Best Practices for Success in Self-Shielded Flux-Cored Welding
Self-shielded flux-cored arc welding (FCAW-S) offers numerous benefits, including good weldability, high deposition rates, and excellent chemical and mechanical properties. These make the process a common choice for many applications, such as structural steel erection, bridge construction and heavy equipment repair. But like any welding process, it is not without its challenges.
There are a few simple tips and best practices that can help address these challenges. Using this knowledge — with a bit of practice — can save time, money and frustration, and help achieve high weld quality.
Slag inclusions
Slag inclusions — the result of molten flux from inside the welding wire becoming trapped inside the weld — can commonly occur in out-of-position and multi-pass FCAW-S applications. Preventing this issue depends on following key best practices and utilizing proper welding techniques. These include:
- Maintain correct travel speed and angle. When welding in the vertical-up position, use a drag angle of between 5 and 15 degrees for the gun. Use a drag angle of 15 to 45 degrees when welding in the flat or horizontal positions. Increase this angle as necessary if the problem persists. Also maintain a steady travel speed, as moving too slowly can cause the weld puddle to get ahead of the arc and create slag inclusions.
- Maintain proper heat input by always using the filler metal manufacturer’s recommended voltage for the specific wire diameter. Too little heat input can result in slag inclusions.
- Clean the material thoroughly between weld passes to remove slag.
- Be sure to correctly place the weld bead. Allow enough space in the weld joint — especially during root passes and wide groove openings — for the weld metal to fill it.
Porosity
Porosity is a common weld defect that occurs when gas is trapped in the weld. Cleaning the base material thoroughly prior to welding is the main way to prevent this problem.
Remove all dirt, rust, grease, oil, paint, moisture and other contaminants from the full length of the weld joint. While welding, be sure to maintain wire stick-out of no more than 1 1/4 inch beyond the contact tip. In addition, using filler metals containing added deoxidizers can help prevent porosity and allow for welding through light contaminants. However, these wires are not a replacement for proper cleaning.
Wormtracking
Another defect, wormtracking, refers to marks on the surface of the weld bead caused by gas that the flux inside the wire creates. Take care to avoid excessive voltage for the wire feed setting to help prevent this problem. In situations where wormtracking occurs, reduce the voltage in increments of 1/2 volt until the problem stops. Undercutting and lack of fusion
Two additional defects affecting weld quality are lack of fusion and undercutting. Preventing these issues can help welding operations save time and money in rework and downtime.
Lack of fusion occurs when the weld metal does not properly fuse with the base material or with the preceding weld bead during multi-pass welding. Using an improper gun angle is the main cause of this problem. Maintain heat input and correct work angle of the gun to help prevent lack of fusion. Use a gun angle drag of 15 to 45 degrees, and keep the arc on the trailing edge of the welding puddle. When using a weaving technique, hold the arc on the groove’s sidewall.
A dirty work surface is another common cause of lack of fusion. Proper and thorough cleaning of the surface before welding and in between passes is recommended.
Undercutting causes a weaker area at the toe of the weld by allowing a groove to melt in the base metal that is not filled in by the weld metal. This defect can often lead to cracking. To prevent undercutting, follow welding parameters for the appropriate welding current and voltage. Gun angle also plays a key role in this issue. In addition, be sure to maintain a travel speed that allows the weld metal to fill the melted-out areas of the base material completely.
Problems with penetration
When it comes to weld joint penetration, too much and too little are both problematic. Good joint penetration is critical to completing high-quality welds, so it’s important to pay attention to how much weld metal is going into the joint.
When weld metal melts through the base metal and hangs underneath the weld, this is excessive penetration. It is most often caused by too much heat. Avoid this problem by maintaining proper heat input for the application. Lower the voltage range, reduce wire feed speed and increase travel speed.
When the problem is a lack of penetration — or a shallow fusion between the weld and base metals — taking the opposite steps will help: increase the voltage range and wire feed speed, while reducing travel speed.
Joint preparation also plays a role in proper penetration. To maintain the right wire extension and obtain necessary arc characteristics for good weld quality, it is imperative to access the bottom of the groove.
Finding success
As with any welding process, FCAW-S can present some challenges. By utilizing proper welding technique and taking steps to address the issues, it will be easier to identify and solve problems quickly — or even prevent them from occurring — in order to reap the productivity and quality benefits the process offers.
WINDSOR, Ontario. Sept. 13, 2016 — A new online configurator from Tregaskiss makes it quick and easy to customize the company’s TOUGH GUN® TT3 reamer robotic nozzle cleaning stations to match the needs of their welding application. Users simply follow a series of steps to configure a reamer model, first selecting the V-block and cutter blade to match the outside diameter (OD) and bore of their robotic MIG gun nozzle. Users can then select from various add-ons, including a wire cutter, lubricator, air blast and/or filter/regulator. Tregaskiss also offers the option to choose accessories sold separately, such as a reamer stand, anti-spatter liquid and an anti-spatter multi-feed system. After choosing all desired components, the configurator provides a summary of the selections, along with a part number for the reamer. Users are given the option to request a quote for the reamer, download spec sheets or owner’s manuals, print the selection summary and part number, or contact Tregaskiss for more information. To help users save time, the online configurator incorporates a new reverse part number lookup function that provides a complete replacement parts list for their reamer based on an existing part number. The reamer is available for customization in both analog and Ethernet models. The analog TOUGH GUN TT3 reamer features improvements to the sprayer system, new plug and play replacement parts, and simplified internal wiring for reliable performance and ease of maintenance. The TOUGH GUN TT3E reamer offers the same high levels of durability, serviceability and repeatability and is enhanced with digital Ethernet communications for better integration into facilities’ digital controls infrastructure.
