For what it's worth
I built a DC welder using a 13hp Honda engine and a 100amp Chrysler alternator, the old "square" style with external regulator (not used).
After about 30 3/32" 6011 rods, the thing still works, much to my surprise. I run the rotor at full voltage - 13.5v, as I have a second car alt to keep the lawnmower battery fully charged during use, as the rotor draws about 6amps - so it runs 100% all the time. I hope to correct this by regulating the voltage going to the rotor somehow, with a reostat that can handle a steady 70w or so, as it burns too hot actually.
After every 2-3 rods, I shut the rotor voltage off for about 5 minutes to let it cool. Poor alternator wasn't designed to run 100% dead short.

Sorry it doesn't have anything to do with these welders you were talking about...just thought someone might find it interesting.