Magnetic mass for welding: what is it and how to make it yourself

Magnetic mass for welding is a special device that provides reliable fixation on metal surfaces. This allows you to comfortably perform welding work on complex surfaces where the use of classic alligator clips is impossible. There are many design options that depend on the work conditions. The structure of this device is not particularly complicated. For this reason, some craftsmen prefer to use homemade magnets for welding.

Clamp types

The grounding terminal for the welding machine can be magnetic or in the form of a clothespin, clamp, or centralizer. Let's look at the main varieties.

"Crocodile" ("clothespin")

This type of clamp is used in most electric welding machines. Attaches directly to the workpiece. Among the advantages of an alligator leather clip it is worth highlighting:

• reliable fastening to the surface of the product;
• the ability to attach a wide range of geometric shapes to parts;
• quick attachment/detachment;
• Ease of use;
• low connection resistance;
• wide opening angle.

The disadvantages of clothespins are as follows:

• it is not always possible to attach the “crocodile” directly to the part (for example, to a large diameter pipe);
• The weak point of the mechanism is the spring, which does not have the maximum level of strength.

Alligator clips are most often found in 200 A, 300 A, 500 A versions. Professional welders will need modifications for 400-500 amps.

Magnetic welding compound

This type of terminal is also often used by welding professionals. Advantages of magnetic locking:

• fastening to any surface, in particular to pipes;
• excellent option for hard-to-reach places;
• simple design;
• ability to withstand voltage surges without exhaustion;
• significant contact area.

Disadvantages of magnetic devices:

• unreliability of fastening in the case of a small contact area with the part;
• incompatibility with workpieces made of non-ferrous metals;
• the need for periodic cleaning;
• demagnetization due to overheating.

It is worth remembering that the magnetic mass clamp for the welding machine heats up when attached to a dirty surface.

Clamp

This is a screw mechanism. Features less frequent use than the two types of ground terminals listed above. Among the advantages of clamps:

• reliable fastening;
• Smooth current transmission due to excellent contact with the workpiece.

The disadvantages of clamps include a complex mechanism and cluttered design.

Do I need to purchase?

Everyone can answer the question about the advisability of purchasing magnetic mass for themselves, since this can only be determined by taking into account the specifics of welding work. Initially, the consumer must evaluate the materials with which he usually deals. For example, for a beginner who works with non-ferrous metal products, terminals are perfect.

The cost of magnetic masses for the welding process cannot be called low, but the product fully justifies its price. Craftsmen who want to save money can make this device themselves.

If you want to become the owner of a magnetic terminal, you should think about how to make the right choice. Initially, attention should be paid to the manufacturing quality of the device. It is worth making sure that the clamp can support the weight of the cable that will be used.

In addition, you should trust only a trusted manufacturer that has proven itself well.

The ground clamp must be selected in such a way that it can withstand the maximum voltage generated by the unit. High-quality welding equipment is produced by companies such as Skrab, Quattro Elementi, and Kord.

General recommendations for selection

When choosing a grounding clamp, consider the following nuances:

• Optimal weight of the connected wire. Otherwise, the welding mass clamp may come off at the most inopportune moment.
• The maximum current supplied by the welder. If the terminal is designed for a lower current than the welding machine, depletion of the contact area is guaranteed.
• Clamp opening angle. The larger it is, the wider the scope of application, since thanks to it it will be possible to attach the mass to products of different sizes.
• Spring reliability. If compression is provided by a spring, the properties of this element must ensure reliable grip of the workpiece.

Also pay attention to the popularity of the brand. Buy products only from trusted manufacturers to avoid counterfeiting.

DIY mass

Make your own ground clamp. To do this, take a magnet, two magnetic washers, a bolt and a nut. Then perform the following steps: 1) drill a hole in the washer with a diameter close to the size of the bolt head - this will be a contact washer; 2) grind the top of the bolt to the thickness of the washer; 3) boil and clean up what happened; 4) pass the bolt through the magnet and cover the latter with the remaining washer; 5) secure the end of the cable to the rod; 6) tighten everything with a nut. Spending some time on a DIY terminal can save you a lot of money.

Weight per welding machine plus or minus

There are welding machines that use alternating current, and there are inverter machines that operate exclusively on direct current. Inverters have two output connectors: “plus” and “minus”. In one, a wire with a holder is connected, in the other, a grounding wire with a clamp. In this case, the connection order can be changed to achieve different results during the welding process.

