Tregaskiss Article Library

Learn more about welding automation, robotic MIG guns, welding consumables and more from our informative technical articles and case studies.

Welding Automation Articles

Interested in automating your welding operation? Troubleshooting? Or maximizing your robotic welding performance? Check out these welding automation articles.


Welding Application

Best Practices for Robotic Welding Supervisors

The welding supervisor managing the robotic welding cell plays a key role in achieving these results — and with some best practices in mind, can help ensure long-term success. There are some basics that provide a good starting point. Read more

Welding Application

How Robotic Welding Supervisors Can Improve the Operation

Even if a robotic welding system is meeting production and quality requirements, it’s important that robotic welding supervisors commit to a continuous improvement process. Read more

Welding Application

How to Successfully Implement a Robotic Welding System

In today’s marketplace, companies continue to automate portions, if not all of their welding operation. The reasons are many: to address a shortage of skilled labour, to improve quality, to decrease waste and rework, and/or to increase productivity — in short, to seek benefits that provide a competitive edge. Read more

Welding Application

Improving Welding Automation Safety with Risk Assessment and Training

Robotic welding systems continue to gain in popularity due to their ability to increase productivity, improve quality and decrease costs in the right application.With more and more robotic welding systems being implemented comes the need for increased attention to safety. Read more

Welding Application

Implementing Robotic Welding: What to Know to Be Successful

The potential advantages of robotic welding are well known — increased productivity, improved quality and greater cost savings compared to semi-automatic welding. But the question is: How do companies best implement this technology to gain these benefits? And how can they ensure a quick return on the investment (ROI)? Simply stated, planning. Read more

Welding Application

Preventive Maintenance for Reamers, Accessories and Other Peripherals

From reamers or nozzle cleaning stations to wire cutters and anti-spatter sprayers, welding peripherals and accessories can contribute significantly to the success of a robotic welding operation. In addition to improving weld quality, they can also help companies maintain high levels of productivity. Read more

Welding Application

Robotic Welding: Troubleshooting FAQs

Every operation wants to avoid downtime, as well as the cost for troubleshooting problems in the robotic welding cell. But sometimes issues happen, whether it’s due to equipment failure or human error. Analyzing some of the most frequent sources of trouble can help you get to the root of the problem sooner. Read more

Welding Application

7 Tips for Implementing a Robotic Welding Cell

Implementing robotic welding can significantly improve a manufacturing operation’s productivity and weld quality, but what are the robotic welding basics you should know to be successful? From choosing the right welding wire to establishing proper tool center point (TCP), many variables play a role in optimizing robotic welding cells to produce the best results. Read more.

Welding Application

5 Common Failures in Robotic Welding and How to Prevent Them

Is your robotic welding operation costing time and money for problems like burnbacks, premature contact tip wear, loss of tool center point (TCP) or other issues? These common failures in robotic welding can be costly, resulting in downtime and unplanned part replacement. Even issues that seem minor, such as the wire sticking to the contact tip and forcing tip replacement, can cost thousands of dollars per day. Read more

Welding Application

Spatter in Welding: Should You Consider Anti-Spatter Liquid?

Are you losing money and arc-on time for excessive contact tip changeovers? Anti-spatter liquid may be an option to help. This compound protects the front-end consumables on your robotic MIG gun from spatter accumulation, reducing downtime for tip replacements and helping to prevent shielding gas flow restrictions that could lead to porosity.  Read more

Welding Application

How to Select and Use Anti-Spatter Liquid

Having the right products for your welding application impacts quality and productivity. Anti-spatter liquid is no exception. When selecting an anti-spatter liquid for a robotic welding application, be certain it sprays with uniform coverage to protect the nozzle. Read more

Welding Application

Anti-Spatter Sprayer: How to See the Best Results

When using anti-spatter liquid in a robotic weld cell, there are steps you can take to optimize the application of the spray. The addition of an anti-spatter sprayer to a nozzle cleaning station helps ensure delivery of consistent amounts of anti-spatter liquid, leading to longer consumable life, better weld quality and higher productivity. Read more

Welding Application

Ethernet vs. Standard Reamer: Making the Selection 

Uptime is key in any robotic welding system. Not only does it help companies increase productivity, but it also supports a solid return on investment in the equipment. The addition of peripherals, like a nozzle cleaning station or reamer, can help further those goals. Read more

Robotic Welding

Tips to Optimize the Robotic Weld Cell

Companies invest in robotic welding systems to improve productivity and gain efficiencies in their operation. But if the weld cell layout is not optimized, it can negatively impact those goals — along with the quality of the completed welds. Read more.

