What Is Secondary Power In Welding?

Welding is an essential part of modern engineering and is used in a wide variety of industrial applications. In the welding process, welders must account for multiple variables, including the type of joint, welding position, and welding power.

One important element of welding is secondary power, which is a form of supplemental power that helps improve the quality of the weld. Today, nearly 55 million tons of metals are welded in the U. S.

each year, and secondary power can help make sure the welds are of the highest quality. In this article, we’ll explain what secondary power is and how it helps in welding.

So, let’s get started!

What Is Secondary Power in Welding?

Welding is an essential process for any metal fabrication or maintenance project. It is important for welders to have the right equipment and knowledge to complete their projects successfully.

One of the important concepts to understand in welding is secondary power.

What is Secondary Power?

Secondary power is the extra electrical current available for welding through a machine. This is in addition to the primary power, usually current between 50 and 200 amps.

It’s also sometimes known as “overload”. Secondary power is used to allow welders to penetrate thicker pieces of metal and can make welding easier in some cases. It is important to understand when and how to use secondary power when welding to ensure that you get the desired weld quality and safety.

How It Works

Secondary power works by giving the welder an extra boost of current on a voltage dip. When the primary current is not at full capacity, the welder can dial-in a boost of extra current.

This boost of power allows the welder to penetrate thicker pieces of metal and make deeper deposits. When using secondary power, the welders should be mindful of the heat input they are putting into the workpiece. Too much heat input may lead to increased distortion, fusion defects and even cracking of the workpiece.

When Is Secondary Power Used?

Secondary power can be used for applications where the extra power is needed to penetrate thicker pieces of metal. It is also used in welding larger parts, when two pieces of metal need to be welded together but one is thicker than the other, or when the joint requires a larger weld pool.

Safety Precautions

When using secondary power to weld, it is important to use safety precautions. This is because the increased current from the secondary power may cause an increased risk of electric shocks or arc burns. Always wear the correct safety gear, including an arc-rated face shield and fire-resistant clothing. Make sure you have a proper ground connection, and measure the voltage and current before starting with secondary power. Also, check the polarity of the electrode for the correct amount of current input.


Understanding and using secondary power in welding can come in handy when thicker pieces of metal need to be welded. It is important to use safety precautions when welding with secondary power and to understand the limits of the machine being used. With the right knowledge and understanding of when and how to use secondary power, welders can get the desired welds with great results. Citations:https://www. goodfoodwelding. com/secondary-power/https://www. lincolnelectric. com/en-us/support/welding-how-to/pages/weld-talk-005-understanding-and-improving-weld-penetration. aspxhttps://www. millercarbonarc. com/how-to-use-high-secondary-power/

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