When it comes to welding, too much of a good thing can often add up to unnecessary costs, potential downtime and lost productivity — especially if you have too large of a MIG gun for your application. Unfortunately, many people believe a common misconception: that you need a MIG gun rated to the highest amperage you expect to weld (e.g., a 400-amp gun for a 400-amp application). That is simply not true. In fact, a MIG gun that provides a higher amperage capacity than you need typically weighs more and may be less flexible, making it less comfortable to maneuver around weld joints. Higher amperage MIG guns also cost more. The truth is, because you spend time moving parts, tacking them and performing other pre- and post-weld activities, you rarely weld continuously enough to reach the maximum duty cycle for that MIG gun. Instead, it’s often better to choose the lightest, most flexible gun that meets your needs. For example, a MIG gun rated at 300 amps can typically weld at 400 amps and higher — for a limited amount of time — and do just as good of a job. In the United States, the National Electrical Manufacturers Association, or NEMA, establishes the MIG gun rating criteria. In Europe, similar standards are the responsibility of Conformité Européenne or European Conformity, also called CE. Under both agencies, MIG guns receive a rating that reflects the temperatures above which the handle or cable becomes uncomfortably warm. These ratings, however, do not identify the point at which the MIG gun risks damage or failure. Much of the difference lies in the duty cycle of the gun. Manufacturers have the option of rating their guns at 100-, 60- or 35-percent duty cycles. For that reason, there can be significant differences when comparing different MIG gun manufacturer’s products. Duty cycle is the amount of arc-on time within a 10-minute period. One MIG gun manufacturer may produce a 400-amp MIG gun that is capable of welding at 100 percent duty cycle, while another manufactures the same amperage MIG gun that can weld at only 60 percent duty cycle. In this example, the first MIG gun would be able to weld consistently at full amperage for a 10-minute time frame, whereas the latter would only be able to weld for 6 minutes. Before deciding which MIG gun to purchase, it is important to review the duty cycle ratios for the product. You can typically find this information in the product literature or on the manufacturer’s website. Based on the gun rating explanation above, it is also essential for you to consider the length of time you spend welding before you make your MIG gun selection. Look at how much time you actually spend welding over the course of 10 minutes. You may be surprised to discover that the average arc-on time is usually less than 5 minutes. Keep in mind that welding with a MIG gun rated to 300 amps would exceed its rated capacity if you were to use it at 400 amps and 100-percent duty cycle. However, if you used that same gun to weld at 400 amps and 50-percent duty cycle, it should work just fine. Similarly, if you had an application that required welding very thick metal at high current loads (even 500 amps or more) for a very short period of time, you might be able to use a gun rated at only 300 amps. As a general rule, a MIG gun becomes uncomfortably hot when it exceeds its full duty cycle temperature rating. If you find yourself welding for longer on a regular basis, you should consider either welding at a lower duty cycle or switching to a higher rated gun. Exceeding a MIG gun’s rated temperature capacity can lead to weakened connections and power cables, and shorten its working life. There are two types of heat that affect the handle and cable temperature on a MIG gun and also the amount of time you can weld with it: radiant heat from the arc and resistive heat from the cable. Both of these types of heat also factor into what rating of MIG gun you should select. Radiant heat is heat that reflects back to the handle from the welding arc and the base metal. It is responsible for most of the heat encountered by the MIG gun handle. Several factors affect it, including the material being welded. If you weld aluminum or stainless steel, for example, you will find that it reflects more heat than mild steel. The shielding gas mixture you use, as well as the welding transfer process, can also affect radiant heat. For example, argon creates a hotter arc than pure CO2, causing a MIG gun using an argon shielding gas mixture to reach its rated temperature at a lower amperage than when welding with pure CO2. If you use a spray transfer process, you may also find that your welding application generates more heat. This process requires an 85 percent or richer argon shielding gas mixture, along with a longer wire stick out and arc length, both of which increase the voltage in the application and the overall temperature. The result is, again, more radiant heat. Using a longer MIG gun neck can help minimize the impact of radiant heat on the handle by placing it further from the arc and keeping it cooler. The consumables you use can in turn affect the amount of heat that the neck absorbs. Take care to find consumables that connect tightly and have good mass, as these absorb heat better and can help prevent the neck from carrying as much heat to the handle. In addition to radiant heat, you may encounter resistive heat in your welding application. Resistive heat occurs by way of electrical resistance within the welding cable and is responsible for most of the heat in the cable. It occurs when the electricity generated by the power source cannot flow through the cable and cable connections. The energy of the “backed up” electricity is lost as heat. Having an adequately sized cable can minimize resistive heat; however, it cannot eliminate it entirely. A cable large enough to completely eliminate resistance would be too heavy and unwieldy to maneuver. Using a lighter MIG gun can often improve productivity since it is easier to maneuver for longer periods of time. Smaller MIG guns can also reduce your susceptibility to repetitive motion injuries, such as carpal tunnel syndrome. When choosing your MIG gun, remember that not all products are created equal. Two MIG guns rated to 300 amps could vary widely in terms of their overall size and weight. Take the time to research your options. Also, look for features like a ventilated handle that permits air to flow through it and keeps it running cooler. Such features can often allow a gun to be rated to a higher capacity without adding any size or weight. Finally, assess the time you spend welding, the process and shielding gas you use, and the materials you are welding. Doing so can help you select a gun that strikes the ideal balance between comfort and capacity.
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. These factors rely on everything from the robot itself to personnel overseeing the weld cell to the smallest factors, like the front-end consumables on the robotic MIG gun. Although consumables may seem insignificant, the nozzles, contact tips and gas diffusers can have a huge impact on performance. The right combination reduces downtime and waste, and improves productivity and quality. In fact, a contact tip often serves as a barometer of the overall effectiveness of the welding process, by indicating how optimized it is — or isn’t. Always consider consumables as a part of the planning process when working with an integrator to design a robotic welding system. Doing so prevents issues with joint access — if the consumables are an afterthought, it’s possible that the front-end of the robotic MIG gun won’t be able to maneuver properly around the part or the fixturing to reach the joint. Reconfiguring the system can be time-consuming and costly. Bottleneck, straight or tapered nozzles can help accommodate for joint restrictions since they are narrower than standard nozzles and provide better access. Take caution when using tapered nozzles, however, as they are thinner and may not be able to withstand the higher amperage or higher-duty-cycles of robotic welding, leading to more frequent changeover. They may also collect more spatter buildup due to their narrower bore. For jobs requiring 300 amps or greater and/or those with a high level of arc-on time, a heavy-duty style nozzle with thicker walls and insulators will be more heat-resistant. It’s usually best to select the heaviest duty consumable for the application that still allows access to the tooling. Consult a robotic integrator or welding distributor whenever in doubt. Consumables come in a variety of materials and sizes. For example, heavy-duty contact tips are available in copper or chrome zirconium and feature an outside diameter (OD) of around 0.3125 inch. In addition to pulsed welding (discussed more later), higher-amperage applications can benefit from chrome zirconium contact tips, as they generally offer a longer performance life than copper contact tips. Nozzles are typically available in brass or copper. The brass variety tends to be more spatter-resistant. However, these nozzles have a lower melting point and can fracture or deteriorate more quickly than copper, if they come into direct contact with the molten weld pool. This factor makes them ill-suited for tight access applications. Extra-heavy-duty consumables are also available in the marketplace and are good for high-amperage applications requiring larger-diameter welding wires — 0.052 inch and greater. Contact tips in this category generally have an outer diameter of about 0.375 in. Regardless of the material, look for consumables that are well-machined with a smooth, consistent surface. These are less prone to spatter buildup and may therefore last longer. In some cases, these consumables may be more expensive, but it’s important to weigh the upfront costs with the longer-term savings of minimizing changeovers and downtime. Likewise, poorly functioning consumables, or ones that are simply not appropriate for the application, can generate weld quality issues that compound productivity delays and could lead to expensive rework. Robotic welding systems typically operate for longer periods of time at higher amperages than semi-automatic applications. As mentioned, heavy-duty consumables, which are more heat-resistant than standard-duty consumables, are often used. But they aren’t always necessary. In some cases, standard-duty consumables can replace them. For example, in applications with low duty cycles, there is less heat because less time is spent welding, and standard-duty consumable will suffice. It is important, however, to test for durability on a given application before introducing them into the welding operation. Also, when frequent consumable changeover is part of a company’s protocol, standard-duty consumables could work on high-amperage applications because the welding operator changes them over before a failure occurs from high heat levels. Mechanical wear on the contact tip is inevitable in any welding application, as the constant friction of the welding wire feeding through the tip naturally wears on it. But electrical wear also can be an issue in high-amperage welding that uses a pulsed welding mode. Pulsed welding programs have a unique waveform that causes the power source to move between low background currents and high peaks, which is particularly harsh on consumables. Often these waveforms reduce weld spatter but are harder, electrically speaking, on the contact tip. It is important to select contact tips that are durable enough for the application, and often chrome zirconium contact tips are the best choice for this welding mode. It is also a good idea to monitor contact tip usage regularly in pulsed welding applications. Changing over contact tips before they are too damaged can help to prevent issues such as loss of electrical conductivity, burnbacks and excessive spatter, resulting in poor weld quality, rework and downtime. Welding operators can use the time during routine breaks in production to changeover contact tips and maximize efficiencies. Robotic welding often uses large drums of wires — 500 to 1,000 pounds — to minimize changeover. The wire in these drums tends to have less cast or helix than wire that feeds off of a smaller spool and, as a result, feeds through the contact tip in a relatively straight fashion, making little or no contact with the tip. This action minimizes the electrical conductivity necessary to create a good arc and a sound weld. It also can cause the welding wire to contact the part being welded and arc back into the contact tip, creating a burnback. This condition automatically creates downtime because the contact tip needs to be changed. Undersizing contact tips, particularly when using solid wire in a high-amperage application, is a good fix. For example, a 0.040-in.-diameter contact tip could work for a 0.045-in. wire. The welding operator should check with a trusted welding distributor for applications requiring metal-cored wires because undersizing is not always an option. It’s worth considering the impact that the wire type has on the longevity of the contact tips as well. Non-copper-coated solid wires, for example, tend to wear contact tips more quickly than copper-coated ones because the coating acts like a lubricant to improve feedability. Improved feedability can, in turn, lead to longer contact tip life. A nozzle cleaning station or reamer cleans spatter from the robotic gun nozzle and clears away debris in the gas diffuser that accumulates during the welding process. Reamers can be outfitted with a sprayer that applies a water-based anti-spatter compound to protect the nozzle, retaining head and workpiece from spatter. Reamers and anti-spatter combined are a good defense against premature consumable failure and poor shielding gas coverage (caused by spatter-blocked gas ports), and can help extend the life of front-end consumables. For the best results, place the nozzle cleaning station close to the robot so it’s easily accessible, and program the robot to use it in between cycles — during part loading or tool transfer, for example. It should only take six seconds for the nozzle cleaning station to complete its job and the results are measurable: less spatter and longer consumable life.