Robotic Welding

Solving Five Causes of Downtime in a Robotic Welding Operation

Ensuring a robotic welding cell stays productive and consistently generates a positive return on investment is determined, in large part, by the amount of downtime it incurs. Read more.

TOUGH LOCK Consumables

Gain Efficiencies and Extend Consumable Life with Anti-Spatter Compound

When it comes to robotic welding operations, uptime is key. Minimizing air movement and ensuring consistent workflow are just as important as selecting the right robot, power source and robotic gas metal arc welding (GMAW) gun. Read more.


CA3 MIG Gun and Reamer

Tips for Optimizing Reamer Usage

A nozzle cleaning station, or reamer, is a peripheral that can be integrated into an automated welding system to maximize its performance. Reamers remove spatter from inside the gas metal arc welding (GMAW) gun's front-end consumables — nozzles, contact tips and retaining heads — that accumulates during routine welding. Read more.

CA3 MIG Gun and Reamer

Getting the Most Out of Peripherals

Peripherals — equipment that is integrated into the robotic welding process to make it more effective — can significantly boost the return on investment you achieve from your welding robot. Read more.

MIG Gun Clutch

What You Should Know About Robotic MIG Gun Clutches

Implementing and operating a robotic welding system requires attention to detail to gain high productivity and consistent quality. It's equally important to do whatever you can to protect your investment for the long term — from the robot to the MIG gun and more. Read more.


Best Practices and Troubleshooting Tips to Optimize Robotic Welding

Companies invest in robotic welding systems to improve productivity, gain more consistent weld quality and reduce costs. Robotic welding can also set companies apart from the competition by allowing for faster completion and delivery of products. Read more.

Robotic Welding

Robotic Welding Can Offer Benefits for Smaller Shops

Welding automation offers numerous benefits for companies of all sizes — from improved productivity and weld consistency to lower costs for production, labor and materials. Read more.

Robotic Welding

Equipment, Training, Maintenance and More: Best Practices for Successful Robotic Welding

The cost to implement welding automation can be substantial, requiring companies to plan out the purchase carefully and to justify the expenditure to the appropriate financial or management personnel. The payback on the investment, however, can be equally beneficial. Read more.

Robotic Welding

4 Strategies for Improving Throughput in Robotic Welding Applications

Robotic welding systems can provide many companies with increased productivity, improved quality and reduced costs — important and differentiating benefits in the fabrication and manufacturing world. However, simply implementing a robot or two isn't enough to maximize such benefits. Read more.


5 Common Myths About Robotic Welding Systems

Robotic welding systems provide speed, accuracy and repeatability in many fabrication and manufacturing applications — features that can increase productivity and consistency, and reduce rework. However, it takes more than just installing the system to have a profitable and automated welding operation. Read more.

Robotic Welding

Top Things to Teach a Robotic Welding Supervisor

Whether it's in a small fabrication shop or a large manufacturing facility, investing in a robotic welding system is no minor expense. However, it's the potential advantages of the system — greater productivity, higher quality, better consistency and more cost savings — that make the purchase such an attractive option; and it's the job of a robotic welding supervisor to make sure these results are obtained. Read more.

MIG Gun and Reamer

From Technology to Technical Support: Welding in Today's Automotive Industry

Worldwide, companies serving the automotive industry have faced a unique set of challenges in the last several years, including changes in material types, a lack of skilled labor and initiatives by OEMs to decrease the weight of vehicles. Read more.

Tregaskiss Conventional Liners 

7 Ways to Save Money on Robotic Welding

In addition to programming the robot in a manner that ensures the accuracy, speed and repeatability needed to complete high-quality welds, there are also several steps that companies can take to increase the return on their investment. Read more.

Robotic Welding

7 Things to Know About Robotic Welding Systems

Implementing a robotic welding system isn't something that happens on a whim — at least not successfully. Converting to this technology can help companies gain greater productivity, improve quality and reduce costs in the welding operation, but the process requires thorough planning to gain those results. Read more.


