Last Updated on September 2020
Spot welding is used for welding overlapping pieces of metal through pressure application and supplying an electric current to the metals that need to be welded together. The thickness of the metals that can be spot welded ranges from 0.02 inches up to 0.118 inches. The pressure point applied by the copper electrodes provides a steady welding point.
The elemental equipment needed for spot welding consists of the workstation that includes the welding power supply and the weld head to which the welding electrodes are attached. The welding electrodes are made of copper for its good conductive ability.
You will want to obtain a spot welder if you need to weld metal sheets to each other. You will need some tools to help you with all the menial aspects, especially if you have a lot of small pieces to weld to each other. Spot welders are a professional tool that is used by welding professionals, but it is not that difficult to learn and become proficient at it. The best way to learn spot welding, or just welding in general, is to learn under controlled supervision of a professional welder.
There are many safety specifications involved in the welding trade, and they need to be very strictly adhered to. Don’t worry, though; welding is within everyone’s grasp. Anyone can learn how to weld, even if it is only to do your repairs at home. If you put your heart, effort, and time into it, you can learn to weld, too.
There is a wealth of different types of spot welders out there, and it is a good thing to get a little bit more informed about the specifications and features of each, so you make an informed choice when choosing one for your specific needs. Selecting the right tool for the job can sometimes be challenging, especially if you have to curtail the salesman’s selling skills and enthusiasm.
We will take a look at some of the more regularly used spot welders available for the DIY hobbyist and the professional welder.
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Top 5 Spot Welders Reviewed
YaeCCC SUNKKO 719A Weller Soldering Pencil
- Dimensions: 8 x 5.8 x 1.4 inches
- Weight: 11.2 ounces
- Input power: 110v from the power supply
- Output: Maximum welding current is 500 Amps
The YaeCCC Sunkko is a Lithium battery-powered welding pencil. The Sunkko soldering pencil is compatible with the 709 series spot welders. The soldering pencil needs to be attached to the power supply via the connector attached to the cables with the screws supplied. It must be securely attached to the welding power supply for safe operation. The welding nozzles are easily replaceable if damaged.
For this pencil to work, you need to have the desktop power supply to attach it to. The soldering points are easily removed and replaced. The Weller soldering pencil comes in a convenient, utterly interchangeable unit. This welding pencil is handy for any small and mobile jobs that need to be done.
The Sunkko is a small spot welder and, therefore, can only weld thin metal sheets. This pencil has an anti-skid shoe attached to it for comfortable use, and the welding needle is manufactured from an aluminum alloy for good, long service life.
- Easy to work with
- Easily interchangeable welding nozzles
- Only compatible with 709 series
- Must be attached to a power supply
Stark Professional Portable Spot Welder
- Dimensions: 4 x 10.6 x 5.7 inches
- Weight: 29.1 pounds
- Input power: 120 / 240 Volts
- Output: 2.5 KVA
- Duty cycle: 50%
This single-phased spot welder makes it easy to weld different types of material. The Stark Professional Portable Spot Welder makes easy, quick, and strong welds on a broad selection of materials, including different grades of steel and cast iron. The simple design of the welding mechanism makes it easy to insert the material that needs to be welded together quickly.
The simple press and weld system makes it easy to do a large amount of work in a short time. A handle attached at the top provides you with an easy pick-up-and-go solution for mobility.
This portable spot welder from Stark is beginner-friendly. The ease with which it can be operated makes it an easy tool for beginners to learn the trade. It is not just for the beginner welder, though. The Stark is a professionally designed spot welder for the on-the-go licensed welder. At the price tag it comes with, it is an excellent choice for the beginner and DIYer, as well.
This is a safe tool for everyone to use. The quick clamp and release action makes it easy to apply the right amount of current and timing safely. This portable spot welder is air-cooled to keep it from overheating when in operation.
When you buy the Stark, you get an extra set of tips included. The tips can be used for many different uses. The 6-inch long tips lock firmly with a robust pressing action onto the materials that need to be welded, providing a strong bonding basis for a good connection.
Also, it is easy to remove the tips when necessary. You need to twist off the tips when it is time to replace them and screw on the new tips.
The Stark is extremely tough for hard-driven spot welding. The welding tips are made from top-quality steel to give you that perfect weld every time you use it. The ease of operation and simple lever system allow you to press down the lever and perform the spot weld in a quick and easy movement.
If you look at the easy clamping and spotting mechanism and the ease at which you can quickly operate, you’ll understand why the Stark portable spot welder is a favorite among beginners and veterans alike.
