Some Facts on Welding Cable

Welding cable is a portable cord that is used in various welding applications as well as many power supply applications. It is the electrical conductor for the welding current. It supplies the electrical current for welding machines and is made up of fine copper strands inside a tough, synthetic or natural rubber insulating jacket. Welding cable is specifically designed to withstand repeated movement over rough surfaces. The fine copper strands also provide more flexibility than other types of wire and the insulating jacket is designed to withstand repeated movements over rough surfaces.

Welding cable is an excellent conductor of electricity. However, copper has a degree of resistance to the electrons flowing through it. It is normal for a properly sized welding cable to feel warm to the touch after prolonged welding.

Finding the right sized cable is very important. If the diameter of the cable is too small for the level of current flowing through it, the cable may overheat. This can result in a potential fire hazard, as well as damage to the cable itself.  The breakdown of the insulation jacket can create an electrical shock hazard. At the same time, an oversized cable for a given amperage level does not conduct current more effectively than a properly sized cable.

While choosing the correct welding cable diameter size, keep in mind the maximum output amperage of the welder. The more amps produced, the bigger the cable should be. For example, a fire fighting hose would require more water than a garden hose. The more the water required, the larger the diameter of the hose. Here are three pointers to help you find the correctly sized welding cable:

·         Measure the total length of the welding circuit, including the full length of both the electrode and work cables.

·         The welder’s rated electrical output should be incorporated in the welder’s model name.

·         Check the welder’s duty cycle, which is the percentage of a ten-minute period that the welder will operate at a particular output current before exceeding its thermal limit.