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Welding Duty Cycle Explained: Why It’s One of the Most Important Specs to Understand

Posted on 27/05/2025

When browsing welding machines or reading a spec sheet, you’ll often see figures like “60% @ 200A” or “100% @ 160A.” These aren’t just numbers—they’re critical to how your welder performs and lasts.

A welding duty cycle describes how long a welder can operate at a given amperage within a 10-minute cycle without overheating. For example:

• A 60% duty cycle at 200 amps means the machine can weld for 6 minutes continuously at that current, then must cool down for 4 minutes.
• A 100% duty cycle at 160 amps allows continuous welding with no pause required.

Why Does Duty Cycle Matter?

Ignoring duty cycles can result in:

• Thermal shutdowns that interrupt workflow.
• Premature equipment failure.
• Inconsistent weld quality.

For workshops aiming to improve efficiency, safety, and machine longevity, understanding duty cycles is essential.

Factors That Influence Duty Cycle

Several factors affect a welder's duty cycle:

• Ambient temperature: Ratings are typically based on 40°C environments—cooler conditions may improve performance.
• Machine size and cooling systems: Fan-cooled or water-cooled systems tend to have better duty cycles.
• Power source type: Inverter-based machines often offer better duty cycles than transformer-based units.

How to Choose the Right Welder Based on Duty Cycle

1. Assess your average welding time and amperage needs. If you're welding high-current jobs back-to-back, look for a welder with a high duty cycle.
2. Don’t just buy the biggest machine. Overspending on amperage you won’t use wastes budget.
3. Match machine performance to task type. For example, intermittent TIG work on stainless steel has very different demands than long MIG welds on thick mild steel.

Common Myths

• Myth: “100% duty cycle means better quality.”
  Truth: It means better thermal performance at a specific amperage—not necessarily better welds.
• Myth: “Duty cycle doesn’t matter for occasional users.”
  Truth: Even hobbyists can trip thermal overloads if they don’t know what the cycle is.

Duty cycles aren’t just a technical detail—they’re vital to productivity, safety, and machine life. Whether you're welding daily or just starting out, make sure you're matching your machine to your workload.

Need help picking the right welder for your needs?
Visit our showroom, explore our online range, or speak to one of our experts for advice.
Machine in images --> https://weldingsuperstore.co.uk/ex-demo-telwin-inverpulse-425-mig-aqua-package.html

The 4 Main Types of Welding Explained: MIG, TIG, Stick and Flux-Cored

Posted on 19/05/2025

When it comes to welding, choosing the right process is essential for ensuring the strength, appearance, and efficiency of your weld. Whether you're just getting started in the industry or looking to expand your knowledge, understanding the differences between the main types of welding is crucial.

In this article, we’ll explore the four primary types of welding: MIG, TIG, Stick, and Flux-Cored. We’ll break down how each works, their pros and cons, and the best applications for each process.

MIG Welding (Gas Metal Arc Welding – GMAW)

How it works:
MIG welding uses a continuously fed wire electrode and shielding gas to create a weld pool. The wire melts and joins the base materials together.

Best for:

• Mild and stainless steel
• Aluminium
• Sheet metal and automotive work

Pros:
 ✅ Easy to learn
 ✅ High productivity
 ✅ Cleaner process compared to stick

Cons:
 ❌ Requires shielding gas
 ❌ Less effective outdoors due to wind

TIG Welding (Gas Tungsten Arc Welding – GTAW)

How it works:
TIG welding uses a non-consumable tungsten electrode and a separate filler rod. An inert gas (usually argon) protects the weld area from contamination.

Best for:

• Stainless steel
• Aluminium
• Thin metals and clean, cosmetic welds

Pros:
 ✅ Precise and clean welds
 ✅ No spatter
 ✅ Excellent control

Cons:
 ❌ Slower process
 ❌ Requires high skill level
 ❌ Not ideal for thicker materials

Stick Welding (Shielded Metal Arc Welding – SMAW)

How it works:
Stick welding uses a consumable electrode coated in flux. When melted, the flux creates a shielding gas to protect the weld from contaminants.