Straight polarity

To operate in this mode, you need to connect the wire with the holder and the electrode to the “minus”, and the ground to the “plus”. With direct polarity, the workpiece receives a higher temperature, and not the electrode itself. Thanks to this, you can boil the very root of the seam. Welding thick metal is also better.

Reverse polarity

For such welding, the cable with an electrical holder and electrode is connected to the “plus”, and the grounding of the welding machine is connected to the “minus”. In this mode, the highest temperature will be on the electrode, not on the workpiece. Moreover, in this case, the temperature at the tip of the electrode will be almost a thousand degrees lower than when soldering in straight polarity mode. This allows you to weld thin metals with minimal risk of burns.

With your own hands

Some craftsmen like to create devices themselves rather than buy an industrial version. For such performers, below are instructions for making all types of accessories with magnets. We do not encourage you to copy the instructions and videos below, but rather consider them as suggestions for ideas.

Square - holder

Magnetic corners for welding work have a fairly simple design, so making such a product with your own hands is easy. The master will need a metal sheet 2-3 mm thick; magnet; fasteners: screws and nuts.

Manufacturing algorithm:

1. On a metal sheet, using a ruler and a felt-tip pen, you need to draw the outline of the future product. The shape can be different, but the most optimal configuration is triangle and trapezoid.

Important! The corners should be as straight as possible.

2. Using a grinder, you need to cut out two blanks of the same size and shape, then sand them on the end and front sides.

Important! The angles of both plates must match.

3. The magnet is fixed between the workpieces and assembly is performed.

4. For assembly, you need to drill holes: for a triangular shape - three, for a trapezoid - five. Using bolts and nuts you need to assemble the product. The nuts must be screwed not only onto the end of the bolt, but also between the metal plates to prevent the product from bending when screwing in the bolts.

5. Bolt tails extending beyond the nuts should be cut off.

Important! Non-magnetic bolts or nuts should be selected. If these are not available, then you can use aluminum or copper tubes as end caps. This will eliminate the possibility of contamination of the magnet and its demagnetization.

6. It is recommended to check the distance between the corners again.

7. The magnetic corner is ready for use.

Torch holders

The burner holder has a more complex design, so it will be necessary to put more effort into making it yourself. The performer will need a magnet, fasteners: a non-magnetic bolt and nut, a 3-4 mm metal sheet.

The holder support can be of various shapes. The welder can cut a workpiece, the template of which will be similar to industrial models, and also develop an individual shape. It all depends on the ability to use the grinder, the assigned tasks and the imagination of the welder.

1. It is necessary to cut a blank of the desired configuration from sheet metal and polish it from the end and front sides.
2. At a distance of 20-30 mm. Bend the workpiece at a right angle from the bottom edge, then screw the product to the magnetic base.
3. The tail of the bolt extending beyond the nut should be cut off.
4. The device is ready for use.

Mass holders

The manufacturing process of the mass holder is simple. The welder will need a minimum of tools. The necessary parts may be at hand. Detailed and understandable instructions for any master are presented in a separate article. The video will help you visually study the process.

Welding mirror

Focusing on the purchased one, a DIY craftsman will be able to make a homemade magnetic welder mirror

To make a magnetic mirror for welding, the contractor will not need to cut metal. A magnet, a brass bendable rod 400-500 mm long, and a mirror whose dimensions do not exceed 100 mm must be available. On the one side; fasteners; hinged holder.

Using a hinged holder, the mirror is attached to a flexible rod, which is then attached to a magnet using bolts and nuts.

Magnetic terminal design

The device consists of two blocks:

1. A holder to which the welding machine cable is connected.
2. Magnetic group with constant or adjustable pressure on the surface. Professional models are equipped with a switch.

You can buy magnetic mass or make it yourself. Both parts are rigidly fastened together. The main parameters of magnetic solder leads include:

1. Dimensions and weight. Models from different manufacturers weigh from 0.85 to 1.2 kg with a diameter of 5 to 6 cm.
2. The clamping force can range from 2 to 50 kg.
3. The current strength that a magnetic mass can withstand. Compact models up to 200 A, professional models up to 500 A.

Design of magnetic contact and its characteristics

It consists of two nodes:

1. Cable holder. The grounding cable of the welding equipment is connected to it using a bolted connection.
2. Magnetic installation. The size of the magnet depends on the design features. Some models are equipped with a mechanism that regulates the pressure of the magnet on the working surface. Professional devices have switches.