BEECHER, Ill./WINDSOR, Ontario. August 9, 2016 – Bernard and Tregaskiss have introduced a new reverse part number lookup function for their semi-automatic and robotic MIG gun online configurators — online tools that allow users to customize a MIG gun for their exact needs, by selecting amperage, neck style and angle, consumables and more. The new time-saving reverse part number lookup function provides users with the complete replacement parts list — from power pin to contact tip — for previously configured MIG guns, based on the existing part number. Reverse lookup information is available for the Bernard® BTB semi-automatic MIG guns and Clean Air fume extraction guns, along with Tregaskiss® TOUGH GUN® CA3 and TA3 robotic MIG guns. It is also available for the TOUGH GUN G2 series robotic MIG guns (both conventional and througharm styles) and features additional functionality for these products to simplify conversion to a TOUGH GUN CA3 or TA3 robotic MIG gun. Users of Tregaskiss robotic water-cooled MIG guns (600 amp) and TOUGH GUN TT3 reamers can also benefit from this reverse part number lookup function. To utilize the part number lookup function, users can visit Tregaskiss.com/ConfigureMyGun and follow the prompts on the home screens to enter an existing part number.
When it comes to robotic welding operations, uptime is key. Minimizing air movements and ensuring consistent workflow are just as important as selecting the right robot, power source and robotic gas metal arc welding (GMAW) gun. Everything should work in conjunction to bring about the greatest efficiencies. The result can be higher productivity, better weld quality and an improved bottom line — not to mention, the potential for a competitive edge. A nozzle cleaning station (also called a reamer), along with a sprayer for delivering anti-spatter compound, can be simple and effective additions to the robotic weld cell — and ones that offer a good return on investment. Anti-spatter compound can also be delivered from a single large drum via a multi-feed system to numerous robotic weld cells. Anti-spatter compound protects the front-end consumables on a robotic GMAW gun from excessive spatter accumulation, which can restrict shielding gas flow, increasing the risk for porosity. This compound also helps prolong the life of the nozzle, contact tips and gas diffuser, and can reduce downtime for consumable changeover. In addition, it can lower the cost for consumable inventory (and its management), and reduce operating costs by improving weld quality and lessening rework by way of consumables that operate at peak performance. All of these factors contribute to a more productive and profitable welding operation. The what, when and where of anti-spatter compounds Constant-voltage (CV) applications and those utilizing solid wire and/or the welding of galvanized steel tend to produce high levels of spatter, and therefore, often benefit the most from the use of anti-spatter compound. However, the application of anti-spatter compound is ideal for any high-volume, high-production environment seeking to minimize potential weld quality issues, extend consumable life and also reduce downtime. Its application can easily be programmed so that it is sprayed onto the consumables after each ream cycle, during routine pauses in production for part changeover. When selecting an anti-spatter compound, be certain that it is capable of providing uniform coverage to protect the entire nozzle, that it cleans up easily and leaves no residue, and that it is compatible with the nozzle cleaning station being used. Water-soluble anti-spatter compound is the most popular option, and is typically non-toxic and eco-friendly. Oil-based anti-spatter compound is also available in the marketplace, but is generally less desirable to use because it is more difficult to clean up if it settles on fixtures or elsewhere in the weld cell. It is also important to note that oil-based anti-spatter compound is not always compatible with all nozzle cleaning stations and it can clog up this equipment. Despite the fact that the more popular water-based anti-spatter compound is non-toxic, welding operators and/or maintenance personnel should still take care when handling and using it. They should avoid breathing in spray mists and always wash their hands after coming in contact with the compound (for example, when filling the sprayer). The use of a NIOSH certified (or equivalent) respirator during spraying is recommended. Also, personnel should wear Nitrile or Butyle gloves and wear chemical safety goggles for the best protection. Local exhaust ventilation near the sprayer is also important. Store anti-spatter compound containers according at the temperatures recommended by the manufacturer. Best practices for anti-spatter compound use Spraying for about a half-second is the standard recommendation. If a company finds that it is necessary to spray the anti-spatter compound any longer, that usually means the sprayer is too far away. In fact, anti-spatter compound should never be sprayed for three or more seconds. In addition to causing harm to the consumables, excess spraying can leave a residue of the compound in the weld cell that could lead to safety issues, such as slick floors and slipping hazards. Over-application of anti-spatter compound may also damage equipment, such as power sources, by adversely affecting electrical circuits it comes in contact with. Some manufacturers offer a spray containment unit, which can help capture excess anti-spatter compound. This 3 to 4-inch unit fits over the spray head on the anti-spatter compound sprayer. After the spatter has been cleared from the nozzle during the reaming cycle, the nozzle docks on the spray containment unit. An opening at the top of the cylinder allows the anti-spatter to spray onto the nozzle while an O-ring seals the nozzle in place so only the outside edge and inside of the nozzle are sprayed. The spray containment unit also collects any anti-spatter compound runoff at the bottom of the unit so it can be easily drained into a container and disposed of properly. Anti-spatter compound cannot be reused and should be disposed of in accordance with federal, state and local environmental control regulations. When employing a spray containment unit, it is important to inspect it regularly, removing any spatter or debris from the bottom that could prevent it from working properly. As part of a preventive maintenance activities, clear the screen or filter inside the unit of contaminants using clean, compressed air. Doing so helps ensure that the screen can continue to fulfill its intended purpose of improving air quality. As with any part of the robotic welding operation, when employed properly, this unit and the use of anti-spatter compound can yield positive results. Always follow the manufacturer’s recommendation for use and consult with a trusted welding distributor with any questions. In conjunction with anti-spatter compound, a nozzle cleaning station improves quality and productivity in robotic weld cells by helping extend consumable life and reducing downtime for changeover. Here are some tips to get the most out from this equipment. Correct placement: Place the nozzle cleaning station in close proximity to the robot so it is easily accessible. Match parts and sizes: Make sure the V-block inside the top of the nozzle cleaning station is the correct size for the nozzle, that the cutter blade is the correct size for the nozzle bore, and that the insertion depth of the nozzle to the reamer is adequate. Monitor the home signal: Monitor the home signal on the nozzle cleaning station to reduce issues during the cleaning cycle and minimize guesswork regarding whether the equipment is ready for use or done with its cycle. Clean and scrape parts: Clean the top seal on the spindle under the cutter and make sure all clamp faces are kept clean by scraping the faces and jaws on the V-block to remove debris. Buildup on these parts can push the nozzle out of position, leading to the fit-up no longer being concentric — and, potentially, to broken cutter blades.