Best for:

• Outdoor work
• Construction and repair
• Rusty or dirty metals

Pros:
 ✅ Works well in harsh conditions
 ✅ Inexpensive equipment
 ✅ No need for external gas

Cons:
 ❌ More cleanup due to slag
 ❌ Harder to learn for beginners
 ❌ Less precise than MIG or TIG

Flux-Cored Arc Welding (FCAW)

How it works:
Flux-cored welding is similar to MIG, but the wire has a flux core. This creates its own shielding gas as it burns, allowing for outdoor use.

Best for:

• Structural work
• Thick materials
• Outdoor fabrication

Pros:
 ✅ Suitable for windy environments
 ✅ High deposition rate
 ✅ Ideal for thicker metals

Cons:
 ❌ Produces slag
 ❌ Can be messy without good technique

Each welding process has its own strengths and weaknesses. The right choice depends on your project, environment, material type, and skill level.

At Welding Superstore, we supply equipment for MIG, TIG, Stick, and Flux-Cored welding, along with expert advice to help you find the right tools for the job.

If you’re looking to learn more or upgrade your setup, get in touch with our team today.

Welding Fumes: The Hidden Danger in Your Workshop – And How to Protect Yourself

Posted on 12/05/2025

Welding is a craft built on precision and power—but it also hides a less visible threat: welding fumes. Whether you're a seasoned professional or a weekend fabricator, understanding what’s in the air around you could be the difference between a healthy career and chronic illness.

In this article, we’ll break down:

• What welding fumes are
• Health risks associated with exposure
• Legal responsibilities under UK law
• Practical steps to protect yourself and your team

What Are Welding Fumes?

Welding fumes are a complex mixture of metal particles and gases released during welding processes like MIG, TIG, MMA, and plasma cutting. These fumes vary depending on the materials and consumables used but may include:

• Iron oxide
• Hexavalent chromium
• Manganese
• Nickel
• Zinc oxide (especially when welding galvanised materials)

Health Risks: Short-Term and Long-Term Exposure

Short-term exposure may cause:

• Irritation of the eyes, nose, and throat
• Nausea and dizziness
• Metal fume fever (common with zinc exposure)

Long-term exposure has been linked to:

• Chronic bronchitis
• Decreased lung function
• Neurological damage (due to manganese)
• Increased risk of lung cancer (especially from stainless steel welding)

The Legal View: What the HSE Says

In the UK, the Health and Safety Executive (HSE) has issued strict guidance following research by the International Agency for Research on Cancer (IARC) classifying welding fumes as a Group 1 carcinogen.

As of 2019, there is no safe level of exposure to welding fumes, and all employers are legally required to provide effective controls—including fume extraction and respiratory protective equipment (RPE).

How to Stay Safe: Workshop Best Practices

1. Use LEV (Local Exhaust Ventilation)
   Systems like mobile fume extractors and arm-mounted units capture fumes at the source.
2. Wear the Right Respiratory Protection
   RPE such as PAPR (Powered Air Purifying Respirators) helmets protect when fume capture isn’t enough.
3. Improve General Ventilation
   Ensure your workshop has good airflow and air changes per hour.
4. Monitor Air Quality
   Use air quality testing or HSE’s COSHH guidance to assess whether your setup is adequate.
5. Educate Your Team
   Safety training should include fume awareness and PPE usage.

How We Can Help

At Welding Superstore, we supply a wide range of Kemper fume extractors, PAPR helmets, and other safety solutions. Whether you're upgrading your current system or setting up from scratch, our team can help you meet safety regulations and protect your health.

Welding fumes aren’t always visible—but the damage they cause can be life-changing. Investing in the right equipment and education is the smartest move any welder or workshop manager can make.

Need advice on fume extraction or PPE?
Get in touch with our team on 01952 290800 / sales@weldingsuperstore.co.uk  or browse our Kemper fume extractor collection.

Stock Up and Save on Workshop Consumables – Bulk Deals Available Now

Posted on 06/05/2025

Keeping your workshop running smoothly means having the right consumables on hand when you need them.

Keeping your workshop running smoothly means having the right consumables on hand when you need them. That’s why we’ve created a dedicated Workshop Consumables promotional category at Welding Superstore – making it easy for you to stock up on the essentials and take advantage of bulk buy offers that save you time and money.

What’s in the Workshop Consumables Range?

