DESIGN AND CONSTRUCTION OF AN ARC WELDING MACHINE USING MICRO-WAVE OVEN TRANSFORMER

Abstract Arc welding machines are widely used in fabrication, repair, and construction because they produce strong and durable joints between metals. However, commercial welding machines can be expensive for small workshops, students, and local artisans. This study focuses on the design and construction of a low-cost arc welding machine using a microwave oven transformer (MOT). Microwave transformers are readily available from discarded microwave ovens and can be modified to produce high current at low voltage, which is required for arc welding. The transformer was rewound to reduce the output voltage and increase the current suitable for welding operations. Additional components such as a welding electrode holder, power switch, cooling system, and protective casing were integrated into the design. The constructed welding machine was tested using mild steel electrodes, and the results showed that it was capable of producing stable welding arcs and satisfactory weld joints. The study demonstrates that locally available materials can be utilized to construct functional welding equipment, thereby reducing cost and promoting technological innovation in engineering education and small-scale industries. Keywords: Arc welding machine, microwave oven transformer, welding technology, transformer modification, fabrication.