BEECHER, Ill./WINDSOR, Ontario. August 2, 2016 – Bernard and Tregaskiss will attend FABTECH 2016 in Las Vegas, November 16 to 18, where they will share booth N3733 with Miller Electric Mfg. Co. There, the companies will showcase the latest products for improving welding in the fabrication and manufacturing industries. Bernard will feature its semi-automatic MIG guns and consumables, while Tregaskiss will showcase its robotic MIG guns, peripherals and consumables — all designed to improve quality, productivity and cost-savings. Select products will be featured on Miller power sources and robotic welding equipment for static and live demonstrations. New products to be featured at the show, include: TOUGH GUN TT3E reamer — The new reamer from Tregaskiss has been enhanced with digital Ethernet communications to simplify integration into companies’ digital controls infrastructure, all at a lower cost. Remote monitoring capabilities allow companies to oversee and troubleshoot the I/O of reamer functioning in real time — without removing the reamer from the weld cell. TOUGH GUN reamer stand – Designed exclusively for Tregaskiss TOUGH GUN TT3 and TOUGH GUN TT3E reamer robotic nozzle cleaning stations, this durable new stand is customizable in heights ranging from 18 to 45 inches. A simplified design allows for lower pricing, while features such as precision- manufactured, reamer mounting hole pattern specific to the two reamer models eliminates potential issues associated with third-party stands. Quick, accurate installation is easy due to compatibility with both reamers’ quick-change base plate.
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. In doing so, this equipment improves quality and productivity in robotic weld cells by extending consumable life and reducing downtime for maintenance. In addition, utilizing a reamer helps prevent loss of shielding gas coverage, a problem that can lead to expensive rework to correct porosity or other weld defects. From proper installation and setup to effective operation, there are best practices to gain the highest performance, quality and long-term use from reamers.
The heat and repetitive motions that accompany gas metal arc welding (GMAW) can take their toll. Customizing your GMAW gun to match your application, however, can make a big difference in improving your comfort, and gaining the best welding performance. A GMAW gun’s trigger, handle, neck and power cable design all impact how long you can comfortably weld without experiencing fatigue or stress. By ensuring your comfort, you lessen the chance of injuries associated with repetitive movement and reduce overall fatigue. To help, some manufacturers offer online systems to help you configure a gun to your exact specifications.
June 27, 2016 The TOUGH GARD® spatter cleaner was discontinued on December 31, 2014. Some replacement parts for this discontinued product continue to be available. Prices and availability of these replacement parts are subject to change without notice.
WINDSOR, Ontario. June 16, 2016 — Tregaskiss has announced the availability of its new TOUGH GUN® reamer stand, designed exclusively for its TOUGH GUN TT3 and TT3E reamer robotic nozzle cleaning stations. This fixed, durable stand can be ordered in custom heights ranging between 18 and 45 inches, and features a simplified design compared to previous models, allowing for lower pricing. The TOUGH GUN reamer stand features a bolt pattern that supports the use of the convenient quick-change base plate featured on all TOUGH GUN TT3 reamer models, as well as a precision-engineered hole pattern specific for mounting the TOUGH GUN TT3 reamer or the new TOUGH GUN TT3E reamer — a nozzle cleaning station enhanced with digital Ethernet communications for better integration into facilities’ digital controls infrastructure. In addition, the reamer stand includes a standardized 8.5- x 6.5-inch hole pattern for mounting the stand to the floor so users can easily swap stands between weld cell stations. These features allow for quick, accurate installation. The new reamer stand includes clamps and fasteners for optimal cable management along the stand and the hardware necessary for mounting a filter/regulator unit (sold separately).
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. And incorporating and operating peripherals successfully doesn’t have to be difficult. To help, it is important to understand how your peripherals are intended to function and employ some best practices for using them. All robotic welding systems require some form of collision detection to prevent damage to both the robotic MIG gun and the robot arm in the event of an impact. Impacts can occur when the robotic MIG gun collides with an incorrectly positioned work piece or out-of-position tooling, or when the gun strikes an item that has inadvertently been left in the welding cell. Some robotic systems incorporate robot collision detection software. Systems that do not have built-in collision detection, however, should always be paired with a clutch — an electronic component that attaches to the robotic MIG gun to protect it and the robot from heavy damage in the event of a collision. In some cases, you may choose to add a clutch to a system that utilizes collision software as backup protection for the robot. Always make sure the clutch works with the weight of the load created by the robotic MIG gun and front-end consumables. If the gun is not properly supported and the robot moves rapidly to another spot on the other side of the part, the extra weight can move the clutch out of its optimal position. If a clutch gets triggered from a collision, reset it by pulling it towards you and letting it snap back into position. After, be sure to check your tool center point (TCP) to ensure the robotic MIG gun is properly aligned for precise welding of the joint. If it is off center, validate that the clutch is in its home position. If you have robotic welding applications that require consistent welding wire stick-out — the distance the wire extends from the end of the contact tip — a wire cutter is a recommended peripheral. As the name implies, a wire cutter cuts the welding wire to a specified length or stick-out and also removes any balling at the end of the wire. Most wire cutters can cut a range of different types of welding wire, including stainless steel, flux-cored and metal-cored, usually up to 1/16-inch diameter. They can often be mounted on a nozzle station or used remotely as needed. In conjunction with a wire brake, the wire cutter can ensure that the stick-out remains consistent for robots with touch sensing capabilities that help locate the joint. Another key peripheral is a neck inspection fixture, which tests the tolerance of a robotic MIG gun’s neck to the TCP so you can re-adjust it after an impact or after bending due to routine welding. The advantage of adding a neck inspection fixture to a robotic weld cell is twofold. One, it ensures the neck meets the specifications to which the robotic welding system has been programmed and, once the tolerance has been determined, you can simply adjust the neck accordingly. This can prevent costly rework due to missed weld joints and can also prevent downtime required to reprogram a robot to meet welding specifications with an existing bent neck. Second, a neck inspection fixture can save you time, money and confusion when exchanging necks from one robotic MIG gun to another. Having this ability is especially advantageous if you maintain a large number of welding robots. You can simply remove a bent neck and change it with a spare that has already been inspected and adjusted, and put the robot back in service immediately. One of the most important peripherals you should consider for your robotic welding system is a nozzle cleaning station or reamer. A nozzle cleaning station removes spatter from the robotic MIG gun nozzle and clears away the debris that accumulates in the diffuser during the welding process. This helps lengthen the life of the robotic gun consumables, as well as the gun itself. A clean nozzle also reduces problems that could lead to rework and helps the robot create better quality welds. During installation, be sure your reamer is on a sturdy base or otherwise securely fastened and not moving around during the reaming cycle. Ideally, the nozzle cleaning station should be placed in close proximity to the welding robot so it is easily accessible when cleaning is necessary. You should program the reaming process to run in between cycles — either during part loading or tooling transfer — so it does not add to the overall cycle time per part. Always keep the covers on your reamer. The electronics within a reamer can be easily ruined by moisture from the atmosphere. Also, remember to use clean, filtered and lubricated air in your reamer. If “dirty” air goes into the reamer, it will clog up the valves. If you don’t have a lubricator installed on the reamer, use an alternative method to lubricate the air that goes through the motor. It is important that your reamer matches the diameter of the nozzle and that the blade does not hit the diffuser or nozzle when it goes through a ream cycle. Be sure you are using the right blade for the nozzle you have and that your nozzle is set at the correct depth within the jaws of the reamer. A reamer can be used by itself or in conjunction with a sprayer that applies an anti-spatter compound to protect the nozzle, diffuser and work piece from spatter. Make sure the nozzle is the correct height away from the spray block and that the duration of the spray is about a half a second. Too much anti-spatter compound can ruin the insulator on your nozzle, and can lead to unnecessary costs for replacement. The compound may also build up on the nozzle, the robot and the parts being welded, resulting in additional cleanup. Frequently check that the sprayer and sprayer head is free of debris; if spatter gets inside the sprayer head, it will cause the spray plume to be distorted, which will create inconsistent coverage. If you are using a multi-feed anti-spatter system, be sure you have a good quality hose, such as a urethane hose, and that it is protected from any spatter that may hit it and create a hole. Also, securely fasten the hose with clamps at every connection to prevent leaks. You may consider using a spray containment unit to capture excess anti-spatter compound. If so, weekly inspections are recommended; remove any spatter or debris that may have fallen to the bottom. Failing to do so can prevent the unit from draining, which will cause the containment unit to overflow and create a mess. The decision to invest in robotic welding equipment is significant. It requires time, knowledge and a trusted relationship with a robotic welding equipment manufacturer to find the right system. The same holds true for peripherals. Although these devices do add to the initial cost of automating, they can lead to measurable cost savings and profits in the long run. But remember, the goal in robotic welding is repeatability and increased productivity, and any additional equipment that can help achieve these results may be worth your investment.