The parts are connected to each other by a rigid support. The main features of the devices are:

1. Dimensions and weight. This depends on the manufacturer and the specific model. Average weight 1-1.2 kg.
2. The force of attraction to the surface. It varies from 2 to 50 kg.
3. Welding current strength. The maximum value of the parameter is measured in amperes. For entry-level models, it does not exceed 200 A. An advanced device is capable of operating at 400-500 A.
4. Execution type. Special corner clamps with gap adjustment are made.

Safety regulations prohibit connecting a cable without a special cable lug, which is secured with bolts.

Types of magnetic squares

Welding magnets can vary in both shape and operating principle:

• The clamp is a flexible square with adjustable angles. An excellent tool for making parts of any complexity.
• Single bend for fixed angle permanent magnet welding.
• Removable soldering magnets are an excellent technical solution for ease of use: after soldering, you can turn off their action, the supports “detach” themselves, which allows you to remove the clamps without effort or deformation.
• Universal magnetic welding angles with several standard angles are another excellent technological solution for performing a variety of jobs of varying complexity.
• Teams with different strengths. It is clear that for fastening massive parts, powerful clamps are needed, and for small work that requires jewelry precision, they must be compact both in size and in terms of attractive force.
• Three-dimensional and tetrahedral squares with cylinders and heat-resistant ferrite magnets for working in difficult temperature conditions and with parts of different sizes and weights.

Squares

One of the varieties of magnets for welding includes special angles that completely replace bulky clamps and provide fixation of parts at angles of 45, 90, 135 degrees.

There are many designs and variants of such magnets produced by different manufacturers. They differ not only in their working dimensions and mounting angles, but also in their adhesion strength.

The magnetic clamp or welding angle can have a variety of configurations, providing the ability to set the required mounting angle. Such magnets can have the following designs:

• ordinary squares, through which it is possible to set fixed angles determined by the profile of the workpieces;
• clamp-type fasteners with the ability to adjust the angle of fixation, ensuring their universal use as welding elements on structures of any degree of complexity;
• modern samples of squares with several fixed angles, also related to multifunctional tools and used in organizing complex welding work;
• angles with different clamping forces, designed for both massive elements of welded structures and small (compact) parts.

Advantages and disadvantages

Electric welding is the most common method of joining metal products. The integrity of the electrical circuit depends on the quality of the future connection.

Therefore, the invention of the device in question aroused serious interest among specialists.

The popularity of magnetic mass for welding is due to the following advantages:

1. A secure fit will allow the welder to concentrate on the job without the distraction of adjusting the clamp.
2. The working mechanism is a permanent or disconnected magnet. Subject to the operating conditions, it can be used for an unlimited time.
3. No consumables are required to use the stand.
4. Even compact models have sufficient contact surface for secure closure.
5. The device is resistant to sudden voltage changes or temperature changes.
6. The magnet can be attached to any place to create a comfortable connection environment.

Despite the large number of advantages, there are a number of disadvantages:

1. Before use, it is necessary to prepare the surface. The procedure involves removing dirt and foreign particles.
2. Cannot be attached to small parts, such as a circle with a small cross-section.
3. You cannot work with non-ferrous metals, as they are not magnetized.

Magnet or clip

Typically, welding machines are equipped with a piece cable with a clamp-type holder. At first glance, this is convenient; such a device can be securely attached to almost any surface (foil, metal tiles, etc.).

But there are situations when it is not possible to install such a mass on one product or, more often, it burns out. A good alternative would be the magnetic contact of the welding cable.

What are its advantages over a standard clothespin clip?

• This is the ability to provide contact with almost any surface without any problems.
• The simple design is almost forever in use and will not break, since there are no springs or mechanisms.
• Such a mass perfectly withstands voltage and load changes, as a result of which it does not burn out.
• The large contact area ensures reliable closure.

But this type of sensory attack also has its drawbacks. The main disadvantage is that the magnetic mass for welding will not be installed well on small parts, for example, a beam or a stiffener. The second negative property will be the impossibility of fastening to welded parts made of non-ferrous metals: aluminum, copper and others. In addition, over time, the magnet becomes contaminated with metal shavings and will need to be cleaned periodically.

Without taking into account the last two factors, this is a fairly affordable device that you can even make with your own hands without additional costs.