What You Must Know About Robotic Welding

In the fabrication and manufacturing world, quality and productivity are everything. To remain competitive, companies need to look continually for ways to increase throughput and minimize defects, while also keeping costs low for parts and labor. Read more.


FAQs About Robotic Peripherals Answered

Automated welding systems add speed, accuracy and repeatability to the welding operation. They can also help companies increase their productivity and reduce costs in a relatively short period of time. Read more.


From the Contact Tip to the Robot: Answers to Frequently Asked Questions About Welding Automation

In addition to offering faster speeds and greater productivity, robotic welding systems can improve weld cosmetics, reduce rework and repairs, lower material costs by limiting overwelding and also reduce labor costs. Read more.

Robotic Welding

Is it Time to Automate? 5 Factors to Consider

Making the decision to automate your welding process isn't something to be taken lightly. It requires careful assessment of your current welding process, a detailed plan to automate and, in most cases, the ability to justify the capital expenditure — tasks that together can take months to complete. Read more.

Robotic Welding

Should You Automate? Considerations for Making the Decision

As the economy continues to show signs of improvement, and manufacturers face greater demands for production, competition will likely increase across the marketplace. Some manufacturers may choose to automate their welding operations as a means to gain a competitive edge or improve profitability. This decision, however, is not one to be taken lightly. Read more.

TOUGH GUN G2 MIG Gun and Reamer

Troubleshooting Robotic Welding

In an ideal world, companies would never experience downtime or costs related to troubleshooting problems in the weld cell. Unfortunately, that just isn't the reality. Read more.

Robotic Welding

Automated Intelligence: Deciding Whether Automation is Right for You

Automated welding systems have the potential to increase productivity, improve welding quality, reduce labor and material costs, mitigate the welder shortage and most importantly increase a company's overall profitability. Read more.

Robotic Welding

5 Tips for Improving Robotic Welding

Robotic MIG welding can provide companies with very significant gains in productivity and excellent return on investment — when done right. Unfortunately, companies often make the mistake of focusing too much on big picture items like the power source and robotic arm, neglecting the small but equally important details like the welding wire, MIG gun and consumables. Read more.

Robotic Welding

Is Automation Right for Your Operation?

Many manufacturers believe that converting their semi-automatic welding processes to a fast, productive, fully automated process is simply a matter of deciding to do it and then applying the money and time to make it happen. Like most things in life, however, it's just not that simple. Read more.

Tregaskiss Clutch

Learn How Peripherals Can Maximize Your Robotic Welding Performance

Peripherals are any equipment integrated into the robotic welding process with the objective of maximizing its effectiveness and protecting the overall equipment investment. In short, these devices (in most cases) can add significantly to the ROI a company achieves with its welding robot. Read more.

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Robotic MIG Gun Articles

Robotic MIG Guns are an important part of the overall robotic welding system. From selection to maintenance, learn the best practices. 


Welding Application

Understanding Fixed Automatic MIG Guns

Guns need to be specified or customized for the application according to the available space, taking into account the distance between the gun and the part and also how far away the wire feeder is. These factors impact neck length and bend or angle, as well as cable choices. Read more. 

Welding Application

5 Misconceptions About Robotic Welding Guns and Consumables

Robotic MIG welding guns and consumables are an important part of the welding operation yet are frequently overlooked when investing in robotic welding systems. Here are five common misconceptions about MIG guns and consumables that may be affecting your robotic weld cell. Read more

Robotic Welding

Reduce Downtime and Costs with Robotic Water-Cooled MIG Guns

In the right application, a water-cooled robotic MIG gun can often prove beneficial by minimizing downtime, increasing productivity and reducing consumable costs. These guns typically have higher duty cycles than air-cooled models and operate at higher amperages, which means they can run for longer periods of time. Read more.

Robotic Welding

What to Know About Liners for Robotic Welding Guns

The liners used in a robotic gas metal arc welding (GMAW) gun play a significant role in the productivity, cost and quality in your automated welding operation, alongside other consumables such as the nozzle, retaining head (or gas diffuser) and contact tip. Liners run the length of the robotic welding gun and power cable — from the contact tip to the power pin — and act as the conduit through which the wire is fed. Read more

Robotic Welding

Maintaining TCP – How Does Your Robotic MIG Gun Neck Factor In? 

