Welding Resources and Tips

The Miller Electric Plasma Cutter Buying Guide

Today’s guest post is by Tim Lux of Miller Electric:

When choosing a plasma cutter, there are a few things to consider. Plasma cutters are rated for different material thicknesses.

The rated cut is the thickness you should get a clean precise cut at a certain speed (normally around 12 – 15 inches per minute) on mild steel. Cutting stainless steel, aluminum and other metals will have a different, normally lesser, rated cut thickness. The plasma cutter will also have a maximum sever thickness. The sever thickness is the maximum thickness the plasma cutter can cut through; although in most cases there will be with some amount of slag build up on the bottom of the cut. The bigger or more amperage the plasma cutter, the thicker metal it can cut.

The Miller line of plasma cutters include:

• 1\8-inch (Spectrum 125C 12 amps)
• 3\8-inch (Spectrum 375 27 amps and 375X-TREME 30 amps)
• 5\8-inch (Spectrum 625X-TREME 40 amps)
• 7\8-inch (Spectrum 875 and 875 Autoline both 60 amps)

Always pick a plasma cutter that will cut a little bit thicker than what you think your maximum cut thickness would be. When choosing a plasma cutter for the first time, customer feedback has shown that they would have gone a size larger after they have made their purchase. Don’t be afraid to ask your distributor or contact the factory and ask for a recommendation.

Plasma Cutter Input Power

Once you’ve decided on what the maximum material thickness you’ll need, the next step is to look at its primary input power. Miller makes four plasma cutters that run off of 115 volts AC. The Spectrum 125C, Spectrum 375 and Spectrum 375X-TREME, and the Spectrum 625X-TREME will run off a 115 volt 20 amp breaker.

The Spectrum 375, Spectrum 375X-TREME, and Spectrum 625X-TREME will also run off of single phase 200/220 volts AC. These three machines will have reduced cutting capacity when running off of 110 volts. The Spectrum 875 runs off of single phase 200/220 volts AC, while the Spectrum 875 Autoline will run off of single or three phase power at voltages ranging from 200 to 600 volts AC.

Plasma Cutter Air Supply

The final factor to consider when purchasing a plasma cutter is the air supply and amount of air needed to run the different models. While it is convenient to purchase a model like the Spectrum 125C which has a built in compressor, there are some additional things to keep in mind.

Plasma cutters with built in compressors normally have cooling coils in place of filters to remove the moisture from the air supply. This type of system — when used in a highly humid environment — can cause excess moisture to enter the torch and can cause reduced consumable life, arc outages and less than ideal cuts. It is important to make sure your compressor can meet the needed air requirements for the plasma cutter you’re choosing.

The following are the air requirements for the rest of Millers Plasma cutters.

• Spectrum 375 and 375X-TREME: 5cfm@ 90-120psi
• Spectrum 625X-TREME: 6cfm@ 90-120psi
• Spectrum 875 and 875: Autoline 6.75cfm@ 90-120psi

Taking these few things into consideration before you purchase a plasma cutter will make sure you are content with your purchase. Visit for more details on the Miller line of plasma cutters.

Learn more about Purchasing a Plasma Cutter at Baker’s Gas and Welding

The Baker’s Buying Guide to Plasma Cutters

Miller Electric Plasma Cutters on Sale at Baker’s

 

About Today’s Guest Blogger

Tim Lux has been with Miller Electric for 25 years. While the majority of that time has been spent with Millers’ industrial products service and end user training department, Tim currently is the service and application’s specialist with the Plasma group at Miller.

 

Get Started with MIG Welding This Spring

With all of the MIG welders on sale at Baker’s Gas and Welding this Spring, now is the perfect time to learn about MIG welding machines, set up your MIG welder in the garage, and strike an arc. However, before you get to work, you’ll want to learn some basic MIG welding techniques. Here is a run down of some essential MIG welding tips that will help you get started when you strike your arc.

Perfect Your Wire Speed

Running your wire too slow through a MIG welder will leave your weld weak since it won’t have enough filler metal and the arc will be erratic. You’ll have a much harder time getting your travel speed right if your MIG welder torch is jumping and bouncing around while you weld.

