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You are here: Home / Home Electrical Circuits / Mini Welding Machine Circuit for Small Welding Jobs

Mini Welding Machine Circuit for Small Welding Jobs

Last Updated on December 8, 2020 by Swagatam 30 Comments

A small transformerless welding machine circuit can be built using a few high voltage, high value capacitors and a rectifier diode, the following article explains more on it. The idea was requested by Mr. Tun.

In one of my earlier posts we came across a full fledged 100 amp SMPS welding inverter circuit for working with reasonably bigger joints and metals.

The Design Concept

Being an SMPS based design and involving high power specs, the above circuit is complex and may be out of the reach of the new hobbyists.

As requested by Mr.Tun a homemade small scale welding machine circuit is what most of the new hobbyists and mechanical engineers would be looking at for solving their occasional work bench metal welding jobs.

A mini welding machine without using complex circuitry could probably be built using a capacitive power supply as shown in the following diagram:

mini welding machine without using complex circuit using a capacitive power supply

The idea shown above is an ordinary capacitive power supply circuit incorporating extreme capacitors in terms of their values.

Circuit Operation

At the input side we can see a formidable 500uF/400V capacitor, while on the output side also a similar rated capacitor can be seen positioned for reinforcing current.

The most basic parameter essential in a welding system is a high current, so that an extremely high temperature can be formed at the short-circuit junction, over the metal joint in question.

This high current generation can be achieved either by using a high watt transformer or an SMPS version of the same which we discussed in the first paragraph.

A transformer could be too bulky and heavy, while the SMPS circuit too complex for the newcomers, the only alternative way to achieve the high current welding through a relatively simpler design is perhaps by employing the high current capacitive power supply as shown above.

The 500uF/400V capacitor can be expected to generate bursts of current upto as high as 36 amps @ 220V, and reinforced with the complementing output filter capacitor this current can be expected to do some serious welding actions.

You can verify the above mentioned specs by using the following two calculator software:

Reactance Calculator

Ohm's Law Calculator

The shown push button enables the user to achieve the welding job through shorts bursts, and not through a continuous arcing, which can be dangerous, and anyway is not recommended in welding operations.

The input 500uF/400V capacitor looks massive and it might not be readily available in the market, therefore this can be built by using 500 numbers of 1uF/400V PPC capacitors wired in parallel, this could occupy some space, but still the method is easily achievable.

Use Non-Polar Capacitors

This capacitor needs to preferably a non-polar capacitor, however since a diode is positioned in series means an electrolyte capacitor could also serve the purpose without issues.

The second capacitor at the output side can be an electrolytic type for sure.

For more current, the values of the caps could be increased to higher limits, that's the only parameter that needs to be focused on.

CAUTION: The mini welding machine circuit explained above is not isolated from mains and has the potentials to kill a person within seconds, therefore extreme caution is advised while handling this equipment in the powered condition.




Previous: Make this Crystal Radio Set Circuit using No Batteries
Next: Single Phase Jet Pump Controller Circuit

About Swagatam

I am an electronic engineer (dipIETE ), hobbyist, inventor, schematic/PCB designer, manufacturer. I am also the founder of the website: https://www.homemade-circuits.com/, where I love sharing my innovative circuit ideas and tutorials.
If you have any circuit related query, you may interact through comments, I'll be most happy to help!

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  1. Search Related Posts for Commenting

  2. Sabbir says

    Mini welding machine
    2 capacitors 500uf 400v
    1 capacitors 500uf 400v ppc
    1 capacitors 500uf 400v none poler capacitors
    1 capacitors 500uf 400v electrolyte capacitors
    Please tell me two capacitors name
    How to make 50amp diode

    Reply
    • Swagatam says

      Capacitors don’t have names, only specifications which you have already mentioned in your comment. The input side is non-polar and the output side is polarized.

      Reply
  3. Sabbir says

    Capacitors name please

    Reply
  4. Patrick says

    I made an arc welder off 2 microwave transformers. I love the output (but can’t tell the exact amps).
    What I’m looking to do I see make an amp-regulator that would enable me to comfortably weld thin automotive sheet metal. Please help me with a circuit layout to add to my welder and achieve the results.
    Thanks.