Homemade magnetic clamps

You can make a magnetic angle for welding with your own hands; it is not difficult, especially since there is more than enough information on the order of the operations performed.

Design

A magnetic fixture or device is typically made from two separate parts. First, there is the contact or point where the lead cable is secured to the holder. Secondly, it is the magnet itself, which can have different shapes and dimensions. The two parts of the prefabricated product for welding are connected by means of a special fastening, ensuring their reliable coupling. In this case, special attention is paid to the total weight, which should not exceed a certain value.

Thus, magnetic welding triangles from ESAB have a total weight of about 850 grams and guarantee ease of handling.

Taking into account the design features of welding magnets, you can begin to directly assemble them.

Self-production

You will need a fairly “strong” magnet, which can be used as the base of a powerful speaker that has become unusable. Next, you will need to find two sets of thick washers that fit them in size. And finally, you should stock up on additional fasteners (bolt and nut) necessary to connect the welded cable clamp. When assembling the system, first drill a hole for the bolt in one of the washers (which will serve as a contact pad). After this, it is inserted into the workpiece and welded.

The head of the fastening bolt is ground down with a file to the thickness of the washer itself (flush with the contact plane).

After welding, the mushroom-shaped structure is carefully cleaned with a file, and then a magnet from the speaker is threaded onto it. To complete the work, a second washer is attached to the protruding threaded rod and the end of the cable is secured here, and then the entire structure is tightened with a nut.

At the end of the review, let us draw your attention to the fact that, despite the significant savings when making a welding holder yourself, branded magnets are still more reliable and durable.

How to use?

The technology for using the device is not complicated. The first step is to connect the welding cable, after which the installation begins.

Most devices have switches that activate the magnetic field. At rest, the magnet will not be attracted to the surface.

One person is required for commissioning. After contact with the countertop, you need to activate the device. Once these steps are completed, the gripper enters operating mode.

When finished, perform the previous steps in reverse order. Do not attempt to separate the switched-on device from the part; many models are resistant to peeling. This may also damage the latch.

Upon completion of work, you should immediately clean the contact surface of the magnet from metal shavings, as this negatively affects the force of attraction.

Setting up the device

The quality of welding depends on the correct settings of the welding inverter, especially regarding the correct choice of electrodes. You should also consider:

• seam depth;
• location of the seam in space (vertical or horizontal);
• brand or type of metal being welded;
• metal thickness and so on

You should know that corresponding electrodes are made for each type of metal. Electrodes with a diameter of up to 5 mm can be used with inverters. But for each thickness of the equipment it is necessary to select the strength of the appropriate welding current. To properly set up your welding machine, use the table below.

Making a holder for a welding machine

Despite the high reliability of the design, the proprietary holder for the welding machine may fail at some point in time. At the same time, there are often situations when no spare parts help to fully restore its functionality.

Taking into account the fact that welding operations do not tolerate any delays or stops, you should always have another holder at hand. Professional welders prefer to make a spare electrode holder themselves.

Advantages and disadvantages

If you compare the magnetic clamp and standard clamps, you can highlight the following advantages:

1. Reliability of fixation allows welding without being distracted by adjusting the weight;
2. Magnetic grounding tolerates voltage and temperature fluctuations without consequences.
3. The design has no moving parts that could break. Therefore, with proper use, life is not limited.
4. The magnetic clip is convenient for working in hard-to-reach places and on curved surfaces where it is impossible to attach a clothespin. For example, welding large diameter pipes. Even in compact models, the metal contact area is sufficient to create reliable electrical contact.

The disadvantages include:

1. The need to clean the mounting area. On a dirty surface, the magnetic lead heats up when soldering due to poor contact with the metal.
2. Unreliable fixation on round parts of small diameter. For example, on reinforcing bars.
3. Impossibility of fixing on non-ferrous metals that are inert to the magnetic field.

What's happened?

This device is mounted on the working plane of the workpiece . Thanks to the active magnetic field, a strong fastening is achieved, creating a closed electrical circuit - the main condition for the formation of an electric welding arc.

The tool is especially popular among novice welders - it will take a few minutes to familiarize yourself with the principles of the work. Experienced specialists use magnetic mass for welding machines for critical work - welding large-diameter pipes or connecting load-bearing units made of profile materials.

Pros and cons of magnetic mass

As with any product, magnetic welding compound has both positive and negative sides. Let's talk about them from my point of view.