Whether you’re working in a fabrication shop, garage, manufacturing environment or doing site work, consumables are the unsung heroes of the job. Our Workshop Consumables category includes a wide range of must-have items, all available at competitive prices:

• Non-Woven Hand Pads – Ideal for surface preparation, blending, and finishing without altering the base material.
• Action Can Aerosols – A popular range including AC-90 Multi-Purpose Lubricant, cutting fluids and degreasers to keep your tools and materials in top condition.
• TIG Welding Rods – Quality filler rods for aluminium, perfect for precision welding work.
• Mag Drill Hole Cutters – Essential for clean, accurate cuts when working with magnetic drill systems.
• Nitrile Gloves – Durable and chemical-resistant, nitrile gloves are ideal for keeping hands protected during messy jobs.
• Cutting Discs – Stock up on discs for cutting through steel and other metals – available in a range of sizes.

These are the everyday items your team uses constantly – so it makes sense to buy smart and keep your supplies topped up.

Bulk Buy Offers – Bigger Quantities, Better Value

To help workshops reduce downtime and cut costs, we’re also running bulk buy deals on some of the most-used cleaning and maintenance products:

• Blue Roll – Strong, absorbent and ideal for mopping up oil, grease and spills in any workshop or garage.
• Mixed Cleaning Rags – An affordable solution for general-purpose cleaning, wiping, and spill control.
• Multi-Use Wonder Wipes – Perfect for cleaning hands, tools, and surfaces quickly and easily without water.

Buying in bulk not only brings down the unit cost – it also means fewer last-minute trips for supplies and a more efficient workflow.

Found another product you require in bulk? Send us an email and we’ll see what we can do sales@weldingsuperstore.co.uk

Why Choose Welding Superstore?

With years of experience supplying to the welding and fabrication industries, we know how important it is to get quality products fast. Our workshop consumables are carefully selected from trusted brands to deliver reliability, performance, and value.

We also offer next working day delivery on UK Mainland orders placed before 3pm (Mon–Thurs), and our team is on hand to help with product advice or order queries if you need a hand.

Shop the Workshop Consumables Category

Whether you're restocking the basics or looking to take advantage of our latest deals, head over to the Workshop Consumables category now to see what’s on offer:

 Browse the full range here

Telford & Surrounding Areas: Stock Up on BBQ Gas Before the Good Weather Disappears!

Posted on 29/04/2025

As temperatures rise and outdoor events become the highlight of the season, securing a reliable gas supply is more important than ever. Whether you're hosting a family BBQ or preparing for garden parties, having the right gas bottle ready to go makes all the difference.

At our Telford showroom, we’re fully stocked with Leisure (Propane) gas and Gaslite cylinders — available in multiple sizes to suit all needs. Collection available directly from our premises:

Welding Superstore
Enterprise House
Stafford Park 1,
Telford
Shropshire
TF3 3BD

Don't let an empty gas bottle bring your plans to a halt. Visit us today and make sure you're ready to enjoy every last bit of the sunshine!

Frequently Asked Questions (FAQs).

 What types of gas are available?
We stock both Leisure (Propane) gas and Gaslite cylinders. Both are ideal for BBQs, patio heaters, camping equipment, and other leisure uses.

What sizes do you offer?
We offer 6kg and 11kg cylinders on the Leisure/Patio gas and we offer 5kg and 10kg on Gaslite.

What regulator do Leisure and Gaslite cylinders fit?
These cylinders fit 27mm regulators which is the regulator which is supplied with most barbeques.

Can I swap my empty bottle for a new one?
Absolutely. Bring your empty Leisure or Gaslite bottle with you and we can arrange a straightforward swap — no need to pay for a new cylinder, only the price of the gas.

How do I know which gas type I need for my BBQ or heater?
Generally, Leisure (Propane) gas is the standard for outdoor appliances due to its ability to work well even in colder temperatures. If you need help choosing, our team is just a phone call away.

The Go-To Argon Cylinder for On-the-Go Welders

Posted on 22/04/2025

Welding Superstore’s shelves are looking sharp with our latest restock of 100% Pure Argon Disposable Gas Cylinders – the perfect solution for small jobs, quick repairs, or portable welding tasks. Whether you’re a hobbyist, mobile welder, or simply working in a compact space, these cylinders provide a reliable, fuss-free gas supply without the hassle of industrial tanks.