A robotic MIG welding system contains many components that impact the quality of the parts it welds, its productivity and the overall operational costs. Among those. the robotic MIG gun neck plays a larger role than may first be apparent. Why? Read more

Robotic Welding

Choose the Right Power Cable to Reduce Downtime in Robotic Welding Applications

In robotic MIG welding applications, minimizing downtime is key. It reduces costs and improves efficiencies to help an operation meet its production goals. Gaining the best performance, in part, depends on the equipment being used. Having the right robotic MIG gun and power cable, for example, is critical. Read more

Robotic Welding

Conventional Guns on Through-Arm Robotic Welding Systems: When to Make the Choice

Through-arm robotic welding systems are becoming increasingly common in the industry, as more equipment manufacturers turn to the development of this style compared to conventional robots. However, there are some applications where it is better to use a conventional robotic gun for these systems.  Read more.

Tregaskiss CA3 MIG Gun

Six Tips for Implementing Your Robotic GMAW Gun...and Getting the Most from It

As companies seek to gain a competitive edge, it’s not surprising that some turn to welding automation. It offers numerous advantages, including greater productivity, improved quality and cost savings compared to a semiautomatic welding operation. Read more.


Through-Arm Robotic MIG Guns: Top 10 Things to Consider

In recent years, the industry has seen advancements in robotic welding technologies that help companies improve productivity and quality and gain a competitive edge. the transition from conventional robots to through-arm robots is among those advancements. Read more.


Optimizing the Robotic Welding Process with the Right GMAW Gun

As companies seek out means to increase productivity and improve quality, the investment in welding automation continues to grow across the fabrication and manufacturing industries. Read more.

Water Cooled Robotic MIG Gun

Water-Cooled Robotic MIG Guns Can Reduce Consumable Cost and Downtime

For some fabricators, the choice between an air-cooled or a water-cooled robotic MIG welding gun is simple. Some heavy-duty applications simply demand a water-cooled model due to the high amperage and duty cycle requirements of the job. Read more.

Through Arm Gun

Trends Associated with Robotic MIG Guns

Manufacturing and fabrication environments are dynamic, ever changing with the economy, customer demands, available labor and skill sets, and competitive forces, among other factors. To maintain a favorable position in the industry, it is critical to continually look for ways to increase efficiencies while also improving quality and decreasing costs. Read more.

Robotic Welding

5 Things to Know About Robotic MIG Guns

Consider some of the top things to know about robotic MIG guns as a way to get the most out of this equipment. When it comes to robotic welding, precision, repeatability and speed are essential to ensuring a successful outcome in the operation. Read more.

MIG Gun with Wire Break

Optional Robotic MIG Gun Features Can Improve Quality and Reduce Downtime

Optimizing the performance of a robotic MIG gun can help improve weld quality and reduce downtime in the welding operation, resulting in cost savings for many companies. Read more.

TOUGH GUN G1 Series Air Cooled

Tips for Selecting the Right Robotic MIG Gun

Choosing the proper robotic MIG gun is essential for optimizing welding automation, and it can also help ensure good weld qualtiy and reduce costs. Gun amperage, duty cycle and cooling capacity all matter. Read more.


Preventive Robotic MIG Gun Maintenance: the Whos, Whens, Whys and Hows

Companies invest in welding automation to increase productivity, improve weld quality and reduce costs. Any unnecessary downtime can quickly interfere with obtaining these goals. But what about small amounts of scheduled downtime for maintenance? Read more.

Tregaskiss Conventional Liners

Preventive Maintenance Isn't Just for Welding Robots

Investing in welding automation can be a relatively quick way for companies to achieve greater productivity, improve weld qualtiy and reduce costs. But protecting that investment is key to maintaining these benefits over the long term. Read more.

Robotic Welding

TOUGH GUN I.C.E.™ Robotic MIG Gun Adds to Automation Benefits for Phoenix-Based Company

When your company focuses on custom contract manufacturing, you have to be prepared for any job that comes through the door — no matter how challenging. Having equipment that can keep up with the unique demands of the customer base is non-negotiable. Read more.

TOUGH GUN ThruArm G2 Series

Selecting, Installing and Maintaining a Through-Arm Robotic MIG Gun

As with any welding equipment, robotic welding systems have undergone improvements in technology. For instance, in recent years, the industry has begun to shift from conventional robots with over-the-arm robotic MIG guns to through-arm robots. Read more.