Positive:

1. Just use
2. Versatility of use
3. Operation duration
4. No mass heating due to hermetic installation
5. convenient to use, for example, when installing where there is nothing to attach a clothespin to... At heights, etc.

Negative:

1. Cost (compared to clothespin)
2. Constant contamination of the magnet area with chips, scale and other metal debris
3. The need to clean the magnetization area based on contact density
4. Welding near a magnetic mass is practically impossible due to the effect of the magnetic field on the electric arc.
5. The main disadvantage is that it is impossible to fully use it when working with non-ferrous metals (if you simply put the conductive part of the mass on the non-ferrous metal.)

Well, what can you do? everything has pros and cons... The point is whether the pros can become more significant than the cons in your case.

Is it worth buying?

The answer to this question can only be given by the master performing the work. For a novice welder who has just started his professional career, this device can make life significantly easier.

If a specialist works primarily with non-ferrous metals, a magnetic clamp will most likely not be useful.

Experienced workers have a set of various clamps for all occasions, including this device.

The cost of the device is quite high. If you have knowledge in the field of electrical engineering, you can try to make it yourself. The technology and manufacturing process will be discussed below.

Installation and connection of the unit

To use your inverter efficiently and safely, you must first properly prepare it for operation. This process is carried out in several stages. The first task is to install and connect the unit. Installation of the inverter must be carried out according to certain rules:

• the unit must be positioned so that it is at a distance of at least 2 m from walls or objects;
• the device must be grounded;
• the welding location must be chosen so that it is away from flammable objects;
• It is recommended to cook on a free area or on a metal table.

The inverter can be connected both to a home network (220 V) and to a 380 V network, which is usually used in production. If you plan to use the unit away from electrical networks, it can be connected to a generator, diesel or gasoline.

Electrical connection

Connecting a welding machine to a household electrical outlet often causes problems. The reason for their occurrence may be old wiring or insufficient diameter of its wires. Typically, the wiring is designed for a current of up to 16 A. And since all switched on devices in the house can exceed this value, for safety reasons, circuit breakers (circuit breakers) are installed. Therefore, when connecting, you need to know the power of the welding machine so that it does not activate the machine.

Connecting the inverter to the home network

It is also worth paying attention to network drawdown. If, when the inverter is turned on, there is a decrease in the voltage in the network, this indicates an insufficient cable cross-section. In this case, it is necessary to measure to what values ​​the voltage drops. If it falls below the minimum with which the inverter can operate (specified in the instructions), it is impossible to connect the device to this network.

Using an extension cord

The network cable connected to the inverter meets all power requirements and does not create connection problems. But if its length is not enough, it is necessary to select an extension cord with a wire cross-section of at least 2.5 mm2 and a length of no more than 20 meters. These extension cord parameters will be sufficient to operate the inverter with a current of up to 150 A.

It should be remembered that when connecting the device to the network through the holder, the remainder should not be wound, since when the unit is turned on, it will turn into an inductor. As a result, the conductors overheat and the extension cord fails.

Connection to generator

In cases where the device cannot be connected to the network, it can be connected to a generator that runs on either gasoline or diesel fuel. The most common are gasoline power plants. But not all of them are suitable for connecting welding machines. For the inverter to work effectively, the generator must have a power of at least 5 kilowatts and provide a stable output voltage. Overvoltages can damage the welding machine.

You should also consider what diameter of electrodes you will be working with. For example, if the electrode diameter is 3 mm, then an operating current of approximately 120 A will be required at an arc voltage of 40 V. If we calculate the power of the welding inverter (120 x 40 = 4800), we obtain a value of 4.8 kW. Since this will be an energy consumption, a power plant capable of delivering only 5 kW will operate at the limit of its capacity, which will significantly reduce its lifespan. Therefore, a generator must be selected with a certain power reserve, approximately 20-30% more than that consumed by the inverter.

Features of using magnetic mass

Before using the device, connect the cable to it in accordance with safety regulations. Do not connect the ground without a lug with a bolt hole. This requirement also applies to the welding machine.

Factory models are equipped with a knob to turn the magnetic field on/off. In the default position, the mass will not be attracted to the metal. In advanced models, the same handle is used to adjust the clamping force.

To activate the magnetic field, a mass is applied to the workpiece and the handle is rotated. After disconnecting, proceed in reverse order. Attempts to quickly move the device to another location while it is active usually end in its being hacked.