However, if the wire speed is too fast, you’ll have sparks and a big messy weld puddle that will be extremely hard to control. The sound of the welder will be much louder when compared to the gradual hiss that you would expect when the wire speed is correct. Some welders compare the sound of the correct wire speed and amperage to the sizzle of bacon frying.

Don’t Forget the Shielding Gas

Shielding gas will keep your weld free from contaminants and will keep your arc running smooth. You can pick up flux cored MIG wire if you’d rather not mess with shielding gas, but don’t try MIG welding without a way to keep your weld puddle clean.

Ground Your Welder

If you can’t get your MIG welder to run smooth, your problem could come from your grounding clamp and not necessarily any of your settings. A solid ground will keep your arc from jumping or spattering while you weld.

Don’t Skimp on Safety Preparation

Welding will send sparks and chunks of metal into the air. Always wear clothing that is either flame resistant or at least clothing that is cotton that won’t catch fire like synthetic clothing. A welding helmet will be essential for protecting yourself from heat and sparks, and if you want to cut or grind your metal before striking your arc, you can pick up an auto-darkening helmet that will make it significantly easier to prep your metal on grind mode before striking your arc and engaging the shade on your helmet.

MIG welding gloves are also essential for safely welding since the heat and sparks could damage your hands, as well as protecting your hands from ultraviolet light beams.

Keep a Steady Travel Speed

If you’re new to welding, it will be especially hard to keep a steady, and straight travel speed while you weld. You’ll have enough things to keep track of while you work that you’ll have to think of ways to keep your travel speed steady and your MIG torch zeroed in on the weld joint without drifting out of it.

The best way to start is by using a simple motion with your torch as you weld. Welders recommend moving the torch in a slight circular motion or a kind of back and forth motion that overlaps. Doing this effectively may require propping your torch slightly with your thumb or free hand depending on the relation of your metal work piece to your welding table.

Don’t Be Afraid to Run a Little Hot

You’ll find amperage setting instructions on the inside of your MIG welder’s cover, and they will help you figure out the best amperage, shielding gas, and wire speed that matches your metal type and metal thickness. However, you’ll usually have to tweak your settings. In fact, welders tend to run better if you can keep the amperage a little hot. That doesn’t mean you should really crank it up—that will just leave you with a mess.

However, a tight arc and a hot amperage will make it possible to create strong welds in a shorter amount of time. If you do run your welder too hot, you’ll notice that the arc and weld puddle will be hard to control, so you’ll need to keep an eye on that. You don’t want to end up with a sloppy weld. However, when it comes to creating a strong weld, a little extra heat will go a long way.

Learn more about MIG welders on sale at Baker’s Gas and Welding.

Check out the MIG Welder buying guide.

Build with Blue: The Miller Diversion 165 TIG Welder

You can now get the complete TIG welding set up for a Miller Diversion 165 TIG welder. Better yet, you can get a Miller Electric TIG welder on sale with Baker’s Build with Blue Promotion that continues through the month of April. This is the lowest price for a welder, a Miller welder that is, at Baker’s, and you’re going to love the extras you can pick up along with your new welder. Here are some TIG welding supplies you can pick up today along with a Miller Diversion 165 TIG welder:

The Starter Kit for TIG Welding

There’s a lot more that you need to get started TIG welding beyond just a TIG welder. For example, a gas regulator and a hose will provide all that you need to get started with using shielding gas and provides a series of welding tips you can put into use right away. In addition, a set up DVD will help you get started quickly and safely in your new welding shop and provides some basic TIG welding tips that will save you from frustrating mistakes

In addition, this TIG welding starter kit comes with plans for building a welder cart. Moving your welder around your shop will be a whole lot easier with a welding cart, and what better way to start using your new welder than to build a cart that will make it easier to move around your shop and to keep it safe.

Lastly, the TIG welding starter kit includes the Welding for Dummies book that will give you all of the basic technical knowledge that you may be afraid to ask.  

Weldcraft Air-Cooled Torch Included

The Miller Diversion 165 TIG welder comes with an air-cooled 150 amp Weldcraft torch with hand controls that make it easier to set your amperage while on the job without having to walk away from your project.