June 8, 2016 Tregaskiss is pleased to announce that the TOUGH GUN® TA3 robotic air-cooled MIG gun offering has now been expanded to include configurations for the Panasonic® TM-2000 robot model. Click here to learn more about the TOUGH GUN TA3 robotic air-cooled MIG gun.
June 6, 2016 Effective immediately, the PER-2510 air motor for the discontinued TOUGH GARD® spatter cleaner is no longer available through Tregaskiss. As a result, the PER-2599 kit will no longer include the PER-2510 air motor (please see revised PER-2599 kit parts breakdown below). This Fiam® air motor may be available directly through another vendor (list provided below): Access a complete list of available and discontinued replacement parts for the TOUGH GARD spatter cleaner here.
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. In some cases, robotic peripherals are an additional means to help and can provide added safety, in the case of a clutch. As a safety device for your robotic MIG gun, a clutch attaches to the robotic MIG gun and protects it — and the robot arm — from damage. If the robot crashes, the clutch will send a signal back to the robot that alerts it to shut down. Not only does this help prevent further damage to the robotic arm, but it also protects your gun and your front-end consumables. While many newer robots are equipped with collision detection software that serves the same function as a clutch, older robots, which are still very commonly used, are not. Regardless of whether you’re operating a new or older robot, everyone knows your robotic welding system is only as good as the uptime it offers. It’s essential to keep as much arc-on time as possible. When selecting a clutch, you need to choose one that can hold whatever load is going to be on it. For example, if the front end of the gun is extremely heavy and requires significant air movement, some clutches may not be able to support it or may require an adjustment to their sensitivity settings. Also, look for obvious size constraints and make sure the clutch fits within your molding application and tooling. When setting up your clutch be sure to check your tool center point (TCP). Putting on a clutch should not significantly change the TCP. If it’s off, be sure to validate that the clutch is in its home position. Also, when replacing a clutch, make sure the TCP is within specifications. Similarly, always reset the clutch to its home position and recheck the tool center point after a crash. If the tool center point is off, look first to make sure no other damage occurred to another component during the crash. It could indicate that the neck bent out of position, for example, and needs to be straightened with a neck checking fixture or replaced. If all components are undamaged and the deflection is still off, you’ll need to trip the clutch again by pulling it back and snapping it back into place. Typically, the only reason a clutch will fail is if its electrical switch inside fails. If that happens, it will no longer send a signal back to the robot, which will shut down the entire system. In order to ensure the switch is working properly, you can either conduct a continuity check in the open and closed position of the switch using a multimeter or manually trip it by bumping the neck with your hand. If the clutch is working properly, it will send a signal back to the robot that indicates there is a problem. This type of check can be done as part of your preventative maintenance whenever the robot is set up and in a stopped position. Remember, as with any part of the robotic welding system, knowledge is key. Peripherals like clutches serve a distinct purpose in helping make robotic welding successful. Keep in mind some of these tips to help you get the most out of this equipment. Want to improve your MIG welding? By following these seven tips, you can take your MIG welding operation to the next level and ensure you are as safe, efficient and professional as any other shop. Never forget that MIG welding, when done improperly, can be hazardous. Electric shock, fumes and gases, arc rays, hot parts, noise and a host of other possible hazards come along with the territory. The ultraviolet and infrared light rays can also burn your skin — similar to a sunburn but without the subsequent tan — and your eyes. This is why the best MIG welding operator knows how to stay safe. Welding helmets, gloves, close-toed shoes and clothes that fully cover exposed skin are essential. Make sure you wear flame-resistant natural fibers such as denim and leather, and avoid synthetic materials that will melt when struck by spatter, potentially causing burns. Also, avoid wearing pants with cuffs or shirts with pockets, as these can catch sparks and lead to injuries. Keep in mind that heavy-duty MIG welding often produces a lot of heat, sparks and spatter, and requires a lower degree of dexterity than some other forms of welding. Therefore, using thick, stiff leather gloves that provide a higher level of protection is smart. Similarly, choose leather footwear that covers your entire foot and leaves as little room as possible for spatter to fall along your ankle line. High-top leather shoes and work boots often provide the best protection. Finally, always be sure you have adequate ventilation per OSHA recommendations and check material safety data sheets (MSDS) for each metal being welded and filler metal being used. Use a respirator whenever required by the MSDS. Before you get started with MIG welding, conduct online research to see what the best practices are for the specific wire you have or contact a trusted filler metal manufacturer to improve the quality of your welding. Doing so not only tells you what the manufacturer’s recommended parameters are for your diameter wire, but also what the proper wire feed speed, amperage and voltage is, along with the most compatible shielding gas. The manufacturer will even tell you what electrode extension or contact-to-work distance (CTWD) is best suited for the particular wire. Keep in mind that if you get too long of a stickout, your weld will be cold, which will drop your amperage and with it the joint penetration. As a general rule of thumb, since less wire stickout typically results in a more stable arc and better low-voltage penetration, the best wire stickout length is generally the shortest one allowable for the application. Before you start welding, make sure all of your connections are tight — from the front of the MIG gun to the power pin attaching it to the power source. Also be certain there is no spatter buildup on your welding consumables and that you have a ground cable as close to the workspace as possible. Whenever possible, hook the ground cable on the weldment. If that is not possible, hook it to a bench. But remember: The closer it is to the arc, the better. If you have a questionable ground, it can cause the gun to overheat, impacting contact tip life and weld quality. In addition, regularly clean any shavings from the welding wire or debris that collects on your consumable parts and in your liner using clean compressed air. Improper drive roll selection and tension setting can lead to poor wire feeding. Consider the size and type of wire being used and match it to the correct drive roll to improve MIG welding performance. Since flux-cored wire is softer, due to the flux inside and the tubular design, it requires a knurled drive roll that has teeth to grab the wire and to help push it through. However, knurled drive rolls should not be used with solid wire because the teeth will cause shavings to break off the wire, leading to clogs in the liner that create resistance as the wire feeds. In this case, use V-grove or U-groove drive rolls instead. Set the proper drive roll tension by releasing the drive rolls. Then increase the tension while feeding the wire into your gloved hand until the tension is one half-turn past wire slippage. Always keep the gun as straight as possible to avoid kinking in the cable that could lead to poor wire feeding. Contact tips can have a significant impact on improving MIG welding performance since this consumable is responsible for transferring the welding current to the wire as it passes through the bore, creating the arc. The position of the contact tip within the nozzle, referred to as the contact tip recess, is just as important. The correct contact recess position can reduce excessive spatter, porosity, insufficient penetration, and burn-through or warping on thinner materials. While the ideal contact tip recess position varies according to the application, a