An Overview of Exhaust Welder

Posted on Dec 2, 2020

An exhaust welder is a welding machine that helps make the parts of the exhaust pipes combine firmly, or repair the wearing part of the exhaust pipes, which ensure the optimal function of the exhaust pipes when the cars are operated.

What Is an Exhaust Welder?

An exhaust welder is a welding machine that is used to weld the exhaust pipes, which can be seen at the bottom of the rear of the cars. The exhaust welder helps combine the joints of the different parts on exhaust pipes or repair the wearing part of them, which ensures the optimal function of the exhaust pipes when the cars are operated.

A welder, or a welding machine, is a device that makes two separated parts of metals, or one piece of metal that has gaps on it due to whatever reasons, join together in order to form the separated parts into one or fill the gaps on the works.

Depending on the categories, thickness, or weights of the metals, from thin, small sheet metal to a thick, heavy exhaust pipe on a big truck, which is supposed to be welded, there are some different types of welders to choose from for the best performance of the welding processes.


Why Do We Need Exhaust Pipes?

An exhaust pipe is a component that is mounted on whatever kind of automobile. It is usually seen under the rear part of a car, and beside one of the rear wheels. What the exhaust pipe does is to receive the poisonous gas, which is produced when the engine turns and the car is operated, from the catalytic converter and release the gas out of the car. When the gas is produced, it would be presented as the form of smoke, and also brings with the heat on the components that it passes through, including the exhaust pipe.

After the automobile has run for quite a long time, the exhaust pipe may be going to gradually wear, or be separated from the catalytic converter because of the high temperature of heat that is given on it, which results in the malfunctioning of these parts, and thus makes the trapped poisonous gas contaminates the other components, or pollutes the atmosphere when it is released.

Once this situation happens, you don’t have to replace the exhaust pipe yours into a new one as it may cost much. What you can do to deal with the problem is to weld the pipe with an exhaust welder, which reduces the cost you might have to spend and keep the normal function that it is supposed to have at the same time.

:: Read more: An Introduction to Automotive Spot Welder


What to Prepare for Using an Exhaust Welder?

Before starting to weld the exhaust pipe, there are some things that should be prepared first, including the safety components, a working table, and a vise, a ground clamp, a shielding gas tank, a torch, and a connecting cable, the welder, and the electric power supply.


● safety components

The safety components contain a pair of leather gloves and safety glasses, and a welding helmet. Also, remember to dress appropriately in order to prevent the sparks that are produced during the welding processes from splashing on your skin.


● a working table and a vise

A proper working site should have a working table that is able to accommodate the height of the operator, so as to facilitate the smoothness of the working processes.

In addition, there should also be a vise that is used to clamp the workpiece, which is the exhaust pipe, in place with the two jaws, in order to ensure the firmness of the work when being welded.


● a ground clamp

A ground clamp is like the pincers that are used to hold onto the exhaust pipe and is used to make a continuous and complete circuit during the welding processes.

To create a complete circuit during the processes, the surfaces where the workpiece is going to be welded should be clean without dirt, chips, oil, or other substances, as well as the site where the ground clamp holds onto.


● a shielding gas tank

During the welding processes, the workpiece would be shielded with gas, which is a mixture of argon and carbon dioxide. Therefore, before the processes begin, you need to make sure the shielding gas tank is turned on so that the tank would provide an adequate flow of gas to protect the exhaust pipe when it is welded.


● a torch and a connecting cable

The torch is regarded as the electrode holder, which holds the electrode that performs the welding work on the workpiece. For the welding of the exhaust pipe, a MIG welder or MIG welding machine is usually applied.

In this circumstance, the torch holds the metal electrode from a wire reel through a drive roll. The metal wire would be gradually consumed, and the new wire would keep being delivered to the working site from the wire reel during the processes.


● the welder

As the above paragraph has mentioned, the welding of the exhaust pipe usually applies a MIG welder. This device should be connected to the electric power supply before the welding work.

On the MIG welder, there would be a dial for adjusting the wire feed. Besides, three sets of switches can be seen on the welder as well. Among those switches, one is used to turn on and off the welder, and the other two are responsible for the adjustment of the high or low temperatures of the electrode.


● electric power supply

Since the welding process is conducted with an electrode that is made of metals, a sufficient electric power supply is required. Thus, when the exhaust welder is about to work, the connecting cable should be plugged into the electrical outlet first.


How Does an Exhaust Welder Work?

To weld a wearing exhaust pipe, which leaves a gap on the surfaces, the pipe should be clamped on the vise first. Afterward, the ground clamp should hold onto the area on the pipe where it is going to be welded.

Next, plug in the welder and the torch, and turn on the welder by pressing the switch. Then choose the appropriate temperature for the other two switches, and adjust the wire feed that the work requires by turning the dial. Also, the shielding gas tank should be prepared here as well.

After the workpiece is prepared, the welder is set properly, and the shielding gas tank is turned on, hold the torch by the handle. On the handle of the torch, there would be a trigger switch.

Once the torch is placed on the welding site, press the switch to expose the electrode to the exhaust pipe. To finish the whole round of welding on the exhaust pipe, this should be done several times, and then you can get the welded pipe that returns to the normal function as it is supposed to have.


Can an Exhaust Clamp Replace Other Welding Process?

In addition to using the exhaust welder to join the separated parts, there is another method that is used to cover the gaps on the exhaust pipes without the welding processes, which is the exhaust clamps.

An exhaust clamp is a circular object that can wrap around and fasten the exhaust pipe, in order to cover the wearing parts on the pipe, which is an additional component that is added onto the pipe.

Using an exhaust clamp is easier than welding the exhaust pipe with an exhaust welder, while the latter joins the gaps on the pipe with the direct seal on the pipe.

Both of them have their own supporters, which means that the exhaust clamp is able to replace the welding process, but they do perform as well as each other, so the choice may vary based on personal preferences actually.


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