Do not install the terminal near the welding site, as the magnet loses its properties when overheated.

Immediately after completion of welding, it is necessary to remove adhering metal particles from the contact surface, which reduce the clamping force.

Rules for servicing the inverter device

Maintenance of an inverter-type welding machine includes the following.

1. Visual inspection. It must be carried out every time before and after starting work in order to detect any damage to the insulation of welding cables and power cables. In addition, during an external inspection, the absence of damage to the housing and controls is checked (it is necessary to check the current regulator).
2. Internal cleaning of the unit. This is carried out after removing the casing from the device to remove accumulated dust and dirt from all its components. Cleaning is carried out with a jet of compressed air directed at dusty parts.
3. Checking and cleaning the device terminals. Power cable connection points should be checked periodically. If oxidation is found on the terminals, remove it with fine sandpaper.

Also avoid exposure to drops of water, water vapor and other liquids that may enter the machine and cause a short circuit in the electrical circuits of the inverter welding machine. If liquid gets into the device, remove the cap and remove all moisture. Dry the inverter electronic board thoroughly with a regular hairdryer.

The direction of electron movement is regulated by polarity by switching the wires to “plus” or “minus”. That is, when working with DC welding, two settings are possible:

1. Straight polarity. The negative is connected to the electrode, the negative is connected to the ground terminal. In this case, the current moves from the electrode to the workpiece, and the metal heats up more.
2. Reverse polarity. The plus is connected to the electrode, the minus to the ground terminal. The movement of current from minus to plus (from the workpiece to the electrode) creates more intense heating.

Direct and reverse polarity of the connection when welding with an inverter is used depending on the work and the quality of the materials. With alternating current, the type of connection is not important, but with direct current, you can change the polarity manually.

Recommendations on how to extend the life of an alligator clip

The main design feature of such a welded mass is a spring, which ensures quick attachment to the metal. This is also the Achilles heel of the device.

Understanding the operating principle of the “crocodile” mass allows you to extend its service life and not have to give up two or three welding jobs. What is it about. Each clamp has a strip (copper or brass) that transfers contact from one jaw to the other. If you do not monitor its condition and incorrectly connect the mass to the metal, it may deteriorate. A common malfunction: the contact fitting with the wire to one clamping jaw can slip through the spring to the other. As a result, the spring begins to heat up, which leads to a loss of its hardness and elastic properties (in metallurgy, this process is called tempering), aimed at reliably securing the clamp to the surface of the metal product. Because of this, the mass quickly collapses. To maintain working condition, it is necessary to monitor the condition of the strip: it should not touch the metal when connected. The photographs clearly show what we are talking about.

Incorrect contact

Correct contact

Find a crocodile for professional work. What positive aspects does it usually have:

• the design is correct (the strip is recessed so that it cannot be touched)
• quality materials,
• more powerful spring;
• greater girth (sometimes simply irreplaceable).

I take it with a reserve of 400 -500A.

How to do it yourself?

Experienced craftsmen try to reduce all costs for the purchase of auxiliary and working equipment to a minimum. Due to the simplicity of the design, no special equipment or complex tools are needed for manufacturing .

To assemble a homemade device, you should prepare the following equipment:

1. Magnet . The working part of the unit. It must have sufficient power to securely attach to metal. Magnets from old car speakers with a power of 10-15 W are ideal for this purpose.
2. Two washers . Their size must correspond to the diameter of the magnet.

Sometimes it can be difficult to select washers for the size of the magnet. It is much easier to make washers yourself from sheet metal.

1. A set of hardware for fixing the welding cable.

Algorithm for performing the work:

1. One of the washers will make contact with the working plane. It is necessary to make a hole in it corresponding to the size of the bolt head.
2. The cap is cut to the thickness of the washer.
3. After preliminary preparation, the structure is connected by welding. The product should resemble a mushroom, in which the threaded part of the bolt plays the role of a leg.
4. A magnet is placed on the mushroom. Place a second washer on the reverse side.
5. A welding tip is attached to the thread, and the entire structure is secured with nuts.

Functionality testing is performed only in the field. The quality criterion will be the correct functioning of the welding machine.

Do-it-yourself welding machine compound is a great way to save money, as well as a means to test your DIY construction skills.

A properly assembled device will last no less than the factory clamp.

