Torches and guns
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Frequently asked questions
How do I size a MIG gun to the welding current?
MIG guns are rated in amps at a stated duty cycle and gas type, so a gun rated 250 A on CO2 is rated lower with mixed gas. Choose a rating no lower than the actual welding current to avoid overheating the handle and cable. Water-cooled guns are used for high current and long continuous welds.
How often should contact tips and nozzles be replaced?
A worn contact tip bore gives poor electrical contact and an erratic arc, so replace it when the bore goes oval or spatter builds up. Spatter in the nozzle deflects gas flow, so clean it regularly and use anti-spatter. Tips and nozzles must match the gun system, since systems differ in thread and dimensions.
Air-cooled or water-cooled TIG torch?
Air-cooled TIG torches are light and simple, used at low to medium current. At high current or long duty, a water-cooled torch is needed to keep the handle cool, but it requires a coolant circulator. Check that the torch connector type matches the welding machine.
How do I choose a cutting tip for an oxy-fuel torch?
Cutting tips are chosen by steel thickness and fuel gas, since acetylene and LPG tips are built differently. Larger tips cut thicker steel but consume more gas. A dirty or damaged tip deflects the cutting oxygen stream and gives a poor kerf, so clean it with the correct size tip cleaner.
How does MIG gun cable length matter?
A longer cable gives more reach but adds wire feeding friction, especially with small or soft wire. 3 to 4 m cables are common for steel wire, while aluminum wire calls for a short cable or a push-pull gun. The liner must match wire diameter and type, and be replaced when dirty or kinked.
When should the liner in a MIG gun be replaced?
The steel liner wears and fills with metal dust over time, causing erratic feeding and jams. Replace it when feeding stays uneven after blowing it out, and cut it to the correct length for the gun. Aluminum wire uses a PTFE or nylon liner instead of steel.
Which tungsten electrode should be used for TIG?
2% lanthanated tungsten (WL20, blue tip) and ceriated tungsten (WC20, grey tip) work well on both DC and AC, and are replacing radioactive thoriated tungsten. Pure tungsten (green tip) is used for AC aluminum welding on older machines. Electrode diameter is chosen by welding current.
How should tungsten be ground?
Grind lengthwise on a dedicated wheel so the grind marks run parallel to the axis, which stabilizes the arc. The taper length is usually about 2 to 3 times the diameter, with a small flat at the tip to resist breakage at high current. Dust from thoriated tungsten needs extraction because it is radioactive.
