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.
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.
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.