TOUGH GUN Robotic Water Cooled

Choosing the Right Robotic Gun for MIG Applications

From high-volume, low-variety manufacturing facilities to low-volume, high-variety fabrication shops, robotic welding has become increasingly popular due to the potential weld quality and productivity improvements it can provide. Selecting the right equipment for a robotic welding operation, however, is not a task to be take lightly. Read more.


Simple Ways to Protect Your Robotic MIG Gun

What if minor downtime could save your company vast amounts of time, trouble and money in the long term? Or give you a greater competitive edge by improving your overall efficiency? Read more.

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Consumables Articles

Consumables (nozzles, contact tips and retaining heads) can affect the overall welding performance in a robotic welding application. Learn to get the best results.

Welding Application

Selecting Contact Tips for Robotic Welding

Contact tips are often referred to as the smallest fuse in the fuse box that is your robotic welding cell. But this small fuse can have a big impact on productivity. In terms of overall efficiency, the contact tip is key. Read more. 

Welding Application

AccuLock R Consumables Reduce Downtime in Robotic Welding

To address the issue of cross-threaded contact tips, Tregaskiss designed its AccuLock™ R Consumables. The design is intended to support higher throughput, provide a long service life and ensure good weld quality. Read more

Welding Application

New HDP Contact Tips Provide Robotic Pulsed MIG Benefits

A new innovative technology on the market today can significantly extend the time between contact tip changeover, thanks to a combination of proprietary materials and tip design. TOUGH LOCK™ HDP Contact Tips from Tregaskiss last more than 10 times longer than copper or chrome zirconium tips. Read more


Steps for Proper MIG Gun Liner Installation

A MIG gun liner is an important consumable because it can make a significant difference in gun performance and the time and money an operation spends in unplanned downtime. Proper installation of the liner is critical to its ability to guide the wire through the welding cable and up to the contact tip. Read more.


Considerations for Consumables in Robotic Welding Applications

Investing in a robotic welding system goes beyond the initial purchase — it is equally important to find ways to maximize the abilities of this equipment. When implemented properly, speed, accuracy and cost savings are fundamental benefits of welding automation. Read more.

TOUGH LOCK Consumables

Ways to Get the Most Out of Your MIG Gun Consumables

Although MIG gun consumables may seem like a small part in the welding process, they can have a big impact. In fact, how well a welding operator selects and maintains these consumables can determine how productive and effective the welding operation is — and how long the consumables last. Read more.


Selecting the Right Size Contact Tip

While only one part of a much larger system, the contact tip in both robotic and semi-automatic welding MIG guns plays a critical role in providing sound weld quality. Read more.

CA3 Application

Understanding and Extending Contact Tip Life

Premature contact tip failure is a common problem that can lead to unexpected downtime — and added costs — in a welding operation. This issue not only hinders productivity, it can also negatively affect weld quality and create rework. Read more.

Liners Conventional

How to Chooose the Right MIG Gun Liner

MIG gun consumables, including the liner, can make significant difference in gun performance and weld quality. A MIG gun liner spans from the front of the gun through to the power pin and is the conduit through which the welding wire feeds. Proper installation of the liner is critical to its ability to guide the wire through the welding cable and up to the contact tip.  Read more.

TOUGH LOCK Consumables

Consumables for High Amperage Welding: What to Know to Minimize Downtime, Costs and Quality Risks

Welding is a tough business requiring equally tough equipment. When it comes to high amperage applications this is especially true. Read more.

Contact Tip

Selecting Consumables for Robotic Welding — and Making Them Last

Companies make the investment in welding automation with an eye toward the potential long-term benefits it can provide — better productivity, improved weld quality and reduced costs. Protecting that investment and eralizing a quick return on it is as much a matter of planning as it is one of proper equipment selection and usage. Read more.


Consumables for Robotic Welding

The consumables, in particular, are an easily overlooked part of an automated welding system, but they can have a measurable impact on downtime and day-to-day costs. Consider these suggestions for getting the best performance from these components. Read more.

Tregaskiss Nozzles

Handling, Storing and Maintaining Consumables

When it comes to welding, many variables can influence productivity and quality. The power source, filler metals, and consumables all factor into the equation and require special attention during the selection process. Read more.

Nozzle Layers

Understanding MIG Welding Nozzles

Nozzles play an important part in the MIG welding process. These components are responsible for directing the shielding gas to the weld pool and protecting it from contamination. Read more.

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