Ogunwusi Adebimpe Abosede¹, Ben-Festus Blessing Nneka¹,  Ben Festus^1,2

¹ Department of Physics, Federal Polytechnic Ede, Osun State, Nigeria

DOI: 

Keywords: E-waste, electric welding machine, environmental pollution, recycling, dimmer, microwave oven 

Abstract

The rising demand for affordable welding solutions in developing regions, alongside the environmental challenge of electronic waste (e-waste), has motivated the design of a low-cost arc welder fabricated from recycled components. This study presents the development and performance evaluation of a portable arc welding machine constructed from repurposed microwave oven transformers (MOTs). Two MOTs rated at 1080 W each were rewound to deliver a combined secondary output of 40.3 V and an average current of 125 A, suitable for welding mild steel rods of up to 5 mm thickness. A 4000 W dimmer circuit enabled smooth current regulation and arc stability during operation, while integrated 12 V DC cooling fans maintained safe thermal conditions. The prototype achieved a transformer efficiency of 78.5%, demonstrating steady arc performance and satisfactory weld penetration comparable to commercial welders in the 120–150 A class. By utilizing e-waste components and maintaining reliable welding capability, this work provides a sustainable and technically viable pathway toward low-cost welding technology in resource-constrained settings.

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