general rule of thumb is that as the current increases, the recess should also increase. See Figure 1. Always know what gas your wire requires — whether it’s 100 percent CO2 or argon, or a mix of the two. While CO2 is considerably cheaper than argon and good for penetrating welds on steel, it also tends to run cooler, making it usable for thinner materials. Use a 75 percent argon/25 percent CO2 gas mix for even greater penetration and a cleaner weld, since it generates less spatter than straight CO2. Here are some suggestions for shielding gases for common types of wire: Solid Carbon Steel Wire: Solid carbon steel wire must be used with CO2 shielding gas or a 75 percent CO2/25 percent argon mix, which is best used indoors with no wind for auto body, manufacturing and fabrication applications. Aluminum Wire: Argon shielding gas must be used with aluminum wire, which is ideal for stronger welds and easier feeding. Stainless Steel Wire: Stainless steel wire works well with a tri-mix of helium, argon and CO2. For the best control of your weld bead, keep the wire directed at the leading edge of the weld pool. When welding out of position (vertical, horizontal or overhead welding), keep the weld pool small for best weld bead control, and use the smallest wire diameter size you can. A bead that is too tall and skinny indicates a lack of heat into the weld joint or too fast of travel speed. Conversely, if the bead is flat and wide, the weld parameters are too hot or you are welding too slowly. Ideally, the weld should have a slight crown that just touches the metal around it. Keep in mind that a push technique preheats the metal, which means this is best used with thinner metals like aluminum. On the other hand, if you pull solid wire, it flattens the weld out and puts a lot of heat into the metal. Finally, always store and handle your filler metals properly. Keep product in a dry, clean place — moisture can damage wire and lead to costly weld defects, such as hydrogen-induced cracking. Also, always use gloves when handling wires to prevent moisture or dirt from your hands settling on the surface. When not in use, protect spools of wire by covering them on the wire feeder, or better yet, remove the spool and place it in a clean plastic bag, closing it securely. As with any welding process, it takes time and practice to gain the best performance when MIG welding. Following some of these simple steps can help along the way.
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.
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. These robots require the use of through-arm robotic MIG guns. As the name suggests, the cable assembly of a through-arm MIG gun runs through the arm of the robot, improving its overall durability. The through-arm design naturally protects the power cable and makes it less prone to snag on fixturing, rub against the robot or wear out from routine torsion — all of which can lead to premature cable failure. Since through-arm robotic MIG guns don’t require a mounting arm like conventional robotic MIG guns do, they provide a smaller work envelope. This makes them particularly advantageous when working in tight spaces. Here are the top 10 things to consider when selecting, installing and maintaining a through-arm robotic MIG gun: When choosing a through-arm robotic MIG gun, look for one that offers good power cable rotation. For example, some manufacturers place a rotating power connection on the front of the cable that allows it to rotate 360 degrees. This ability provides stress relief for the cable and power pin, and allows for greater maneuverability for a wider range of applications. It also helps prevent cable kinking that could lead to poor wire feeding, conductivity issues, or premature wear or failure. Choosing a through-arm robotic MIG gun is similar to choosing a conventional robotic MIG gun, except that through-arm guns are sold with predetermined cable lengths. It is still important, however, to choose a gun with power cables that are constructed of durable components and materials to help prevent wear or failure. Always know your robot make and model when placing an order for a new gun to ensure you make the proper selection. Always select the proper amperage of gun and be certain it has the appropriate duty cycle for the given application. Duty cycle is the amount of arc-on time within a 10-minute period; a gun with a 60 percent duty cycle, for example, can weld for six minutes within that period without overheating. As a rule, most manufacturers offer guns up to 500 amps, in both air- and water-cooled models. Check if the robot that the through-arm gun is installed on has collision detection software. If not, identify a clutch that will pair with the gun to help ensure the robot remains safe if it collides with a workpiece or tooling. For through-arm robotic MIG guns, it is important to note that the power cable needs to be installed in a slightly different manner than a conventional over-the-arm robotic MIG gun. Installing a through-arm robotic MIG gun incorrectly can lead to a host of problems, not the least of which is cable failure. Incorrect installation can also cause weld quality issues, such as porosity, due to poor electrical connections; premature consumable failure caused by poor conductivity and/or burnbacks; and, potentially, failure of the entire robotic MIG gun. To prevent such problems, it is imperative to consult the manufacturer’s instructions for each specific MIG gun. When installing a through-arm robotic MIG gun, first position the robot with the wrist and top axis at 180 degrees, parallel to each other. Install the insulating disc and spacer the same as with a conventional over-the-arm robotic MIG gun. Be certain that the power cable position is also correct. The cable should have the proper “lie” with the robot’s top axis at 180 degrees. In addition, it’s important to avoid a very taut power cable, as it can cause undue stress on the power pin. It can also cause damage to the cable once the welding current passes through it. For that reason, it’s important to make sure the power cable has approximately 1.5 inches of slack when installing it. (See Figure 1.) The stud on the front of the power cable needs to be fully inserted into the front connector of the through-arm robotic MIG gun. To achieve this result, always install the stud into the front housing prior to bolting the front end onto the robot wrist. By pulling the cable through the wrist and making the connections in front of the gun, it’s easy to slide the whole assembly back (once the cable is fastened) and bolt it onto the wrist. This extra step will ensure the cable is seated and will allow for maximum continuity and maximum power cable life. Be certain to position the wire feeder in close enough proximity to the robot that the power cable on the through-arm robotic MIG gun will not be stretched unnecessarily after installation. Having a wire feeder that is too far away for the length of the power cable can cause undue stress on the cable and front-end components. Consistent preventive maintenance is key to the longevity of any robotic MIG gun, including the through-arm style. During routine pauses in production, check for clean, secure connections between the MIG gun neck, the diffuser or retaining heads, and the contact tip. Also, check that the nozzle is secure and any seals around it are in good condition. Having tight connections from the neck through the contact tip helps ensure a solid electrical flow throughout the gun and minimizes heat buildup that could cause premature failure, poor arc stability, quality issues and/or rework. In addition, regularly check that the welding cable leads are secured properly and assess the condition of the welding cable on the robotic MIG gun, looking for signs of wear, including small cracks or tears, and replace as necessary. Spatter buildup can cause excessive heat in the consumables and MIG guns, and block shielding gas flow. Visually inspect consumables and the through-arm robotic MIG gun on a regular basis for signs of spatter. Clean the gun as needed and replace consumables as necessary. Adding a nozzle cleaning station (also called a reamer or spatter cleaner) to the weld cell can also help. Like its name implies, a nozzle cleaning station removes spatter (and other debris) that builds up in the nozzle and diffuser. Using this equipment in conjunction with a sprayer that applies an anti-spatter compound can further protect against spatter accumulation on the consumables and the through-arm robotic MIG gun.
