“Welding” includes many different processes and systems.
MIG (Metal Inert Gas) welding involves the use of spools and MIG welding guns. This welding process is very good for both steel and aluminum. It can handle any material from sheet metal to up to 1/4 inch thick. According to the settings, MIG welding uses inert shielding gas (we use a mixture of 75% argon and 25% CO2).
The flux cored arc welding (FCAW or FCA) process requires a continuous supply of consumable hollow electrode with a flux core. No protective gas is required for this process. The flux actually produces a gas that protects the arc during the welding process. Among all welding processes, we think this is the most portable. It can handle outdoor windy conditions, uses less power, and is easier to master.
Tungsten inert gas (TIG) welding, also known as gas tungsten arc welding (GTAW), uses non-consumable tungsten electrodes. This is paired with a separate consumable filler rod and uses an inert protective gas such as 100% argon. TIG welding generates less heat than MIG and is very suitable for light metal alloys.
Bar welding is the most basic type of arc welding, using consumable electrodes. You heat it and the workpiece until they melt-welding the two parts together. The welding rod is coated with flux to protect the weld from contamination. This type of welding generates a lot of heat. Therefore, bar welding is very suitable for heavy-duty applications where thicker or heavier metals are joined together. Bar welding also leaves a large amount of slag deposits on the top of the weld. This requires chipping or tapping with a hard wire brush.
The setup of the welder starts by going to Home Depot to get the correct 240V socket. We have a dedicated 240V power supply, but it requires an updated 4-pin plug. Although the Forney 220 multi-process welding machine is converted to operate at 120V, the greater the input power, the greater the output power. We want to increase the duty cycle of 240V.
After converting our 4-pin socket to Forney’s preferred 3-pin version, we stopped at the local welder supplier. We took some E6011 and E6013 electrodes (for rod welding). Next is a roll of 0.030 steel MIG welding wire. Finally, I replaced our new 20 cubic foot empty fuel tank with a fuel tank containing 75% argon and 35% carbon dioxide.
Once we put the welder on the new trolley, we decide which welding process to start with. Since there is another wire welding machine in our shop, we think we should set it up for MIG. Don’t get me wrong, we can solder very well with flux, but gas will produce greatly improved results.
I followed the instructions to connect the fuel tank, gauges and hoses to the back of the welder. Next, I inserted a spool of 0.030 wire and installed a MIG welding gun on the front of the welding machine. It is important to note that the correct polarity is used in the MIG welding process. In our case, the positive electrode of the DC electrode meets the requirements.
Next, I turned on the welding machine and pressed the trigger on the MIG gun to feed the welding wire into the welding tip. From here, gas pressure, voltage, and wire feed adjustments need to be matched to the application. Although the welder has an easy-to-read digital front LCD display, you must manually adjust all settings. In general, setting up the welder seems fairly simple. Anyone who is accustomed to MIG welding will find that the settings and dynamic adjustments of the Forney 220 MP welder are very simple.
Our audit welders are also equipped with optional TIG settings, including TIG welding torches and foot pedals. In this review, we only tested the MIG and Stick welding functions.
In the Pro Tool Review store, we always have small items and things that need to be repaired. On our best impact driver test bench, we found that the original model had some design issues. Even if we clamp it on the table, the rig still bends under the heavy load we put on it.
The existing drilling rig consists of a three-foot-long 5 x 5 x 5/16 inch thick angle steel structure. To create a more stable base, I cut two 12-inch pieces of the same angle steel to create a base. This will stabilize the rig when using our torque multiplier to set a specific high torque value on the nut.
As with any welding operation, we first clean and prepare our workpieces. I used a grinder to remove a layer of galvanized steel in all the areas I planned to weld. I also made sure to clear an area for my ground clamp to ensure good continuity.
I started welding some scrap steel to make sure I could dial in my weld before starting the real project. It is very easy to set the feed and voltage. Forney provides you with a handy playboy chart on the cover to let you know what you might be trying to do. After setting up based on these numbers, I dialed it further while processing the test material.
The dial on the front of the Forney 220 multi-process welder is large and easy to adjust. This is also true when wearing thick leather welder’s gloves. The large and bright LED readings can also be easily read while you are working. I don’t have to go back and forth too many times to set it up correctly. Crude steel is almost beyond the capacity of the 0.030 wire I chose. Even so, I found it took more time and patience to fix the new bracket bracket to the bottom of the torque test bench. I got clean welds and sufficient penetration of the base metal. I also noticed a large amount of packing accumulated at the joint.
In order to test the bar welding, I did not complete the top welding and switched the mode. In view of the heavier material of the test bench, bar welding proved to be the ideal choice for joining two components together. Using the Forney 220 MP multi-process welding machine, I only need to install the electrode leads and ground clamps into the correct terminals. Then I installed one of the E6011 electrodes into the electrode holder. When connecting the ground clip and electrode lead to the front of the device, be sure to set the electrode polarity correctly.
Using the watch face, I set the appropriate amperage setting for my project. After doing more sanding of the flap to prepare the area, I started welding. Since we only had short welds on this project, I did not encounter problems with welders’ work cycles. Once I glanced at the chart inside the machine, dialing in the appropriate amperage was also easy. Once I got a sense of what the welder wanted to do, I added a little current.
One of the most impressive moments of our experience with the Forney 220 MP was when welding stainless steel. We decided to test the welder in 120V mode when welding stainless steel downpipes. To set up Forney for MIG, we changed the power cord to 120V and started welding. To our delight, the system automatically switched on the power supply and solved our small pipeline reinforcement project without hesitation or effort. Using this method, we were able to preemptively strengthen a known problem with Volkswagen stainless steel pipes.
Welding is one of the few industries that leaves most of the results of the final product to the user. Learning to solder is a skill that requires a lot of practice. With experience, dialing in settings and understanding materials becomes second nature. In our shop, we only make and repair occasionally. It really makes sense to have a multi-process welder around. First, it saves a lot of space. Second, it provides a lot of flexibility in what we can build or fix. Finally, it provides portability because we might throw it behind a truck with a generator and perform some repairs on site.
We think this welding machine provides an ideal solution for various users. At about $1145, we found it to be a very compelling product. Check this and other products on the Forney Industries website.
When he is not remodeling part of the house or playing with the latest power tools, Clint enjoys the lives of her husband, father, and avid reader. He has a degree in recording engineering and has been involved in multimedia and/or online publishing in one form or another for the past 21 years. In 2008, Clint founded Pro Tool Reviews, followed by OPE Reviews in 2017, which focuses on landscape and outdoor power equipment. Clint is also responsible for the Pro Tool Innovation Awards, an annual awards program designed to recognize innovative tools and accessories from all walks of life.
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Post time: Jun-08-2021