What Are the Benefits of a Battery-Powered Welder?

A battery-powered welder uses lithium-ion (Li-ion) batteries to create the required power for a welding arc. Lithium-ion batteries offer a higher energy density compared to older battery types, such as nickel-cadmium (NiCd) or nickel-metal hydride (NiMH). They can store more energy in the same amount of space, propelling advances in numerous cordless tool categories, including welding.

However, unlike tools that are either cordless or connected, battery-powered welders such as the ESAB’s Renegade VOLT™ ES 200i also connect to 120/230V primary power, giving users the benefit of a standard welder.

Why would you use a battery welder?

Battery welders optimize logistics, especially when downtime is expensive. Some of their advantages include:

• Portability and quick set-up. 
• Weld in difficult-to-reach locations and locations without power. 
• No need to drag heavy and expensive welding cables or extension cords.
• No need for a heavy truck, trailer or crane to move the machine. 
• Eliminating issues related to engine drives that include obtaining a hot work permit, fuel storage and costs, fumes and noise.

What type of batteries do battery welders use?

Welding machine manufacturers have taken two different approaches to battery welder design. One approach features a large, custom-designed battery that is an integral part of the welding unit. When the battery is discharged, the welder needs to be connected to a primary power source to recharge the battery. Welding cannot continue until a minimum power level is reached or the unit can operate in primary power mode. 

The Renegade VOLT uses a detachable battery box with a twist-lock cable connection to the back of the power source. The battery box contains ports for four standard DEWALT® FLEXVOLT® 12 Ah (amp-hour) Li-ion batteries, which are the exact same batteries used for DEWALT power tools. When a battery is depleted, the user can swap in fresh batteries and continue working in seconds, just like they would with a cordless cool.

To operate on primary power, disconnect battery box cable using the twist-lock connection and connect a primary power cable. This cable comes with a hardwired 230V plug, and a simple adapter enables welding with 120V primary. In fact, because the battery box (29 lbs. with four batters) easily detached from the power source (25 lbs.), Renegade VOLT can function exactly any a premium 200-amp Stick/TIG welder.

How much power does a battery welder provide?

Welding output is machine-specific. On battery power, the Renegade VOLT offers a Stick welding output of 10 – 140 amps and a TIG welding output of 10 – 150 amps. It is optimized for performance with 3/32-in. diameter Stick electrodes but also has the power to run 1/8-in. Stick electrodes in battery mode.

When connected to 230V primary power, it provides a welding output of 200 amps at 25% duty cycle (more than enough for 5/32-in. Stick electrodes). When connected to 120V power, it provides a Stick output of 110 amps at 25% duty cycle and TIG output of 140 amps. 

In addition, the Renegade VOLT welder offers an exclusive “AMP +” hybrid mode. When connected to 120V power, operating in AMP + mode supplements the wall power with battery power to provide a Stick out of 150 amps and a TIG output of 180 amps, both at 25% duty cycle. The added power mitigates nuisance tripping.

How long can you weld with a battery welder?

Renegade VOLT lets you get 50 to 100% more work done compared to other battery welders. With fully charged batteries, it can weld at 80 amps with up to 33 3/32 x 10-in. 6013 electrodes, and it can TIG weld at 70 amps for approximately 45 minutes. The machine’s battery status display and remaining arc time calculator provide clarity.

Welding duration will vary by welding output. In a video demonstration, two operators Stick welded for more than 26 minutes at 95 amps, consuming 26 electrodes. However, note that with the Renegade VOLT, the batteries are hot swappable. When a battery is depleted, swap in a fresh battery (one or all four) and continue welding. 

This machine comes with separate four-port fast charger and four 12 Ah batteries. The charger brings the batteries from zero to full charge in about 100 minutes. With extra batteries, you can weld continuously within the machine’s duty cycle. Continuous welding may also be obtained by connecting to primary power (again, within the machine’s duty cycle).

Note that 6 and 9 Ah batteries may also be used, but they will not weld as long.

Are battery welders “real” welders?

Like conventional welders, the quality and capabilities of battery-powered welders runs the gamut from low-cost electronics to sophisticated, professional welding tools. 

As of early 2024, there are only a few products that meet the “professional” standard, which starts with a design built for tough welding environments and includes an arc quality that will be identical whether the machine is operated in battery-mode or connected to primary power. 

In fact, welders like Renegade VOLT use a next-generation current control module with built-in intelligence that can detect and clear a short circuit or manage current transients faster than the microprocessor controls used on other units. They create a stable, more controllable weld pool while also minimizing spatter.

Currently, these professional-level products offer outputs for Stick and Live-TIG (for TIG welding without the use of a high-frequency arc starter). A premium battery-powered welder will also have the advanced controls found on standard professional welders. These include:

• Electrode type selector:
  • Adjusts the arc characteristics the low-hydrogen (7018) electrodes used for welding structural and high-strength steels
  • Adjust the arc rutile (6013) and cellulosic (6010/6011) electrodes used for pipe, field construction, farm and applications. 
• Adjustable Hot Start, which fine tunes the optimal energy during the arc starting sequence for improved strike performance and reduced sticking.
• Adjustable Arc Force function enables the operator to adjust the arc characteristics so that they are crisper or softer, tailoring the arc for different electrodes, applications, and operator preferences. 
• A “jobs” function where favorite settings can be stored in one of three memory functions. 

What can you weld with a battery welder?

When you choose a professional battery welder, you can weld anything you could weld with an equivalent “connected” Stick/TIG welder. The arc characteristics and performance will be the same.