Plus, the fact that it is, indeed, a portable spot welder means it does not keep you pinned down in one location. You can get multiple jobs done even on remote sites, and you can take the Stark with you to a job site.
The professional look and build of the Stark spot welder give a solid base of operation to get the welding done quickly to provide a reliable bonding for every spot on the material.
The Stark can easily weld a variety of materials of varying thickness, up to a maximum of 0.118 inches. The materials that can be spot welded by the Stark spot welder are mild uncoated steel, galvanized steel, and stainless steel sheets.
- Easy to operate
- Quick press and release mechanism
- Can work on a variety of materials
- Well-constructed and durable
- A little heavy for a mobile spot welder
Tooluxe RIDGE10915L Professional Spot Welder
- Dimensions: 20.5 x 6.1 x 10 inches
- Weight: 34 pounds
- Input power: 115V at 60Hz
- Output: 125 Amps
- Duty cycle: 30% at 6.6kw
The Tooluxe electric is yet another portable spot welder for professional work. With a conveniently attached handle for easy pick-up and go, the Tooluxe is a true portable welder, though it is a little heavy, weighing in at 34 pounds.
Unfortunately, the extra weight may tire you out when you are on a busy schedule with a lot of portable jobs. It is still ideal that you can take your spot welder where it is needed. The Tooluxe portable machine is a versatile welding machine that can be used to weld a variety of different sheet metals together.
This Tooluxe professional spot welder is an easy-to-operate welding machine, and that makes it ideal for the professional and the amateur alike. The Tooluxe can easily be the right tool for those who want to take up the welding trade either as a hobby or a profession.
The Tooluxe is a beginner-friendly welding machine. It is easy to use and set up for performing welding operations. It can be used for spot welding on metal sheets and the making of delicate jewelry.
Easy to handle and operate, the Tooluxe Spot welder is quite a safe welding machine to work with, as long as you stay in the safe operating parameters. The single-phase option makes it safe to use in the home environment for the DIYer and the beginner welder, as well.
When purchasing the Tooluxe Professional portable spot welder, you get a neatly built, solid, and sturdy welding machine that is manufactured with durability in mind. It provides you with a heavy-duty machine.
The welding tips are made from high-quality steel to allow you to deliver a faultless and reliable welding connection for materials up to 0.039 inches. The 6-inch welding tips give you a solid grip to assist you in applying strong pressure that is needed to deliver a strong welding bond in the materials that need to be welded together.
This machine will help you in your quest to deliver professional and quick on-time welding jobs. This is a sturdy, perfect spot welder and professional tool in one package.
The Tooluxe Ridge Professional portable welder is ideal for heavy-duty and general spot welding jobs that need to be done on a variety of materials. The ease with which the job can be done with this portable tool makes it ideal for all-around spot welding.
The easy way with which you can perform spot welding operations with the Tooluxe makes it a favorable choice for the beginner and the professional alike. It is also suitable for any DIY repairs that need to be done. The easy way you can pick up the spot welder and go to the next site makes it perfect for portable jobs and on-site repairs. Even if you are not that strong, it will not be cumbersome to bring it along.
The solid and robust construction of the Tooluxe professional portable spot welder makes it a good, solid tool to help you do professional metalwork anywhere. The rapid press and release actions of the clamping mechanism of the Tooluxe give you the edge of completing the welding of the metals. The intense pressure supplied by the welding tips will help you get that solid weld every time.
A variety of materials can be spot welded with the Tooluxe for perfect and long-lasting, if not permanent, metal sheet bonding. Stainless steel can also be easily fused with the Tooluxe, as well as mild steels and carbon steels. Also, do not forget about the uncoated galvanized steel sheet metal that can also be welded with the Toolux Ridge professional portable spot welder.
- Easy to handle and operate
- Good, strong, and sturdy built
- Strong pressure point from tips
- All-around good and quick operation
- Low duty cycle
Lenco Autobody Dual Spot Welder
- Dimensions: 9 x 3 x 2 inches
- Weight: 110 lbs.
- Input power: 208/230V
- Output: 60/50A
This Lenco spot welder offers users a smooth, consistent weld that makes it ideal for people who need a good machine. You can set the time, and it will stop automatically. It does, however, take some testing to get wholly used to the right settings. There’s nothing complicated about using this product; you have to press the two electrode guns against the work, press the button, and the welder will do the rest of the work for you.
Because there are no wires involved, you don’t have to worry about that extra expense, and there are no flames or gasses that can cause injury. Of course, you should still handle any tool like this with care and keep safety in mind at all times.
