• Home
  • »
  • Blog
  • »
  • Contact Tips Problems and How to Solve Them


Jun 01,2022
Normally while I'm meeting with a Foreman or Production Manager and have an opportunity to talk direct to their welders, one of the most widely recognized points that surface is their contact tips. The issue: they need to transform them to an extreme. This kills efficiency for the shop, whittles down cost, and for the most part makes a less productive environment for the welder to work in.

So for what reason are your contact tips not enduring? Also, what are the issues that cause the contact tips to come up short? How would you forestall them? The three most normal issues you presumably experience constantly are:

• Unfortunate Contact Tip Life and Quality
• Burn back
• Wire Whip

I will go through beneath the 3 most normal contact tip issues I stumble into on an everyday premise, and how regularly you can conquer those issues.

Unfortunate Contact Tip Life and Quality
They appear to be identical, string something similar, feel a similar in your grasp, yet when you put it under serious scrutiny it's an alternate story. Pretty much every welding supply producer makes a copper contact tip, yet assuming you've attempted large numbers of them telling that not all hold up the same is simple.

Not all tips are made equivalent. Unfortunate contact tips equivalent terrible quality welds and high measures of margin time. The objective of any contact tip is to supply voltage into the wire. However, on the off chance that you have a contact tip that isn't directing voltage the manner in which it would it be advisable for you'll to you'll encounter high obstruction, expanded heat at the tip, expanded wear, and weld quality issues. How? A contact tip that isn't leading voltage as it ought to will deliver more splash and miniature arcing.

The best answer for this issue is to check out and consider higher grade contact tips. Utilizing a copper zirconium, silver-plated, or even a cleaner copper tip can have a major effect in contact top execution, life range, and weld quality. We really detail different contact tip materials in another blog entry.

Taking a gander at your contact tip resilience is one more method for safeguarding and get more life out of your contact tip. Not all contact tip creators produce tips with similar resiliences on the tip hole. Those that have bigger resistances, or deviations, on the contact tip size can prompt issues like miniature arcing and unfortunate conductivity. Investigate your contact tip resiliences and perceive how cozy the wire is on the stick out.

Burn back is the point at which the wire in going through the opening of the tip bends right toward the start of the tip and consumes once more into the contact tip. Burn back is an issue for welders and welding tasks - particularly in proficient conditions, since it makes a ton of free time. Whether you attempt to record the burn back harm off the tip and pull the wire, or simply need to garbage it and supplant it, one way or another it costs the welder time away from manufacturing. Also, on the off chance that you take the most widely recognized (and simple) course, supplanting the contact tip, you're adding material expense along with time, which intensifies the misfortune.

To address getting burn back it truly boils down to understanding the reasons you get burn back in any case. There are a ton of causes, however a portion of the significant ones are:

• Weld Parameters
• Excessively Low or High Voltage
• Messy Material on the Base Metal
• Low quality Filler Metal
• Poor/Incorrect Contact Tip
• Worn or Damaged Liner

One of the more normal causes is a wrong tip and wire size. Assuming you're utilizing, for instance, an .045 contact tip welding with .035 wire, this will cause burn back. An erroneous tip size means unfortunate conductivity inside the contact tip, miniature arcing inside the contact tip, and the wire hauling and encountering burn back subsequently. So check to ensure you're utilizing a contact tip size that matches the wire first assuming you get burn back.

Low quality filler metal or tip material is one more justification for burn back that is normal. Utilizing higher grade materials will assist with making the bend start and conductivity cleaner and more solid, and cut down on the miniature arcing and other early indications of burn back.

Taking a gander at the base metal is another arrangement. Assuming it's grimy or you're attempting to weld through some rust or oxidation, burn back could happen. Clean and prep your base metal completely before you weld whenever the situation allows. Additionally make a point to really take a look at your liner for defiles.

Wire Whip
This is commonly to a greater extent an issue in mechanization as opposed to handheld welding. Wire whip is the point at which the wire standing out from the contact tip sort of meanders around somewhat away from the bearing of the contact tip opening. It's an issue of the contact tip, nonetheless, on the grounds that inside the tip it's not holding the wire cozy and is permitting it to shift askew and not hit the welding joint where it needs to.

Wire whip is caused a great deal by basic link twist or welding administrators not having or wire straightener. At the point when wire is emerging from a spool barrel it has a memory, or cast, so when the wire is unspooled from the barrel through the liner and in the end out of the contact tip, that memory will play a consider where the wire goes. Now and again, it can miss the entire joint.

At the point when a welder encounters wire whip, they frequently can change position and control the light neck to beat that issue. In mechanization, an issue can't necessarily be killed yet can continuously essentially be made up for. One of the ways of defeating wire whip resilience for this situation addresses the tip hole. is by utilizing tight resilience contact tips, which seat the wire in a significantly more constrictive way and permit a negligible measure of deviation from the heading of the contact tip hole.