Increasing Productivity

Three TIPS to Maximize Productivity

If you’re responsible for keeping the production line running smoothly, there might be times when MIG gun welding equipment problems are keeping you awake at night. Take a look at the productivity tips below. One of them may help prevent a problem, or solve an existing problem, and have you “sleeping like a baby” once again.


Are the contact tips properly designed and made of the correct alloy to supply consistent electrical conductivity and heat transfer?
If not, you could be making more contact tip change-outs than necessary. Tip failure can result in burn-back and weld problems that require weld re-work.

• High heat applications can benefit by changing to Copper Zirconium alloy or Extra Heavy Duty tips with greater mass.
• Mobile-device welding apps are available that calculate optimum settings for your equipment, covering a variety of topics like shielding gas flow, welding position, heat input and weld design. The Lincoln® mobile device app Weld Parameters Guide addresses many of the basics.
• Check with your local welding supplies store for recommended settings for your project – To find a store near you, call us at 800-342-8477



Are the nozzle and contact tip designed and properly paired to allow optimum electrode stick-out and minimum spatter build up?
If not, spatter may clog the diffuser resulting in insufficient gas weld coverage or double arcing situations between nozzle and work piece. These situations lead to poor quality welds, which could require costly repairs.

• Diffuser, contact tip and nozzle sets are designed for very specific applications, e.g., metal type, gauge, amperage and equipment. You may be able to get a weld from mismatched consumables, but it probably won’t pass your weld quality test. Use this chart to select the correctly matched consumables for your semi-automatic MIG gun.


MIG robotic consumables


Are the diffusers and nozzles designed to channel the shield gas properly?
If not, turbulent and unbalanced gas flow will allow air pockets to mix with the shielding gas, which can lead to weld contamination and porosity. Nozzle size and shape is critical and dependent on wire type, diameter, deposition rate, and type of shielding gas.

• Use this chart to select the correctly matched consumables for your semi-automatic MIG gun.
• Keep nozzles clear of spatter.
• Verify that shield gas flow is properly set using the settings from your equipment manual. If you don’t have your equipment manual, try the Shielding Gas Flow mobile device app from Messer®.


MIg Tro

If you’re unsure of the answers to any of the questions above; or want to learn more about avoiding costly tip change-outs, gun wire feed problems and weld repairs; talk to our MIG technical specialist at 800-342-8477. 




Got an idea to save time on the production line? Try our Arc Time Calculator and build custom “What if?” scenarios.

What if we reduced the number of contact tip change-outs required per day? What would I save per month? Per year?

You can even customize the calculator to use your company manufacturing overhead expense, the number of active welding stations, shifts per day, etc.

Determine costs and/or savings that result from changing variables like: the number of contact tip change-outs per shift, or the number of weld repairs.



How to fix wire feed problems


Welder using MIG welding equipmentCritical for quality welds:

Use the correct diffuser, contact tip and nozzle pairing for your application and equipment. See our online parts reference catalog to find the right consumables for your project.

We have 75 years of experience helping industrial customers, like you, keep their production lines moving. Call 800-342-8477 to speak to a MIG technical specialist.