BINZEL BASICS: Air-cooled MIG Welding Torch Maintenance Tips

During my years as an Area Sales Manager, there was one question that I regularly got asked from our customers & welders:

"Danny, why am I going through an excessive amount of contact tips, gas nozzles, gas diffusors, tip adaptors & liners?"

The answer may be simple.

First check the following: 

1. Is the tip adaptor & contact tip loose?

• Loose front end consumables will result in overheating & poor current transfer - make sure they are tight.
• Contact tips will look overheated (cooked).
• Diffusers will have a burnt look at the edges - the diffuser is wearing away or cracked
• Liners with signs of overheating ringlets may even look melted together.

Next step:

2. Is there a gas flow problem?

• Use a gas flow tester to check what is actually being delivered to the front end of the torch.
• Welding at a current of 300 amps will require between 16-18 litres per minute.
• MIG torches are gas cooled and need gas to not only protect the weld metal but gas also cools the front end consumables and increases their lifetime.

Regarding Liners:

3. Liners must be fitted correctly to avoid wire feeding problems:

• Short or poorly fitted liners will result in wire burn backs. See fitting instructions on the liner packet.
• The liner should have a 45 degree angle at the front end so it fits centrally in the flute at the back of the contact tip.
• If you're using a torch with a removable neck - such as an ABIMIG A T or W T, consider using neck liners to make a quick neck change.

Follow these simple 'Care & Maintenance' tips and you'll see a significant reduction in your consumables usage.

Looking for more in-depth information on welding guns and how they impact performance? Our free guide, The Advantages of Lightweight Torches, takes an in-depth look at every facet of the welding  gun design and how it impacts comfort, performance, and you. Check it out by clicking here or on the button below.