A welding whip is an important part of a stick welding setup. Stick welding, of course, involves the use of a consumable rod-like electrode.
Also known as Shielded Metal Arc Welding (SMAW), stick welding uses heat to melt the electrode and the base material. With temperatures reaching 6,500 to 10,000 degrees Fahrenheit, it essentially fuses them together. In addition to the actual machine, however, stick welding typically requires the use of a welding whip.
What Is a Welding Whip?
A welding whip is a cable that connects a welding machine to an electrode holder. It’s responsible for carrying the electrical current from the power source to the electrode. Without a welding whip, there wouldn’t be any way for the electrical current to reach the electrode. And without an electrical current, the electrode wouldn’t melt and fuse with the base material.
How a Welding Whip Works
A typical stick welding setup consists of a few key components, including the machine itself, a welding lead, a welding whip, an electrode holder and an electrode.
One end of the welding whip connects to either the machine or the lead (assuming the machine has a lead attached). Welding whips typically feature a molded connector on one end that’s designed specifically for a welding machine or lead.
The opposite end of the welding whip connects to the electrode holder. There are different types of electrode holders, one of the most common being clamp-style holders. Clamp-style electrode holders feature a spring-loaded mechanism that allows them to “clamp” down on electrodes.
What Are Welding Whips Made Of?
Because they are designed to carry an electrical current from the welding machine to the electrode holder, welding whips must be made of a conductive material. The core typically consists of thousands of conductive strands. Some welding whips use all-copper strands, whereas others use tin-coated copper strands. Regardless, these conductive strands provide a conduit for electricity.
In addition to a conductive core, welding whips feature a protective outer jacket. This jacket acts as insulation, protecting the inner core from moisture and interference. Common jacket materials for welding whips include rubber or EPDM.
Welding Whips and Flexibility
Welding whips do more than just provide electrical current to the electrode holder; they allow the operator to easily move the electrode holder around.
When welding, the operator must move the electrode holder over the areas or parts that require welding. A stiff welding whip will make this task difficult if not impossible. Fortunately, welding whips are designed with an emphasis on flexibility. They can bend and flex without interfering with their operation.