    Reply
    • Swagatam says

      The only way to limit current in a high current AC system is by adding resistive load in series. You can probably add a 2000 watt heater coil in series, or as per the specs of the welding machine

      Reply
  5. Satish D. Naik says

    Sir, Can you please give me a simple transformerless welding inverter circuit with 230v AC input for arc welding of small jobs, brcause in the above circuit description, it is mentioned for short burst of current and not for continuous arc welding.

    Regards,
    Satish Naik
    +91-9590018250

    Reply
    • Swagatam says

      Satish, an SMPS welding circuit can be quite complex, I do not have an easier version at this moment with me.

      Reply
      • Satish D. Naik says

        Sir, then can I use the above circuit (Mini Welding Machine Circuit for Small Welding Jobs) for small welding jobs?

        Regards,
        Satish Naik

        Reply
        • Swagatam says

          Yes you can try it, if the power is not sufficient you can add more capacitors in parallel

          Reply
          • Satish D. Naik says

            Thanks, I will try it.

            Regards,
            Satish Naik

            Reply
  6. Abba says

    thanks a lot
    what is the used of the capacitor the one in series with the mains? if its only function is to provide small constant current then why don’t we use a fuse instead?

    Reply
    • Swag says

      Abba, fuses are not designed to suppress current they are designed to blow off as soon as the rated current is exceeded through them. A Capacitor cannot be compared to a fuse

      Reply
      • Abba says

        thanks a lot for the reply

        Reply
  7. Abba says

    sometimes I hear electronics student say their capacitor exploded, though I never encountered such a situation but I really want to know the cause and how to prevent that from happening. am referring to the capacitor used in transformerless power usually connected in parallel with resistor in AC lines.

    Reply
    • Swag says

      Capacitor will blow when the the supply voltage across its terminals exceeds the printed breakdown voltage value. In transformerless power this may happen due to sudden current surge when the capacitor is unable to stop the rise in voltage and bursts, a resistor and zener network will normally prevent this situation.

      Reply
  8. dennis rollo says

    HI SWAG how to make this as adjustable current

    Reply
    • Swag says

      Hi dennis, you can put different ranges of capacitor from 100uF to 500uF and add a selector switch to chose from them….

      Reply
  9. Chunyelu says

    Pls sir,is there any chances of electrocution as this circuit is not isolated with transformer.

    Reply
    • Swag says

      yes definitely there is…even in transformer based welding machines you will have this danger

      Reply
  10. Unknown says

    Hi sir please show how to make a 0-40v 0-3a smps

    Reply
    • Swagatam says

      you can try the following concept

      https://homemade-circuits.com/2017/06/12v-2-amp-smps-circuit.html

      the Rfbb can be changed for getting different voltages at the output

      Reply
  11. Swagatam says

    Hi tun, I do not have asn SMPS version at the moment, however you can build an iron core based auto-transformer for the achieving the results

    Reply
  12. Tun says

    Hi sir,i need to show me how to step down 230VAC/2A to 150VAC/2A

    Reply
    • Smartdude says

      You should put the 230v line wire on top of the step, and depending the number of taps each one will have a specific voltage drop (230v/no.of tapping). The last one is at the lowest level and should be connected to ground. The output you take it from the desired step and the ground.

      Reply
  13. Jeremiah Michael Rebello says

    Hey there,, I have a 470uF 250v cap,, can I use it?
    Also what is the component no for 50A diode.? I have 5A diodes, can I put 10 in parallel to achieve 50A??

    Reply
    • Swagatam says

      470uF/250 can be tried and will work as long as the input voltage does not exceed the 250V mark.

      please search online regarding "50amp diode" you will be able to find a suitable one.

      5A diodes in parallel will not help, and is not recommended

      Reply
  14. Ali says

    Hi dear,
    thanks for your best site,
    Inpute voltage is 220 v? How can i use it ?like a welding machine to connect output?
    Can melt Iron?
    Thank you

    Reply
    • Swagatam says

      Thanks Ali!

      This circuit won't melt iron but join iron with the help of welding rod.

      just connect the iron which needs to be joined with one of the output terminals, and the other output terminals with a welding rod, now touch the welding rod end at the point on the iron which needs to be fused…

      Reply
    • Ali says

      Thanks Swagatam,
      input is 230 V AC?
      560uf 450v can i use?
      what is the model 50amp diode?
      50 amp push is a fuse?
      thank you

      Reply
    • Swagatam says

      yes will do.

      50 amp diode is required for rectification.

      the 50amp push is a push button which is required to be pushed and released while operating the power supply

      Reply


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