anything. I got spoiled at the last shop I worked at. We had an Arco Three phase 240 that was incredable.

Now, that being said, I use a Millermatic 135 at work nearly every day and it really does do a nice job for us (we have three of them). DO NOT EVEN THINK of using flux core. The money for the gas is CHEAP vs how much better it works.


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MartinSr, I was curious about preheating thicker metal if you are using a miller 135, That is what I have and I love it. Does preheating give you a better weld?

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Ive got a 110volt 140 amp MIG, and have welded up to 1/4" with it. I've built trailers, done frame mounts, suspension, sheetmetal and everything else that I've wanted to. I have yet to wish for a 220 unit. Besides, it rolls around the yard and I have more 110 outlets than 220 ones grin


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Uhhhh Martin Senior . . . single phase is single phase regardless of voltage. The 220Volt AC voltage in your circuit breaker panel at home yields a single phase-to-phase 60 Hz sinewave. It looks the same as the sinewave that you get when you go from one phase leg to neutral to yield 110V except that it has twice the amplitude - which by new math and old math = 220V. grin

The AC is stepped down through a single phase transformer and run through a big honking (technical lingo for High Current capacity) diode bridge. :p This is typically a full bridge diode device that gives a DC waveform with a 60Hz ripple.

A 3-phase source has a 120 degree ripple with a higher RMS voltage value due to the fact that the peaks of the summed sinewaves are only 120 degrees apart (5.55 msec) vs being 360 degrees apart (16.67msec). You could smooth the ripple using big honking bus capacitors, but I don't think they do that because they would source so much current when you struck an arc that it would blow a hole in your metal or vaporize your rod - in other words, you would need a big honkin inductor to limit the current surge at the welding arc and this would need to be adjustable and bla bla bla - ie it is easier to simply run with a diode bridge and the 60Hz ripple or 120Hz ripple . . . in the end, you have to ask yourself, does the arc really care? I don't think so. . .

The big advantage of 220V is that you pull 1/2 the line current to get the same amount of weld current. You have less of a copper mine in the box for the same duty cycle . . . but beings copper is cheap, you typically have the same amount of copper but twice the duty cycle. . .

Advantage of 110volt wirefeed? Plug it in anywhere just about . . . typically smaller because duty cycle is less . . . cheaper, etc.

But like a chainsaw or an aircompressor. If you plan on using it regularly on a broad range of applications . . . bigger is better! wink

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Rusty,
I'm not aware of any reason to pre-heat on mild steel.
I've welded 3/8" mild steel using my 110 licoln-100 then did a bend test at school and had no problems.

At work we sometimes weld with the higher carbon steels (T-1) and there is pre-heat procedures you must follow to prevent ripping and such.

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The fact of the matter is no matter what you intend to do with the welder now, later you will want more. I think I can say everyone here does most work themselves. The great thing about the 110 is that you can take it anywhere and plug it in. If you get the 110 get the largest amp possible for the budget. Some may disagree but sooner or later you will run across a situation where you will need more, and you will wish you bought the bigger of the two. Once you have a welder you will want to weld everything you can get your hands on.

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you have got to like that tech lingo. (engineering)


Yes, officer it's licensed.

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