Common Causes and Solutions to GMAW Gun Overheating 

Image of welder with gloves, starting to take off a nozzle on a MIG gun

When choosing a gas metal arc welding (GMAW) gun, there are several factors to consider. After all, welding is simply the result of one large electrical circuit — and the gun reflects that. The general rule is to select the lightest, most flexible gun for the application. The following considerations impact that selection: duty cycle, amperage requirement and work site location. Striking the right balance between gun size and capacity can increase the efficiency of a welding operation and decrease the risk of issues that could damage the equipment — including overheating.

No matter the cause, there are several signs that precede catastrophic gun failure. Knowing these signs and taking steps to prevent them can minimize the cost for unnecessary downtime, reduce gun and consumable replacement costs, and prevent weld quality issues. Consider some simple troubleshooting tips and best practices.

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