Many welders consider the MIG consumables as normal welding products- an ordinary item to be ‘thrown-away’, but the reality is far different than what is gossiping around. MIG welding consumables are essential to generate quality welding output in the least possible timeframe.
Such a component has enough potential to affect the overall productivity as well as the cost of the welding operation. This is why it is crucial than ever to find the best, long-lasting welding consumables and maintain them with as much attention as would for any other piece of welding equipment.
Significance of MIG consumables maintenance
MIG consumables comprise different components- nozzle, head and contact tip, and the liner. Altogether, the smooth functioning of these elements produces quality arc to the MIG welder while feeding the welding wire via MIG gun and establishing electrical conductivity. However, these MIG components are the most overlooked part of the entire welding operations. With no proper care, installation, and timely maintenance, these components can cause significant downtime.
Fortunately, there are ways to extend the life of these crucial MIG welding components. By putting to practice any of these before-mentioned tips are likely to improve the quality and durability of your front-end welding consumables- which in turn increases the productivity, reduced downtime, and cost savings.
Tip 1. Keep the Tip tight
While welding, make sure the contact tip is not too tight or too loose to the wire. A tight connection could cause a freeze-up inside the tip, whereas a loose connection could cause arcing inside the tip. If possible, use a contact tip (comprise contact tip and retaining head or diffuser), that stays tight or has locking features. To handle the contact tip and retaining head with utmost care. When you are installing it with the best MIG welder, make sure they are free of oil or debris because any contaminant can cause electrical resistance which can overheat the component.
Always remember good connectivity results in quality weld output. Moreover, it helps the MIG consumables last longer.
Tip 2. Select and maintain nozzles properly
The function of the nozzle is accountable for releasing the shielding gas around the welding wire and it protects the weld from contaminants. Therefore, to prevent the spatter around the welding arc, select a nozzle with a smooth, non-porous surface that is free of sharp edges or flat surfaces. Also, for its lasting use, store it in the plastic bag.
Tip 3. Choose the right alloy
Nozzles and diffusers are available with different alloy types- ranging from copper, brass to nickel-coated, each well-suited for specific applications. However, copper alloy 122 is the most standard alloy used for MIG welder guns contact tip.
It is best in MIG welder’s interests to check the manufacturer’s recommended alloy type before starting welding operation.
Tip 4. Select heavy-duty consumables
Installation of heavy-duty front-end consumables can help to extend the life. Heavy-duty tip and diffusers installed inside the consumables have thicker walls than any standard consumables. Such consumables act as a heat sinking medium, reducing damage to the front-end consumables. Therefore, if possible, then use heavy consumables as they are more able to resist both heat and spatter, and they often last longer.
Tips 5. Proper maintenance to consumables
Efficient usage and timely maintenance can play a key role in extending the life of MIG front-end welding consumables. For this, regularly clean the nozzles to avoid contaminants that may build up spatter inside the nozzle. After cleaning the nozzle, ensure that the tip, diffuser, and nozzle are installed in proper alignment.
Maintaining the quality of your welding consumables saves both time and money, and most importantly, it enables the welder to concentrate on creating accurate weld with precision.