23 Apr 2020

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Welding Industries Australia

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Money Saving Tips for MIG Guns

Money Saving Tips for MIG Guns

6 Ways to Save.

Using these tips will help to reduce MIG gun and consumable downtime and costs, so you can get back to welding faster, get equipment back into service sooner, and save money.

Tip 1. Protect the assets

Keep nozzles, gas diffusers and contact tips in their original packaging until they’re ready for use. This will protect them from environmental damage, and will prevent scratches, dents and spatter accumulation, all which cause the consumables to fail prematurely. In addition, it will prevent dirt, oil and other debris from sticking to the consumables and entering the weld puddle, which can lead to poor weld quality and costly and time consuming re-work.

Tip 2. Select the right neck

Choose the most appropriate neck for your MIG application. Rotatable necks are especially useful for welding different angles or in tight spaces. These can be adjusted without tools so neck angles can be changed quickly, reducing changeover downtime.

Tip 3. Perform regular inspections

Take a look at both the inside and outside of your nozzle for spatter built up. Either clean the nozzle with a tool designed specifically for the job or replace it if necessary. Also check that the nozzle, contact tip and retaining head are tightened properly.

Regular inspections help ensure good shielding gas coverage, reliable electrical conductivity and consistent weld quality, as well as reduce replacement costs.

Tip 4. Trim the liner properly

Cut your MIG Gun with the right tools and to the correct length, as outlined by the manufacturer. A liner too long can cause kinking, and one too short can allow debris to build up between the liner and the gas diffuser. Either way, the wrong liner length can cause poor wire feeding and premature failure of both the liner and the contact tip. After cutting, make sure there are no burrs or sharp edges.

Protect the liner from contaminants and handle it with clean hands or gloves, don’t let it drag on the ground. These precautions can help prevent contaminants entering the weld puddle, and can prevent costly weld quality issues or weld time re-work.

Tip 5. Select the best cable length for the job

Use the shortest length MIG gun cable possible. This will minimise the opportunity for kinking and premature wear of the cable and MIG gun liner. A shorter cable helps prevent wire-feeding problems that can lead to an erratic arc, poor weld quality and unnecessary downtime for rework or consumable replacement. It also tends to cost less, savings costs on repair jobs.

Choose the correct diameter liner and contact tip for the welding wire, as this prevents similar problems and helps extend the life of these consumables.

Tip 6. Invest in consumables

Sometimes spending a little more initially can mean significant savings in the long run. Investing in quality durable consumables can provide longer tip life, and fewer and faster tip changeovers, reducing both consumables costs and operator downtime.

When selecting a nozzle, look for a smooth, non-porous surface, check that the nozzles are free of any sharp edges or flat spots. This will help prevent spatter to adhere and accumulate.

View our full range of Bernard MIG guns and Centerfire consumables

For information on our MIG guns and consumable range contact our customer support team on 1300 300 884.

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