Designed for TIG and MIG welding on aluminium and stainless steel, our premium Argon cylinders deliver up to three times more usage than standard disposable options, giving you maximum performance and value for money. With a lightweight, portable design, these cylinders are easy to handle, transport, and store – ideal for on-site work or workshops with limited space.

Why Choose Disposable Argon Cylinders?

• 100% Pure Argon for clean, high-quality welds
• Extended usage time – up to 30 minutes at 6 LPM
• Compact and portable – no need for heavy gas bottles
• Fits most disposable gas regulators
• Durable steel construction with a stable plastic base
• Fully compliant with EN 12205 TPED safety standards

Whether you're setting up a new project or need a top-up for your Zapp Permanent Jewellery Welder, we've got you covered. Don’t forget – you may need a hose adaptor kit for compatibility, also available on our site.

 Shop Disposable Argon Cylinders now
 Need an adaptor? Find it here

We also stock a wide selection of other disposable welding gases, including Argon/CO2 mixes, Nitrogen, and CO2 cylinders – ready to ship and perfect for a variety of welding applications.

Shop all Disposable Welding Gases here

Frequently Asked Questions (FAQs) About Disposable Argon Cylinders

How long does a disposable Argon cylinder last?
The duration depends on the flow rate and the specific welding task. At a flow rate of 6 litres per minute (LPM), our Argon cylinders provide approximately 30 minutes of continuous welding. Adjusting the flow rate to the minimum required for your task can help extend usage time.

Do I need a specific regulator for disposable Argon cylinders?
Yes, disposable cylinders typically require a mini regulator designed for their valve type. Ensure compatibility between the cylinder and regulator and consider using an adaptor if necessary. The suitable regulator for our disposable argon cylinders can be found here.

Can I recycle or refill a disposable Argon cylinder?
No, disposable cylinders are designed for single use and are non-refillable. After use, they should be disposed of following local recycling guidelines. Do not attempt to refill them, as this can be hazardous and is not permitted.

How should I store unused disposable Argon cylinders?
Store cylinders in a cool, dry, and well-ventilated area, away from direct sunlight and sources of heat or ignition. Ensure they are upright and secured to prevent tipping. Avoid storing them near flammable materials.

What materials can I weld using a disposable Argon cylinder?
Disposable Argon cylinders are ideal for welding non-ferrous metals like aluminium and stainless steel using TIG or MIG welding processes. They provide a clean, inert atmosphere necessary for high-quality welds on these materials.

Customer TIG Welding Setup: High-Spec Parweld Gear Collected from Our Showroom

Posted on 14/04/2025

A recent customer visit to the Welding Superstore showroom saw the collection of an exceptional TIG welding setup, showcasing a professional-grade selection of Parweld equipment—ideal for anyone serious about precision welding, especially aluminium work.

The order included three standout pieces:

Parweld XTT 212DI AC/DC Pulsed TIG Inverter Welder – This advanced dual-voltage TIG and MMA welder offers the flexibility of AC and DC output, making it ideal for welding a wide range of materials including aluminium, stainless steel, and mild steel. With high-frequency start, pulse functionality, and digital control, it’s built for those looking to achieve top-tier TIG welds in both workshop and on-site settings. Learn more here.

Parweld XR942H Panoramic Welding and Grinding Helmet – Designed for serious welders, the XR942H provides a full panoramic lens with a 1/1/1/1 optical clarity rating, True Colour lens technology, and light state 2.5 for better visibility when not welding. It’s ideal for TIG work, offering excellent arc detection and comfort during long sessions. Explore the features here.

Parweld Panther Pro TIG Welding Gloves – Created for TIG precision, these gloves provide both dexterity and heat protection with soft goat grain leather palms, reinforced seams, and a snug fit. They’re designed to give welders excellent control without compromising on safety. View the gloves here.

This customer knew exactly what they needed—and we’re fully stocked for more! Whether you’re upgrading your TIG gear or kitting out a new workspace, our team is here to help you choose the right equipment.

 Visit our showroom to get hands-on advice from the experts, or shop online 24/7 for fast UK delivery.

FAQ’S

What materials can I weld with the Parweld XTT 212DI AC/DC TIG Welder?
The XTT 212DI can weld aluminium, stainless steel, and mild steel using both AC and DC TIG functions. It also supports MMA (stick) welding.