WINDSOR, Ontario. April 26, 2016 — Tregaskiss has introduced its new TOUGH GUN® TT3E reamer, a robotic nozzle cleaning station enhanced by digital Ethernet communications to better integrate into companies’ digital controls infrastructure. The TOUGH GUN TT3E reamer can reduce integration costs by up to $1200 compared to analog reamer models by eliminating the need for an analog switch and reducing cabling requirements within the robotic weld cell. Plus, fewer components reduce potential failure points. The new reamer also offers remote monitoring capabilities, allowing companies to oversee and troubleshoot the I/O of each reamer function and its allowable parameters through the programmable logic controllers (PLC), all in real time and without the need to remove the unit from the weld cell. This feature, along with error diagnostic and recording capabilities minimize troubleshooting downtime and support greater productivity. Featuring discrete control, the TOUGH GUN TT3E reamer offers the flexibility to monitor and adjust all motions, along with insert recovery or fault control, further increasing productivity. In automatic mode, the reamer provides control over double-stroke, start-up dwell time and top-of-stroke dwell time. In the manual mode, there is control over the sequence and duration of each function by firing individual I/O. The TOUGH GUN TT3E reamer offers users the flexibility to operate the system as a switch to link robots with a single Ethernet port to an Ethernet welder or other peripherals. It also features a single wiring harness for all wire connections and improved wire labeling, minimizing the risk of wiring errors during routine maintenance and with it, unnecessary downtime. This new reamer offers the same high levels of durability, serviceability and repeatability as Tregaskiss’ popular TOUGH GUN TT3 reamer. A 3/4 horsepower lubricated air motor with gear reducer offers the high torque necessary for spatter removal, while operating at lower speeds to protect the spindle and cutter blade from excessive wear. Adding to this durability, the spindle has a rotating rod accuracy of 0.001 to 0.004 inch at its extended position, providing optimized, repeatable spatter removal. Additionally, external setup switches allow independent operation of the sprayer, clamp and spindle during manual setup, and the cutter blade lifts into position but does not spin when activated by the spindle setup switch. Momentary manual override switches further increase safety.
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. Because of the cost for investing in this equipment, it is important to take steps to protect the system and ensure it is operating at its maximum potential. Keep in mind these best practices and troubleshooting tips to help you avoid downtime and increase throughput in your operation.
Tregaskiss proudly announces its new TOUGH GUN® reamer stand. This simple fixed height durable stand is compatible with all TOUGH GUN TT3 and TT3E reamer models and can be ordered to a custom height between 18 and 45 inches. This new simplified design also allows for quick installation and new lower pricing. Click here to learn more.
March 26, 2016 Tregaskiss is pleased to announce the new TOUGH GUN® TT3E reamer robotic nozzle cleaning station offering the same high levels of durability, serviceability and repeatability now further enhanced by digital Ethernet communications that better integrate this unit into the digital controls infrastructure of your facility. Enjoy greater control optimization, remote monitoring capability, and faster troubleshooting of all discrete TOUGH GUN reamer I/O functions to facilitate increased productivity in your robotic welding applications. Automating spatter removal will help to extend the life of your robotic MIG guns and consumables, benefiting both your bottom line and production uptime and throughput.
Planned downtime for preventive maintenance in the welding operation is not time wasted. Rather, it is a crucial part of keeping production flowing smoothly and avoiding unplanned downtime. Proper maintenance can extend the life of consumables and equipment, and help prevent issues such as birdnesting or burnback that can lead to costly and time-consuming troubleshooting and rework. Keep in mind a few simple maintenance tips and best practices to get the most from your MIG gun and consumables. Prior to welding, ensure all connections are tight and that consumables and equipment are in good condition and free from damage. Start with the front of the gun and work your way back to the feeder. A tight neck connection is essential to carry the electrical current from the welding cable to the front-end consumables. Loose connections at either end of the neck can cause poor electrical conductivity, leading to weld defects and, potentially, overheating of the gun. When using a rotatable neck — one that allows the gun neck to be rotated to the desired position for welding, for increased flexibility and operator comfort — make sure the hand nut on the neck is tight and that the neck is secure in the cable fitting. Also, be sure to visually inspect the handle and trigger to check there are no missing screws or damage. The cable should be free of cuts, kinks and damage along the outer cover. Cuts in the cable can expose the internal copper wiring and create a potential safety hazard to the welding operator. In addition, these issues can lead to electrical resistance that causes heat buildup — and ultimately cable failure. In checking the feeder connection, make sure the power pin is fully inserted and tightly connected, otherwise it can cause birdnesting of the wire at the feeder. A loose connection can also cause electrical resistance at the joint, which could lead to an overheated gun. A clean liner that is the correct size is important in producing quality welds. The liner is often both the most difficult part of the gun to inspect and maintain, and one of the most frequent sources of weld troubles. A liner that is cut too short can cause wire feeding problems. Follow the manufacturer’s instructions for proper trimming and installation of the wire for the best results. Also, take care to keep the liner off the floor during installation to avoid picking up dirt and debris that could enter the weld pool and cause defects. A dirty liner reduces shielding gas flow, which can lead to porosity in the weld. Fragments of welding wire can also chip off and accumulate in the liner. Over time, this buildup can cause poor wire feeding, birdnesting and burnback. To maintain your liner, periodically blow clean compressed air through it to clear out dirt and debris. This task can be done in a few extra minutes during wire changeovers or when removing the wire from the gun — and helps save considerable time in troubleshooting problems later. MIG gun front-end consumables are exposed to heat and spatter and therefore often require frequent replacement. However, performing some simple maintenance can help extend consumable life and improve gun performance and weld quality. The gas diffuser provides gas flow to the weld pool and also connects to the neck and carries the electrical current to the contact tip. Make sure all connections are tight, and check the diffuser’s O-rings for cracks, cuts or damage. The nozzle’s main role is to focus the shielding gas around the weld pool. Watch for spatter buildup in the nozzle, which can obstruct gas flow and lead to problems due to inadequate shielding coverage. Use welper pliers to clean spatter from the nozzle. The contact tip is the last point of contact between the welding equipment and the welding wire. Keyholing of the contact tip is a concern to watch for with this consumable. This occurs when the wire passing through the tip wears an oblong-shaped slot into the diameter of the tip. Keyholing can put the wire out of center and cause problems such as an erratic arc. If you are experiencing wire feeding issues, try changing the contact tip or switching to a larger-size contact tip. Tips that look worn should be replaced. Taking the time for preventive maintenance can pay off in less downtime in the long run. Along with that, always remember to properly store your MIG gun consumables to help you achieve the best results and extend the life of your equipment. When not in use, the gun should be stored in a coiled position, either hanging or lying flat, such as on a shelf. Do not leave MIG guns on the floor of the shop, where there is a chance the cable could be run over, kinked or damaged. Ultimately, the better care you take care of this piece of equipment, the better results you can achieve in the weld cell.
