Yeah old rods are usually absolutely terrible to weld with, because they tend to stick and freeze no matter how hot you get them...
And yes, MIG is about as easy as it gets. It's literally a point-and-click interface. If you can play Tremulous with any decency, you can run a MIG.
This is some of the SMAW I worked on earlier today:
It's not as pretty as a comparable TIG weld, but that's just the nature of stick welding:
You will know when you're stick welding correctly when you're laying a nice straight bead, and the arc itself is nice and tight - giving off a sweet hissing and crackling sound like it's literally burning.
Welding is just such fun, lol.
As for the project I'm working on, I'm going to be building a 24kW solid-state switch-mode power supply for experimental use... although I have absolutely no justification for making something capable of handling 24,000 watts (48,000 surge for 10 seconds
) other than the fact that I
love the brute force side of electric power, it's something I've wanted to do for a long time.
The design will be capable of outputting continuously variable voltage from 0-240VAC, or 0-350VDC at anywhere from 0 to 100 amps continuously... 200 momentarily for about 10 seconds. It will have a manual (unregulated) control input for setting precise AC voltage, and an automatic (regulated) control input that *should* be able to regulate DC volts, as well as AC and DC amps. The unit will have absolutely no transformers or computers inside of it, except for the main cooling blower, and a few of the self-contained SMPS units powering the controls.
This is
about what it will look like when it's finished... there have been some minor changes since that sketch was made, but the aesthetics are almost the same. All measurements are in feet and inches because 'Muricah.
It will use 10 of these
mean little Fuji IGBT transistor modules to switch line voltage AC... each one of them has 6 individual transistors inside (wired in 3x2 parallel-series) that are rated for 100 amps at 600 volts each (adding up to a total of 300 amps at 1,200 volts across the positive and negative bus terminals). I managed to find a bunch of them on E-bay for $13 each.
Because these just happen to be three-phase transistor modules, I should be able to convert the unit to operate on three-phase power instead of standard North-American split-phase if I ever so desire.
And yes, this is going to cost me a lot in parts and aluminum... but this is a project that I have been looking forward to and saving for for some time now.
Since we're speaking of welding, this unit could probably pull off a few beads just for show if I found a suitable current-limiting device now that I think about it. XD