Better Weld Penetration and Power Options

The best option for a TIG welder is to get a lot of options for the various types of materials you’ll be welding. With a TIG welder you can get a better welding arc and use less power if you’re able to switch between AC and DC settings. In addition, the HF start feature on this Miller welder provides a non-contact start so that you can strike your arcs easily without having to wear away your tungsten.

With TIG welding you’ll need to be especially careful about protecting the weld puddle. By using the right shielding gas you can keep your weld puddle free from contaminants. In addition, the Diversion’s auto-postflow option will protect the puddle and electrode by optimizing the flow time based on the welding amperage.

Lastly, the Advanced Squarewave AC feature will provide a fast freeze weld puddle and help you achieve deeper penetration. For any out of position welds, Squarewave will help you get a great weld without having to worry about the filler metal seeping out of the weld joint.

How to Protect Your TIG Welder

Your welder could get damaged in any number of ways from moisture, to mold, to dust, or to scuffs and scratches from other materials in your shop. By investing in a cover for your welder, you’ll keep it in tip top shape without putting it in harm’s way. Learn more about buying a specially designed cover for your Miller TIG welder today.

Get a Miller Welder on Sale Today

Learn more about Miller’s Diversion 165 TIG Welder.

How to Choose the Best Miller Plasma Cutters on Sale

Now is the best time to pick up a Miller Spectrum plasma cutter on sale since you can get free shipping and additional discounts on specific models from 5-15% with Miller’s limited time Build with Blue Promotion. Miller’s Spectrum plasma cutters come in 5 different models, and each will provide some different features you’ll need to consider such as rated output, duty cycle, rated cutting thickness, the recommended generator power, and the plasma cutter’s weight. Here’s a look at some of the specs for Miller’s latest plasma cutters on sale and how they stack up to each other.

Miller Spectrum 125C Plasma Cutter

This lower cost and lower power model of plasma cutter is the ideal cutting solution for thinner metal and can handle most of what the typical hobby welders need to do. As of this writing, it’s priced at $970 with free shipping, making it one of the most affordable offers for a Miller plasma cutter with comparable specs.

For power it delivers 12 amps at 120V, so you can plug it in anywhere you have an outlet. The 35% duty cycle will provide enough cutting time before needing to cool off. The 50 pound weight of this machine isn’t the heaviest, but it’s enough to prevent it from being very portable. You’ll most likely keep this machine in your shop and use it to cut mild or stainless steel that is 1/8 “ thick or 1/16” thick aluminum.

Learn more about the Miller Spectrum 125C Plasma Cutter.

Miller Spectrum 375 Plasma Cutter

This model provides more power and options than the 125C model. With the option to switch between 115V and 230V, you’ll be able to cut 3/8” mild and stainless steel as well as 1/4” aluminum. If you need to cut a lot of aluminum, paying a few hundred dollars more for this model significantly increases your cutting capacity while still slicing through plenty of steel to keep you in business.

While providing more power at a similar duty cycle when compared to the 125C, the 375 is still a hefty machine at 56 pounds. If you need something more portable with the same amount of power, the 375 X-TREME is another great choice to consider, and we’ll discuss that next.

Learn more about the Miller Spectrum 375 Plasma Cutter.

Miller Spectrum 375 X-TREME Plasma Cutter

This portable version of the 375 model is much easier to carry around to a variety of job sites since it weighs in at 18 pounds. It still offers all of the same cutting capabilities you’ll find in the 375 for a slightly higher price. Even if you don’t need a portable welder for a mobile welding business, you could just as well pick up this machine since since it will take up less room in your shop and be significantly easier to move around.

Learn more about the Miller Spectrum 375 X-TREME Plasma Cutter.

Miller Spectrum 625 X-TREME Plasma Cutter

If you need a bigger jolt of power and a longer duty cycle, then a 625 X-TREME plasma cutter will be your best bet for a machine that can handle 5/8” mild steel and 1/2” stainless steel. It’s also quite light, weighing in at 21 pounds. This may be the best value and greatest versatility for a plasma cutter since you can cut more and take it just about anywhere, while the next model up is over twice the weight.

