Summer 2009 Edition

Ask Tech Services

Image of orange phone for calling Tech Services at TregaskissQUESTION:  When does it make sense to switch from heavy-duty to standard-duty contact tips to save money?

ANSWER:   When buying an automated welding system or when using a mid- to high-amperage semi-automatic MIG gun, most people default to a heavy-duty contact tip system.  This is usually due to historical buying behavior—we buy what we know.

However, there are certain semi-automatic and robotic welding applications that may be suited to standard-duty tips, nozzles and retaining heads.   In general, these standard-duty consumables are recommended for lower heat applications that result from one or more of the following:

  • Brief arc-on times
  • Short welds or tacks
  • Long periods of time between welds
  • Low amperage and voltage settings
  • Small diameter wire sizes
  • Mixed gas type

Standard Duty Tips for Semi-Automatic Welding

Generally speaking, if you use a low amperage semi-automatic air-cooled welding gun for short welds or tacks, then standard duty tips should work very well for you.

Semi-automatic applications with restricted access are also good candidates for the switch to standard-duty contact tips, retaining heads and nozzles.  If you are currently using heavy-duty tips that are tapered at the front end, you may be able to switch to a standard-duty contact tip.   This tip’s smaller outside diameter will enable you to:  increase gas coverage, reduce the bore size of the nozzle, and improve access to the weld while saving you cash!

Standard Duty Tips for Robotic Welding

Unlike semi-automatic applications where operators can adapt their welding as needed to maximize tip life, robots must weld the same way every time regardless of the condition of their consumables. 

For this reason, consumable changes are scheduled at specific times during or between shifts to prevent poor weld quality and unexpected downtime.  The frequency of these changes results in a certain amount of “wasted” consumable life since they occur regardless of the amount of wear on the consumables.  If this waste factor is large enough, a standard-duty tip might be more than adequate for your welding application.

To identify potential candidates for switching to standard-duty contact tips, nozzles and retaining heads, review the robotic applications in your facility and earmark those that have one or more of the lower heat characteristics listed at the start of this article.  Then it’s time to take them to trial!

Take a Trial Run!

Taking the time to run a trial with your semi-automatic or robotic welding application can help you determine if you can successfully make the switch from heavy-duty to standard-duty consumables.  Your Tregaskiss Account Representative has all the tools needed to run a successful contact tip trial in your facility and would be happy to assist you – just give them a call! 

Once your data has been collected, you can then do a Detailed Cost Analysis to determine the potential savings of switching to your lower cost standard-duty consumables.  If your numbers are in the black, then it’s time to roll out the change to all guns used in the same welding application so that you can begin to enjoy your savings.

Do you have a question for Tech Services? 

You can contact them by email or by phone at 1-877-737-3111.  Assistance is available Monday to Friday from 8 am to 5 pm EST.