DeWalt Stick and Live TIG welder

A hybrid welder that actually makes sense in the field

I’ve spent enough days dragging leads and babying small generators to know the pain of portable stick work. This hybrid welder solves a bunch of those headaches in one shot: it runs on AC mains, on batteries, or in a mode that blends both. In practice, that flexibility isn’t a gimmick—it’s the defining reason I kept reaching for it on repair calls and remote jobs.

I used the welder primarily for stick (SMAW) and some live TIG (GTAW) on carbon and stainless. The unit ships with a battery box, four FLEXVOLT packs, and a four‑bay fast charger. That means you can actually put it to work on battery power right out of the case instead of hunting for compatible batteries and chargers. The enclosure is compact but stout, with an IP23 rating and multiple grab points. At 23 kg with the battery box loaded (about 51 lb), it’s not featherweight, but the carry handle and shoulder strap make short moves easy, and its footprint works well in a cramped truck bed.

Setup, interface, and controls

The front panel is better thought out than most portables. A color screen shows battery status for each pack, total remaining arc time, and your primary welding parameters. The time estimator wasn’t a novelty; it kept me honest about how many rods I could burn before swapping packs or finding a wall outlet. You also get adjustable hot start and arc force, a dedicated 6010 mode, and up to 10 programmable memories. That combination made it quick to bounce between 7018 structural repairs and 6010 root work without fiddling every time.

Open-circuit voltage sits at 78 VDC, which is part of why the 6010 mode behaves like it should. Beads start reliably and stay lit without that mushy, wandering arc you sometimes get on inverter boxes that claim to be “6010-capable.”

Power modes: battery, mains, and AMP+ hybrid

• Battery-only: On batteries, the welder tops out around 150 A. That’s enough for 1/8 in 7018 and 6010 in real-world scenarios. The arc is stable and consistent; I didn’t have to change my travel or manipulation to compensate for battery sag—the machine handles that.
• Mains (120/230 V): On 230 V, you get full output up to 200 A with respectable duty cycles. On 120 V, you’re limited (as expected), but the arc remains clean and usable.
• AMP+ hybrid: This turned out to be the killer feature for light shop circuits and jobsite temp power. Plugged into a common 120 V circuit, the machine blends in battery assist when the arc demands more current, which keeps from tripping breakers and extends your usable range. It’s a practical way to run hotter on a 20 A line without the dance of flipping breakers or limiting rod choice.

Power factor is 0.99 at max output and efficiency is specified at 80%. Subjectively, that tracks with the machine’s steady behavior and lack of “bogging” under load.

Real-world arc performance

With stick, the arc quality feels tuned, not generic. Hot start and arc force adjustments are meaningful, not token sliders. I left hot start moderate for 7018 to avoid chewing into edges and bumped arc force for out-of-position 6010 to keep the arc tight without sticking. The dedicated 6010 mode was the right call; it avoids the soft arc you sometimes get on inverters trying to be everything at once.

TIG is “live TIG,” which is to say a simple DC process without high-frequency bells and whistles. I used a lift‑start approach with a valve torch. Starts were predictable, and arc stability was good for stainless and carbon. If your work is aluminum with all the AC TIG trimmings—balance, frequency, HF start—this isn’t that machine. If you need clean DC TIG in the field or on the bench for fittings, brackets, or cosmetic passes, it does the job well.

Duty cycle claims lined up with my experience. On 230 V mains, the 200 A top end feels honest for short bursts with 1/8 in rods, and dropping to around 129 A gives you a generous 60% duty cycle for more continuous work. On battery, plan your welds like you would on a remote job: a few rods, a quick chip and brush, then keep moving. The arc doesn’t taper off as the batteries discharge; it holds steady and then calls it.

Battery life and charging

With four 12 Ah packs, my stick productivity was credible. Manufacturer estimates list roughly two to three dozen 2.5 mm rods depending on type; my mixed bag of 6010 and 7018 fell in that range with normal field prep and interpass times. The display’s remaining arc time was conservative enough to trust, which is what you want when you’re mid-repair and debating one more pass.

The four-port fast charger is a big deal for actual uptime. All four packs charged in well under two hours in my shop on a dedicated circuit, and that let me cycle sets throughout the day. Operating temp range of -10 to +40 °C is realistic; I used it in a cold morning start with no drama, though charging cold packs always benefits from acclimating them indoors first.

Ergonomics and build

The housing is impact-resistant and appropriately sealed for a jobsite (IP23). The battery box latches positively and doesn’t rattle, and the cable strain reliefs are robust. The included electrode holder and ground clamp are serviceable—nothing boutique, but they didn’t hold the machine back. If you have a favorite stinger, swap it in, but you won’t need to on day one. The fan curve isn’t obnoxious; it spools audibly under sustained load and idles down quickly. Standby draw is less than 30 W with Energy Save enabled.

Dimensions with the battery box (about 19 x 9 x 19 in) make it stack nicely on a rolling cart or tuck into a service body compartment. I appreciated the multiple lift points; grabbing it out of a trench or onto a scaffold felt safe and balanced.

Where it fits—and where it doesn’t

This is a field and maintenance machine first, a small-shop utility box second. It shines for:
- Remote repairs where dragging a generator or chasing power is a time sink
- Jobsites with limited 120 V circuits where AMP+ prevents nuisance trips
- Mixed stick work, especially if you regularly switch between 6010 and 7018
- DC TIG touch-ups on carbon and stainless, on location

It’s less ideal for:
- Dedicated AC TIG aluminum work (this is a live/DC TIG solution)
- Heavy, continuous production welding at high amperage
- Situations where sub-30 lb carry weight is essential—battery convenience comes with mass

Small details worth noting

• The NEMA 6‑50 plug is standard fare, and the 16 A slow‑blow rating aligns with the machine’s real current draw on 230 V.
• Open-circuit voltage at 78 VDC plays nicely with stubborn rods.
• Rated kVA is 2.7 kVA at 120 V and 6.0 kVA at 230 V, which matches my experience sizing circuits and seeing stable performance.
• The memory banks are genuinely useful. I saved presets for 6010 roots, 7018 fill/cap, and a couple of TIG settings, which sped up job transitions.

Pros and cons

Pros:
- Three power modes (battery, mains, hybrid) that meaningfully expand where and how you can weld
- Honest 6010 performance with high OCV and a dedicated mode
- Clear UI with battery health and remaining arc time that’s actually accurate
- Included battery ecosystem and fast charging enable real off-grid work
- Practical duty cycles at 230 V for day-to-day stick and TIG work

Cons:
- At ~51 lb with batteries, you feel it over longer carries
- Live/DC TIG only—great for field TIG, not a replacement for AC/HF TIG needs
- Battery runtime is finite; plan consumables and charge cycles like you would fuel for a generator

Recommendation

I recommend this welder for anyone who splits time between shop and field or regularly tackles maintenance and repair under less-than-ideal power conditions. The hybrid AMP+ mode, credible battery-only performance up to 150 A, and thoughtful controls (hot start, arc force, 6010 mode, and memories) make it a dependable problem-solver. If your work demands AC/HF TIG for aluminum or all-day, high-amperage production, pair this with a dedicated TIG or heavier inverter. For everything else—especially stick-heavy jobs where mobility matters—this unit earns a permanent spot on the truck.