Is the Parweld XR942H Helmet suitable for TIG welding?
Yes, the XR942H is ideal for TIG welding. It features a high optical clarity rating (1/1/1/1), True Colour technology, and a light state 2.5 for excellent visibility between welds.

Do I need special gloves for TIG welding?
Yes, TIG welding gloves like the Parweld Panther Pro offer better dexterity and heat resistance, essential for precise TIG work.

Can I buy these items online or do I need to visit the showroom?
You can do both! All products are available to purchase online 24/7 or to collect from our showroom.

Is this setup suitable for beginners?
While the Parweld XTT 212DI offers advanced features, it’s user-friendly and great for both experienced welders and ambitious beginners looking to invest in quality equipment.

Are these products kept in stock for quick delivery?
Yes, we hold stock of popular Parweld products for fast dispatch or immediate collection—check live stock status on our website.

Spring Deal Spotlight: Cutmax 150mm Portable Metal Bandsaw

Posted on 07/04/2025

If you're looking to upgrade your cutting setup this season, the Cutmax 150mm Portable Metal Bandsaw (110V) is one of the standout products in our Spring Sale, offering precision, power, and portability at a reduced price. Whether you're in the workshop or out on-site, this machine is built to deliver smooth, quiet, and highly accurate metal cutting with minimal fuss.

View Here

At the heart of the Cutmax 150mm bandsaw is a robust 1500W variable speed DC motor designed to handle demanding metal cutting tasks while maintaining a quiet operating noise thanks to its digital motor and noise reduction technology. The manual pull-down operation ensures you’re always in control, making each cut precise and consistent.

Unlike many bandsaws in its class, the Cutmax doesn’t require lubrication, making it virtually maintenance-free. Its lubrication-free cutting capability allows you to work cleaner, with less downtime, and without compromising on performance—ideal for workshops that need to move quickly between jobs.

The bandsaw’s adjustable cutting angle from 0° to 60° opens up a wide range of applications, from clean 90° cuts to more intricate angled sections. Its cutting capacity is impressive for a portable model:

• 150mm at 90°
• 90mm at 45°
• 65mm at 60°

Whether you're cutting box section, tube, or solid bar, the Cutmax 150mm handles it with ease.

The saw also includes an integrated vice, blade tensioning device, and an anti-reset safety function, ensuring both performance and operator safety are top priority. Plus, the ergonomic hand-grip and 30kg lightweight frame make it genuinely portable without sacrificing stability.

Key Specifications:

• Motor: 1500W DC, available in 240V or 110V
• Cutting Capacity: 150mm (90°), 90mm (45°), 65mm (60°)
• Blade Size: 1735 x 13 x 0.9 mm
• Blade Speed: Variable, 30–80 m/min
• Dimensions: 1000 x 430 x 495 mm
• Weight: 30 kg

Why Buy from Welding Superstore?

As part of our Spring Sale, the Cutmax 150mm Portable Bandsaw is available at a limited-time discounted price. With decades of industry experience, a reputation for expert support, and a large UK stock holding, Welding Superstore is your go-to supplier for reliable, workshop-ready equipment.

Frequently Asked Questions (FAQs):

Is the Cutmax 150mm bandsaw suitable for on-site use?

Yes, its compact design, 30kg weight, and quiet operation make it ideal for mobile use on job sites as well as in workshops.

Does this bandsaw require cutting fluid?

No—this model is designed for lubrication-free cutting, saving time and reducing mess.

What is the cutting capacity at different angles?

• 150mm at 90°
• 90mm at 45°
• 65mm at 60°

Is this model available in 110V?

Yes, this product listing refers specifically to the 110V version, perfect for site use where lower voltage is required. We also offer a 240v version which can be found here.

Can I adjust the cutting angle?

Absolutely. The Cutmax allows angle adjustment from 0° to 60°, giving you flexibility for various projects.

What safety features does it have?

It includes an anti-reset safety function, amps and temperature protection, and a stable base with integrated vice to ensure safe operation.

Ready to add precision to your workshop or site setup?

Shop the Cutmax 150mm Portable Metal Bandsaw (110V) in our Spring Sale today — while stocks last!