The Lenco spot welder’s features include a solid-state time, protected control panel, and nice, streamlined construction. This is a favorite product with many welders, as it is considered a high-quality option. It does not come with clamps but instead uses two different arms that you can put anywhere.
It should be noted, though, that this welder isn’t as suitable for beginners – you need some experience before picking up and using this machine. Accuracy can sometimes be a problem since this product does not have spot welding tips that can easily line up, as is the case with other welders.
You will be able to quickly and more effortlessly join body parts (non-human, of course!) with the Lenco spot welder than with gas welders. That is due to the smooth and clean welds you can expect from the product.
Unfortunately, finding parts for this welder can prove difficult – not all shops have them in stock. If you need parts and look hard enough, though, you might be able to track down parts from an online supplier.
- High-quality product
- Includes wheels for mobility
- Not suited to beginners
- Somewhat pricey
Mophorn 737G Pulse Spot Welder 0.2mm Battery Welding Machine
- Dimensions: 9.1”x5.5”x8.3”
- Weight:12 lbs.
- Input power: 110V
- Output: 50A-800A
If you’re on a tight budget and looking for a spot welder to suit your light work needs without breaking the bank, this could be the right product for you. The Mophorn 737G Pulse Spot Welder is great for welding very thin (0.03 – 0.2 mm) nickel-plated steel strips and works well with rechargeable lithium batteries.
Thanks to its nifty LCD Display screen, you will be able to keep an eye on the current and pulse as you work. This product is great for anyone who has small projects that need to be done effectively and quickly. It will not be able to use a welding pen, though.
It should be noted, however, that the Mophorn Pulse Spot Welder is not recommended for use to weld aluminum or copper. It is well-suited to working with nickel, iron, nickel-plated iron, and nickel-plated steel (and other alloys), though. Because the Mophorn Pulse is rather limited in that sense, it is not very popular with users. But there have been users who were able to work with stainless steel with this welder.
However, using it for anything other than the mentioned alloys or nickel is not recommended.
In general, the Mophorn Pulse Spot Welder does work great for getting used to welding with this type of machine, and it is considered a great budget welder.
Unfortunately, there have been several online reviews that do not recommend the Mophorn because it seems the electrodes can be faulty. Because it isn’t very powerful, it often does not meet expectations. However, if you’re looking for something for very light work once in a while, you should be satisfied.
- Suitable for alloys and nickel
- Useful LCD Display
- Not very powerful
- Wouldn’t be able to support a welding pen
Let’s briefly take a look at the considerations you need to make and information you need to know when it comes to picking a spot welder and using it to the best of your (and its) ability. If you keep this info in mind when choosing, you might end up making a better choice that will satisfy your specific needs even more efficiently.
Price is, of course, one of the biggest reasons you will either buy a spot welder or skip it and move on to the next product. Prices are different depending on the brand and what the spot welder can do. Make sure you’ve budgeted according to your needs – these welders can sometimes be pricey, but in most cases, they are worth every penny spent.
To ensure that you have peace of mind with a purchase, most brands will offer some form of warranty. Make sure to check what kind of warranty you will get from the welder you choose so you won’t end up feeling like a fool should something go wrong.
What to look for
Spot welders can be very reliable and give high-quality welds – something that all of us would want.
In some cases, though, you might have to remove or tear solder joints. That will most likely happen if you’re using your welder in projects that involve auto repair or lots of sheet metal with spot welds. This is when a good welder will stand out from the rest. You will be able to cut around the repair with ease and save much more of the original metal.
How Does Spot Welding Work?
If you’re looking at buying a spot welder, you should know how they are used. You might be an expert and already know. In that case, you can skip over this part. If you’re new to spot welding and want to know as much as possible before jumping in, you will benefit from what we have to say here.
Spot welding comes into play when you have two pieces of metal that you want to combine so that you will have a thicker piece of metal to work with. It is a type of resistance welding that forms two (or sometimes more) pieces of metal together.
In most cases, these welders are used in the car industry, but many hobbyists and a variety of manufacturers also find them useful. You can even find the odd artist or two who make use of spot welders to create exciting pieces of art.
While welding, your welder will create what is called thermoelectric heat, which will be applied to the metal in areas that are called circular points. Copper alloy electrodes will typically be used because it can pass electric currents very well. Depending on the welder and how much pressure you apply, your welds will be something between about three and 12mm in diameter.
