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WELDER GENERATORS: How They Work + How They’re Used

The beauty of a welder generator is that it’s independent of outside power sources, so you can use it where power isn’t available. Typically, if you need power to weld at a worksite that’s off-grid, you need to bring both a generator and a welder. Let’s look at how a welder generator works and how it’s used.

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How Does a Welder Generator Work?

A welder generator features an internal combustion engine powered by diesel, gasoline or propane. The engine generates electricity that powers the welder via an alternator that converts mechanical energy into electricity. The alternator works by virtue of its rotor and stator. When the engine turns the rotor, it induces electrical current in the stator through the process of electromagnetic induction. The resulting electrical output is typically an alternating current (AC). The voltage and frequency of the output varies with the model of a specific welder. However, voltage is typically in the 120–480V range and frequency is typically in the 50–60 Hz range.

The welding system on a welder generator is the other major part, usually the big reason for acquiring a welder generator in the first place. The welder usually includes a rectifier, which is a critical part because it converts AC current from the generator into direct current (DC), which is usually preferred for welding because it gives a welder operator more control over the process. As for the welder output, the operator adjusts the DC power to preferred voltage and current levels to maximize control over the welding process and product. Optimal voltage and current levels vary by the type of welding you’re doing. Stick (SMAW), TIG (GTAW) and MIG/MAG (GMAW) welding techniques each call for different settings for ideal control and results.

How Is a Welder Generator Used?

The short answer is “widely.” The blend of power and welder in one unit makes a welder generator super convenient, so it’s the welder of choice in many environments: agriculture, construction, disaster response and mobile maintenance and service.

Agricultural

In agricultural settings, welder generators are great for repairing equipment and fences and more–quickly. A welder generator can be transported easily into a field or wooded area to repair something critical and thereby keep a daily production schedule on track.

Construction

In construction settings, generator welders are commonly used for fabricating and modifying structures and for large and small repairs. Again, a welder and power source together in one piece of equipment delivers a lead over a typical welder accompanied by a separate generator. If you need a welder to work a new building that’s not wired, a welder generator is best, hands down.

Emergencies

Disaster response is another area where a welder generator shines, especially if both power and repair are urgently needed. A welder generator can provide power not only for welding and other tools used for repairing damage, but also for lighting, which is critical during a storm that happens in the dead of night.

Mobile Service

Mobile maintenance and repair services are another environment for the use of generator welders. They can be used for quick fixes, as well as major infrastructure repair and modification. When a client can’t bring a large piece of equipment into a shop, a mobile service with a generator welder can show up on location to repair or maintain that equipment.

If you’re considering acquiring a generator, it would be well worth your time to check out welder generators. If you anticipate working off-grid even a few times, and you don’t have a generator, or if you prefer to work outdoors away from a power source, a generator welder is probably a great choice for you.