Andy MonkClick image to enlargeBy Andy Monk

Overcoming common problems and consumables issues


Making a high quality MIG weld depends in part on having a gun and consumables that are functioning properly. When something isn't right with these components, problems can occur. Here are some tips for solving common consumables and gun-related problems associated with MIG welding.

Contact tip burn back can simply occur from time to time, but it can also be caused by improper equipment set-up. Check for improper contact tip recess or improper wire stick out. Adjusting the distance between the gun and work piece can resolve the problem, as can replacing cables to prevent a faulty work lead/ground that may lead to burn back.

Erratic wire feeding can be caused, in part, by a worn or kinked liner, dirt in the liner or the wrong size of liner. Trimming the MIG gun liner according to the manufacturer's recommendations is key, as is using the proper tools to cut it. Some manufacturers offer a liner gauge to determine proper length and/or a spring-loaded module that combines with a front-load liner to minimize issues of an incorrect liner length. The modules, housed in the power pin, put forward pressure on the liner and allow up to 1-in. forgiveness if the liner is too short.

Short contact tip life can stem from the wrong size contact tip, exposure to excessive heat or erosion caused by the wire. If the contact tip is melting, it's likely a result of exceeding the rated amperage or duty cycle. If the wire is prematurely wearing out the contact tip, the drive rolls may be creating small burrs on the wire that can erode the inside of the tip. Setting the drive roll tension too high also can create deformities in the wire. Rectifying these issues can help lengthen the contact tip life.

A gun running hot is likely caused by exceeding the rated amperage or duty cycle, or loose power connections or a degraded power cable, which can cause excessive resistance in the weld power circuit. Make sure to keep parameters within the gun's range or use a higher-rated gun. Clean and tighten connections and replace those that are worn out. A discoloured liner is a sign of loose power connections or a degraded power cable. Also, check to make sure the work lead connection is tight and free of obstruction. SMT

Andy Monk is product manager for Bernard, Beecher, IL.


Clean Air for Less

by Jim Reid

Optimizing your air quality system

Enhanced LiveArc reality-based training for welding

Miller has enhanced its LiveArc reality-based training system with features designed to further advance students’ welding skills—quickly and efficiently.

Translas partners with Gullco on distribution deal

Translas, a global manufacturer of on- torch fume extraction solutions, has announced a distribution partnership with Gullco International Ltd. Based in Newmarket, Ont., Gullco will be the global distributor of Translas’ newest fume extraction solutions, namely Translas 7XE Semi-Automatic Fume Extraction welding gun and the ClearO2 W-Series hi-vac units, designed and engineered for welding automation.

High performance micro TIG

The high performance MAWA-300B pulsed micro TIG welding power supply is ideal for pulse arc welding of coils and terminals, bus bars and coated wires in the automotive, medical, battery and electronics industries.

Looking ahead

by Kip Hanson

Photos by Tyler Garnham

BC job shop takes a slow but steady approach to growth

The Problem: Switching machine tool brands to save costs leads to lacklustre results
The Solution: Return to the fold with a vertical machining centre

Global manufacturing expertise

by Steve Rodgers

Canadian automotive suppliers gaining international respect

One of the recognized truisms of the Canadian automotive industry is that from a manufacturing perspective, we have long punched above our economic weight.

Managing Growth

SMEs are an important economic engine of growth for Canada. Indeed, of the nearly 12 million Canadians employed by the private sector in this country, close to 70 per cent work for SMEs. And just over half of that 70 per cent work in the goods producing sector. 

Training for Canada's manufacturers

The work is there, the skilled workers are not

by Tim Wilson

There is good news for Canada’s manufacturing sector.

14 roads you wouldn’t want to drive on

Here's a look at 14 roads around the world that are not for the faint of heart.

10 Ways To Reduce Weld Fumes

by Nestor Gula

A systematic approach to reducing weld fumes 

Robotic programming for welding and plasma cutting

A case study on Quebec fabricator Groupe Gravel. How Hypertherm's Robotmaster helped the company get setup for robotic programming for cutting and welding and the benefits the company achieved.

Spindle fix

Maintenance, repair and rebuild tips for machine spindles

by Kevin Sekerak

Identify theft

In the movie “Identity Thief” actor Jason Bateman plays the role of a man whose identity is stolen by a con artist. 

Stay In Touch

twitter facebook linkedIn