The wire is one MIG gun component that can make or break a successful weld. A good, steady wire feed increases your ability to maintain consistently good welds.
But what if your MIG wire burns back to the tip, causing burnback and sputtering your work to a quick halt?
What is Burnback?
This common issue happens because of the MIG wire burning back to your tip. This often happens when your wire arcs at the contact tip and welds itself inside the tip.
Burnback is solely a MIG issue because it only happens when the wire is continuously fed through a small contact tip hole.
5 Possible Sources of Contact Tip Burnback
Here are 5 ways to find the source of your contact tip burnback, fix it, and get back to your weld.
1. Wire-Feed Speed
Finding the right wire-feed speed for your gun can mean the difference between a smooth weld and one plagued with problems. In fact, a feed that’s too slow is one of the most common causes of burnback.
When your arc melts your wire faster than it comes out of your gun it can not go anywhere and therefore will travel back into the contact tip. Double-check your machine’s parameters, and up your feed speed if necessary.
Another reason for erratic wire feeding is that the filler wire was not tensioned correctly. On the other hand, you may have added too much tension leading to the wire to struggle to feed and become stuck.
If your parameters are correct, remove the nozzle and check your contact tip. The liner could also be a trouble spot. Look for buildup, a well-cut trim, and correct sizing.
A less-than-perfect ground is another common cause of burnback. If your clamps lose contact, even for a second, you’ll lose voltage but the wire will keep feeding.
Always attach your grounding clamps to your work instead of the table.
Get the Right Parts from American Torch Tip
While there are always operational issues that can cause burnback, with the right equipment your chances are much lower. High-quality, durable contact tips can help reduce your chances of burnback and therefore decreases downtime.
Ask About Our Torch Replacement Conversion Program.
Ready to increase the lifetime of your consumables and the quality of your cuts (or welds) by switching to American Torch Tip? We are so sure you will love our products that we will replace all of your torches – for free – with lifetime warranties when you become a regular customer. Reach out to learn more.