Advantages Of Spot Welding
As with any welding, there are positives and negatives to using this method. The biggest positive (by most people’s standards) is that, with spot welding, you will get superbly durable welds. When you need welds that are made to last and reliable, you will tend to make use of spot welding.
- You do not have to get extra metal weld materials for spot welding, because this method uses electrical currents that go through the attached electrodes. All that is required is an electrical power source. Of course, this will also help you save on equipment costs if that is a motivator for you.
- It doesn’t require extreme heat either, so you won’t have to stress about burning the rest of the metal you’re working with.
- Spot welding is an excellent way for beginners to learn about welding because these tools tend to be very easy to use. That doesn’t mean that they shouldn’t practice before working on important projects, though. You still need to be sure that you are using the welder correctly, or you could just as easily mess up.
- Speed is another consideration that makes spot welding popular. With spot welders, you will get your work done quicker, and these products are mobile so you can take them wherever you need to, provided there is electricity to power it.
Disadvantages Of Spot Welding
- It should be noted that spot welding is not effective on all materials. Low carbon steel – titanium, nickel alloys, and stainless steel – are the most common options that are great to work with.
- In general, many people will find that spot welders can be tricky to maneuver. The position of the electrodes will often influence how limited you are. Angles and odd shapes aren’t exactly great friends of spot welders.
Safety Precautions to Always Keep in Mind
You must always make a point of reading the safety instructions and the user’s guide of your welding machine. This is true for all the different kinds of welders on the market. If you follow the tips and guidelines provided by manufacturers, you’re off to a good and safe start. [ Read our full guide on safety equipment]
The electrodes will pass the heat, and you risk getting burned and possibly starting a fire when you use a spot welder. Always make completely sure that the electrodes are cool before you place them on a surface that could be flammable. Remember, better safe than sorry.
Do not forget; you should wear gloves at all times – that is one of the first and most basic rules.
Like any welder, spot welders make sparks, so always ensure that you are wearing suitable eye and face protection. Also, never look directly into the light that is produced when using a spot welder.
It is possible that electrodes can become stuck while you’re welding – you want to avoid this mess of a situation. Electrodes can do this when they are not aligned properly or when the force is just too low. Remember to check this regularly. A dirty work environment can also result in electrodes sticking because a metal surface can easily be contaminated. You should always make sure that your space and equipment is clean before you weld.
Too much heat can also be a reason for electrodes to get stuck, so keep an eye on this as you work, as well.
A precaution you may want to take before welding metal together is to add corrosion protection to them. You can use bonders and sealers or even primers or finishing paint coats. This will make your work much more manageable.
Test alloys before welding metals together
This is to make sure you’ve got the right settings on your spot welder. Before starting your work, use two pieces to test – weld them together and then check if they’re adequately welded by using a hammer and forked chisel to perform a destructive test. This way, you can test the strength of the weld.
What about single-side resistance spot welding?
You may wonder if you can use this approach because spot welders are tricky to move around and not suited to different odd angles. However, this isn’t a good option.
In most cases, you will have to use the double-sided method. Instances in which single-sided spot welding actually works are very rare. If you need this kind of approach, you may find that you will be better off using a different welding machine.
There are numerous places where you could order one of these machines online – eBay, industrial sites, etc. Additionally, there are always people who post their offers on tech sites, which might or might not be related to whatever you are looking for. However, these machines aren’t toys, food, or something you should take too lightly – buying one will always be a costly investment, not to mention the risk of purchasing faulty equipment.
That being said, the safest place where you can order this tool online is Amazon. Apart from being the most popular and reliable online service, this online market has a strict set of rules that apply to users on both ends: vendors and buyers. They also provide free shipping to some areas.
One of the best things about Amazon is that you are entitled to use their return/refund policy. People ship their items overseas all the time, and even if your vendor local, an accident can occur at any time. Your package might be delivered to you in a damaged condition – that’s where return policies come into play.
Now that you know what goes into choosing a spot welder and all the things to look out for, you should be able to find the perfect welder for your needs. As long as you keep everything mentioned here in mind, you will be just fine.
In the end, whether you choose a Stark welder or a product by Lenco, it all depends on what you will be doing with it and how much you can afford to spend on the welder. Such machines are always good investments, though, so after making sure you’ve found the welder you need, you shouldn’t have to worry too much about forking out the required cash.
Also, always keep safety in mind to prevent damage to the welding machine, as well as the welder wielding it. So, what are you waiting for? Go out and find that spot welder that will make your work easier, more robust, and reliable by using everything you have learned here.