How to improve the ground terminal?

As a rule, novice welders face this problem. Purchase an inexpensive inverter for manual arc welding at home: for a fence, gate, barn, etc. Such an inverter, which costs 6-10 thousand rubles or more, is equipped with an alligator clip. In addition to other negative aspects of such a clothespin, which were already mentioned above, it most likely has steel jaws coated with a thin layer of galvanized copper (to give the impression that they are copper). It is very easy to check whether it is copper or steel; you just need to bring a magnet. If it is magnetized, it is steel. Food grade stainless steel usually does not magnetize to an uncured state, but that's a different story (see the article "How to Tell What Type of Metal is It").

Why are steel jaws dangerous? They get very hot: steel is a much worse conductor than copper or brass. To prevent this from happening, you can remake a cheap clothespin, which costs 40-50 rubles. (unless, of course, you have copper or brass in your house, such as a plate or pipe, rubber).

What should be done? It is necessary to unscrew the original jaws, which are held on by bolts, and make other jaws from them, as if using a template. It is enough that they represent the Russian letter “P” in cross section. You can easily get good contact with a low-quality clothespin!

How to improve mass clamping

A conventional mass clamp has a spring in its design. It allows the clothespin to perform its main function. But most often the spring fails. To extend the service life of such a clamp, it is only necessary to promptly monitor the condition of the current-transmitting contact on the clamp.

This contact is made of copper or brass. You always need to clean it of carbon deposits and also monitor the condition of the strip. In no case should it intersect with the metal to which the clamp is connected.

Also, to improve the clamping of the mass, it is enough to replace cheap jaws with expensive ones, which are made of copper, and not of copper-plated steel. To check whether it is really copper and not some alloy, you just need to use a magnet.

Do-it-yourself magnetic clamp for welding

Welders can appreciate the benefit of using a magnetic clamp when working on complex structures where there is simply no place for a regular crocodile clamp to hook. And so you throw the mass onto the metal surface to be processed - and you start welding.

You can buy one from any soldering shop, but will it meet your needs and be as reliable as a custom terminal? Everyone somehow comes up with trident carriers, some make crocodiles in the garage, but few people undertake to invent magnetic masses... In general, do it, and you will have something to brag about to your welding friends!

• The terminal itself is cut from a sheet 2 mm and 0.5 mm thick, and the magnet is taken from a non-working column, and a piece of hot-rolled angle 20x20x3 mm is used here as a mounting plate for the cable. All other components: screws, washers, nuts are standard.
• The connection can be made to the grounding cable of the welding machine, replacing the standard “crocodile”, or it is possible to equip this type of grounding separately with a bayonet connector and a cable with a cross-section of 1x16mm.

What is needed to make a homemade device?

1. ring magnet;
2. copper bolt;
3. nuts and washers;
4. plexiglass - for making a mounting platform with a handle.

Main stages of work

You will need to make a mounting pad and a handle with finger holes from plexiglass.

If thick plexiglass is not available, thin strips can be used. But first they need to be glued to the desired thickness.

We drill two holes at the installation site: one for installing a magnet and the second for installing a copper bolt (we make an electrode from it).

The homemade product is ready!

It turned out to be cheap, reliable and very practical. Pay attention to this.

How to make a magnetic mass holder

The main advantages of a magnetic holder were described above. First of all, this is the ability to fasten the cable in the most inaccessible places, those that are simply impossible to crawl into with an ordinary crocodile.

A magnetic ground holder is a magnet to which a cable with ground is connected. There is a contact inside the magnet. Therefore, when it is fixed to the metal, the welding current is transferred to the workpiece, which is welded.

To make a magnetic terminal you will need the following materials:

• Sheet steel. Steel thickness no more than 2 mm;
• Non-working speaker from a Soviet receiver or tape recorder;
• A long bolt, washers and nuts for connecting the ground cable from the welding machine.

The manufacturing process of a magnetic holder is as follows. First you need to cut two circles from thin steel, exactly the same in diameter as the magnet.

Then, in the center, you need to drill a hole for a bolt, which could be used to fix the ground cable coming from the welding machine, and also tighten the two circles. For reliable fixation, it is recommended to use several washers as pads.

After fixing the ground cable to the magnet, you can check all the advantages of such a homemade product. The magnet will reliably hold the mass of the welding machine anywhere on the workpiece, while it is easy to create reliable contact, which will improve welding work.