Cutmax 150mm Portable 110v Bandsaw | Welding Superstore

United Utilities Completes Intensive MIG Welding Training at Our Telford Showroom

Posted on 31/03/2025

We recently welcomed a team from United Utilities to our Telford showroom for an intensive MIG welding training course. Over the course of a week, 20 participants dedicated a total of 120 hours to developing their welding skills, combining in-depth theory and safety training with hands-on practical work.

We recently welcomed a team from United Utilities to our Telford showroom for an intensive MIG welding training course. Over the course of a week, 20 participants dedicated a total of 120 hours to developing their welding skills, combining in-depth theory and safety training with hands-on practical work.

The training began with essential welding theory, covering MIG welding principles, best practices, and critical safety procedures to ensure every participant had a solid understanding before moving to practical applications.

During the hands-on sessions, the trainees worked on bench welding and overhead welding, two essential techniques used in industrial and field applications. Our expert trainer guided them through each stage, helping them refine their technique, improve efficiency, and build confidence in their welding abilities.

At Welding Superstore, we take pride in supporting businesses by providing high-quality welding training and equipment. Whether you’re an individual looking to enhance your skills or a company needing to upskill your workforce, our expert-led training sessions help bridge the gap between theory and real-world application.

We would like to extend a huge thank you to United Utilities for choosing us as your training provider. We look forward to seeing how your team applies their new MIG welding skills in the field!

If your business requires professional welding training, high-quality MIG welding equipment, or expert guidance on workshop essentials, get in touch with Welding Superstore today.

Call us: 01952 290800

Email us: info@weldingsuperstore.co.uk

Visit us: Welding Superstore, Enterprise House, Stafford Park 1, Telford, TF3 3BD

Telwin Tecnica 188 MPGE: The Reliable, Compact Welder for Workshop and Site Work

Posted on 26/03/2025

Welding professionals and hobbyists alike know the importance of a machine that offers both reliability and versatility. One of our local customers recently visited our showroom looking for just that—a powerful yet compact welder that could handle everything from routine workshop tasks to site work with a generator. After discussing their needs, it became clear that the Telwin Tecnica 188 MPGE was the perfect match.

Why Choose the Telwin Tecnica 188 MPGE?

The Telwin Tecnica 188 MPGE is an MMA and TIG DC inverter welding machine designed to deliver consistent, high-performance results even in demanding conditions. Its compatibility with various electrode types—including rutile, basic, stainless steel, and cast iron—ensures that welders can tackle diverse projects with ease.

One of its standout features is the MPGE multiprotection control device, which provides exceptional stability even when connected to a motor-generator. This makes it ideal for professionals working in environments where power fluctuations are a concern.

Key Features:

• Compact and Lightweight – Perfect for on-the-go welding jobs, easy to transport and store.
• High Current Stability – Maintains steady welding output even under voltage fluctuations.
• Advanced Welding Features – Includes Arc Force, Hot Start, and Anti-Stick functionalities for optimal weld control.
• Enhanced Safety – Equipped with thermostatic, overvoltage, undervoltage, and overcurrent protection.
• Fully Equipped – Comes with MMA welding accessories and a durable plastic carry case for convenience.

Technical Specifications:

• Duty Cycle: 140A @ 25%
• Electrode Size: 1.6 to 4.0mm
• Input Voltage: 230V
• Output Current Range: 10 to 150A
• Frequency: 50/60Hz
• Fuse Rating: 16A
• Weight: 7kg
• Phase: Single-phase
• Includes: MMA welding accessories and plastic carry case
• Codes: ECLASS - 21080701; UNSPSC - 23271409

Is This the Right Welder for You?

If you’re looking for a welding machine that combines cutting-edge technology with durability, the Telwin Tecnica 188 MPGE is a solid choice. Its ability to handle diverse welding tasks, paired with its compact design and advanced protection features, makes it a trusted tool for professionals and DIY enthusiasts alike.

Common Questions Answered:

• Can this welder be used with a generator? Yes! The MPGE multiprotection system ensures stable operation even with power fluctuations from a generator.
• What electrode types can it handle? It’s compatible with rutile, basic, stainless steel, and cast iron electrodes.
• Is it easy to transport? Absolutely—at just 7kg, it’s lightweight and comes with a sturdy carry case.

Whether you’re a seasoned welder or just starting, the Telwin Tecnica 188 MPGE is a powerful addition to any workspace. Ready to upgrade your welding setup? Explore our full range of MMA welding machines here.