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Step 1
Consider your current and future welding needs. Even if you're initially buying a welder to fix a small crack in your outdoor grill, you may still want to consider opting for a heavier-duty welder if you anticipate larger-scale jobs in the future. Generally speaking, metal 1/4-inch-thick or thicker requires a heavy-duty welder, whereas you can get by with a hobbyist's welding kit for thin sheet metal.
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Step 2
Consider the material you'll be working with. For ferrous metals such as steel, you'll want to get a Shielded Metal Arch Welder or Gas Tungsten Arch Welder---also known as SMAW and GTAW units, respectively. For nonferrous metals like aluminum, a Gas Metal Arc Welder works best---this type of welder is also known by its acronym: GMAW.
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Step 3
Use the appropriate power source. For smaller welding jobs, a low-cost AC-powered welder will do the job. For a larger, heavy-duty job, go with a welder relying on DC power. DC welders cost more, but typically offer better output and deeper heat penetration. In addition to AC versus DC powering, you should also consider how much energy the welder uses, making sure you do not get one too big for your workshop's power supply---the last thing you need is a blown circuit because you plugged a huge welding unit into a small power supply.
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Step 4
Research Duty Cycles. When purchasing a welder, the thickness of the project is not the only determining factor; you also need to know how long the project will take. Ask a sales clerk to help translate the Duty Cycle rating for individual welders; the Duty Cycles represent how long a welder can stay active before needing to cool off.
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Step 5
Talk to experts. Discuss your welding needs with a salesperson or a local, experienced welder for further guidance.