You’ll be able to run the 625 X-TREME at 40 amps with 140 volts and a 50% duty cycle that will keep you at your welding set up with minimal interruption for cooling down. At just a hair over $1500 currently, you’ll get a lot of power and time on task with this top of the line machine that is one of the newest additions to Miller’s Spectrum plasma cutter line.

Learn more about the Miller 625 X-TREME Plasma Cutter.

Miller Spectrum 875 Plasma Cutter

This heavy duty plasma cutter delivers the most power and the highest cut rating  available from the Spectrum line. You’ll be able to slice through mild and stainless steel that is just shy of an inch thick and aluminum as thick as 5/8” is well within its capabilities. Best yet, you’ll get 60 amps of cutting power with a 40-50% duty cycle. Baker’s is currently listing this high powered machine for a dialed back price that is $500 off the retail price.

Learn more about the Miller Spectrum 875 Plasma Cutter

Miller Welders and Plasma Cutters on Sale Through Build with Blue Promotion

The price for a Miller welder or plasma cutter has dropped from March 1st and May 31st with the latest Build with Blue promotion offered by Miller Electric. Welders will be able to take an additional 5-15% off the already discounted price of Miller welders and plasma cutters at the Baker’s Gas and Welding online store. If you’re looking for a new welding machine or plasma cutter for your welding projects, these prices will be among the lowest for a Miller machine all year. In addition, if you need some new welding supplies such as a welding helmet, welding jacket, or welding table, you can use these purchases to get additional savings. Here’s how you can save money on a new Miller welder or plasma cutter.

How This Promotion Works

Between March 1st and May 31st, purchase an already discounted welder from Bakersgas.com.  The list of participating machines is below.

• Millermatic 140 Auto Set MIG Welder
• Millermatic 180 Auto Set MIG Welder
• Millermatic 211 Auto Set MIG Welder
• Multimatic 200
• Diversion 165 & 180 AC/DC TIG Welders
• Spectrum 375 Plasma Cutter
• 625 X-Treme Plasma Cutter

For models that offer the cart option, this promotion includes those machines as well.

Once you know which machine you want, consider whether you want the 5% or 15% promotion.

How to Save an Additional 5% on a Miller Welder or Plasma Cutter

If you just need to buy a new welder or plasma cutter, you can visit Bakersgas.com and purchase one of the participating machines in the promotion in order to be eligible for the 5% rebate. Make a purchase of one of the machines included in the promotion and then submit the rebate form after the machine arrives.

How to Save an Additional 15% on a Miller Welder of Plasma Cutter

If you need a new welder and some essential welding supplies, the 15% rebate option is your best bet. You can find a welder from Baker’s at the sale price and then buy at least $150 worth of genuine Miller products in the same order with the welder.

You can review a complete inventory of Miller products that you can pick up as part of this promotion. You’ll find everything from welding helmets to welding tables to welding jackets to welding supplies such as MIG Consumables. If you’re planning to weld with aluminum wire, a spool gun would be a nice item to pick up, while welders who want to protect their investments should consider picking up a heavy duty cover that will protect their welders from dust and debris in a work shop.

Click here for a list including part numbers.

When the machine arrives, download the rebate form where you will fill in the amount you paid for the machine and accessories in order to receive your rebate.

How it works: Take a standard Millermatic 211 (907422) as an example. The sale price at Baker’s is currently $1,070. If you add a Spoolmate 100 ($240) to the order you will now be eligible for the 15% rebate. The rebate will be for $160.50 ($1,070 x 15%). There is no discount on the accessories. The 15% off only applies to the sale price of the machine. Once you’ve filled it out, submit the rebate through the instructions on the rebate form.

Why Miller Welding Products?

While there are many high quality brand names in the welding business today, these particular welders and plasma cutters by Miller Electric are among the best selling products at the Baker’s Gas and Welding online store and all have received extremely positive reviews from customers. This is the one time throughout the year that Miller offers a rebate promotion on top of the sale price that you’ll already find at Baker’s Gas and Welding. If there was ever a time to invest in a new welder or plasma cutter, this is the time.

Learn More About the Build with Blue Promotion Today!