MIG welding is considered among the easiest welding processes to learn and is useful for a variety of applications and industries. Since the welding wire constantly feeds through the MIG gun during the process, it doesn’t require frequent stopping, as with stick welding. The result is faster travel speeds and greater productivity. The versatility and speed of MIG welding also make it a good option for all-position welding on various metals, including mild and stainless steels, in a range of thicknesses. In addition, it produces a cleaner weld that requires less cleanup than stick or flux-cored welding. To maximize the benefits this process offers, however, it is imperative to select the right MIG gun for the job. In fact, this equipment’s specifications can significantly impact productivity, downtime, weld quality and operating costs — as well as welding operators’ comfort. Here is a look at different types of MIG guns and some key factors to consider when making the selection. It is important to select a MIG gun that offers adequate amperage and duty cycle for the job in order to prevent overheating. Duty cycle refers to the number of minutes in a 10-minute period that a gun can be operated at its full capacity without overheating. For example, a 60 percent duty cycle means six minutes of arc-on time in a 10-minute span. Because most welding operators don’t weld 100 percent of the time, it is often possible to use a lower amperage gun for a welding procedure that calls for a higher-amperage one; lower-amperage guns tend to be smaller and easier to maneuver, so they are more comfortable for the welding operator. When evaluating a gun’s amperage, it is important to consider the shielding gas that will be used. Most guns in the industry are tested and rated for duty cycle according to their performance with 100 percent CO2; this shielding gas tends to keep the gun cooler during operation. Conversely, a mixed-gas combination, such as 75 percent argon and 25 percent CO2, makes the arc hotter and therefore causes the gun to run hotter, which ultimately reduces duty cycle. For example, if a gun is rated at 100 percent duty cycle (based on the industry-standard testing with 100 percent CO2), its rating with mixed gases will be lower. It is important to pay attention to the duty cycle and shielding gas combination — if a gun is rated at only 60 percent duty cycle with CO2, the use of mixed gases will cause the gun to operate hotter and become less durable. Deciding between a water- or air-cooled MIG gun depends largely on the application and amperage requirements, welding operator’s preference and cost considerations. Applications that involve welding sheet metal for only a few minutes every hour have little need for the benefits of a water-cooled system. On the other hand, shops with stationary equipment that repeatedly weld at 600 amps will likely need a water-cooled MIG gun to handle the heat the applications generate. A water-cooled MIG welding system pumps cooling solution from a radiator unit, usually integrated inside or near the power source, through hoses inside the cable bundle, and into the gun handle and neck. The coolant then returns to the radiator, where a baffling system releases the heat absorbed by the coolant. The ambient air and shielding gas further disperse the heat from the welding arc. Conversely, an air-cooled system relies solely on the ambient air and shielding gas to dissipate the heat that builds up along the length of the welding circuit. These systems, which range from 150 to 600 amps, use much thicker copper cabling than water-cooled systems. By comparison, water-cooled guns range from 300 to 600 amps. Each system has its advantages and disadvantages. Water-cooled guns are more expensive upfront, and can require more maintenance and operational costs. However, water-cooled guns can be much lighter and more flexible than air-cooled guns, so they can provide productivity advantages by reducing operator fatigue. But because water-cooled guns require more equipment, they can also be impractical for applications that require portability. While a lower-amperage gun can be appropriate for some applications, be sure it offers the necessary welding capacity for the job. A light-duty MIG gun is often the best choice for applications that require short arc-on times, such as tacking parts or welding sheet metal. Light-duty guns typically provide 100 to 300 amps of capacity, and they tend to be smaller and weigh less than heavier-duty guns. Most light-duty MIG guns have small, compact handles as well, making them more comfortable for the welding operator. Light-duty MIG guns offer standard features at a lower price. They use light- or standard-duty consumables (nozzles, contact tips and retaining heads), which have less mass and are less expensive than their heavy-duty counterparts. The strain relief on light-duty guns is usually composed of a flexible rubber component and, in some cases, may be absent. As a result, care should be taken to prevent kinking that may impair wire feeding and gas flow. Also note, overworking a light-duty MIG gun can lead to premature failure, so this type of gun may not be appropriate for a facility that has multiple applications with various amperage needs. At the other end of the spectrum, heavy-duty MIG guns are the best choice for jobs that require long arc-on times or multiple passes on thick sections of material, including many applications found in heavy equipment manufacturing and other demanding welding jobs. These guns generally range from 400 to 600 amps and are available in air- and water-cooled models. They often have larger handles to accommodate the larger cables that are required to deliver these higher amperages. The guns frequently use heavy-duty front-end consumables that are capable of withstanding high amperages and longer arc-on times. The necks are often longer as well, to put more distance between the welding operator and the high heat output from the arc. For some applications and welding operations, a fume extraction gun may be the best option. Industry standards from the Occupational Safety and Health Administration(OSHA) and other safety regulatory bodies that dictate allowable exposure limits of welding fumes and other particulates (including hexavalent chromium) have led many companies to make the investment. Similarly, companies that seek to optimize welding operator safety and attract new skilled welding operators to the field may want to consider these guns, as they can help create a more appealing work environment. Fume extraction guns are available in amperages typically ranging from 300 to 600 amps, as well as various cable styles and handle designs. As with all welding equipment, they have their advantages and limitations, best applications, maintenance requirements and more. One distinct advantage to fume extraction guns is that they remove the fumes at the source, minimizing the amount that enters the welding operator’s immediate breathing zone. Fume extraction guns can, in combination with many other variables in the welding operation — welding wire selection, specific transfer methods and welding processes, welding operator behavior and base material selection — help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment. These guns operate by capturing the fumes generated by the welding process right at the source, over and around the weld pool. Various manufacturers have proprietary means of constructing guns to conduct this action but, at a basic level, they all operate similarly: by mass flow or the movement of material. This movement occurs by way of a vacuum chamber that suctions the fumes through the handle of the gun and into the gun’s hose through to a port on the filtration system (sometimes informally referred to as a vacuum box). Fume extraction guns are well-suited for applications that use solid, flux-cored or metal cored welding wire as well as those conducted in confined spaces. These include, but are not limited to, applications in the shipbuilding and heavy equipment manufacturing industries, as well as general manufacturing and fabrication. They are also ideal for welding on mild and carbon steel applications, and on stainless steel applications, as this material generates greater levels of hexavalent chromium. In addition, the guns work well on high amperage and high deposition rate applications. When it comes to cable selection, choosing the smallest, shortest and lightest cable capable of handling the amperage can offer greater flexibility, making it easier to maneuver the MIG gun and minimize clutter in the workspace. Manufacturers offer industrial cables ranging from 8 to 25 feet long. The longer the cable, the more chance it can get coiled around things in the weld cell or looped on the floor and possibly disrupt wire feeding. However, sometimes a longer cable is necessary if the part being welded is very large or if welding operators must move around corners or over fixtures to finish the task at hand. In these cases, where operators are moving back and forth between long and short distances, a steel mono coil cable might be the better choice. This type of cable doesn’t kink as easily as standard industrial cables and can provide smoother wire feeding. A MIG gun’s handle and neck design can impact how long an operator can weld without experiencing fatigue. Handle options include straight or curved, both of which come in vented styles; the choice often boils down to welding operator preference. A straight handle is the best choice for operators who prefer a trigger on top, since curved handles for the most part do not offer this option. With a straight handle, the operator can rotate the neck to place the trigger on top or on bottom. In the end, minimizing fatigue, reducing repetitive motion and decreasing overall physical stress are key factors that contribute to a safer, more comfortable and more productive environment. Choosing a MIG gun that offers the best comfort and operates at the coolest temperature allowed by the application can help improve arc-on time and productivity — and, ultimately, increase the profitability of the welding operation.
Tregaskiss Offers Online Configurator for Robotic Nozzle Cleaning Stations
Tregaskiss Offers Online Configurator for Robotic Nozzle Cleaning Stations
Understanding Gun Ratings: What You Need to Know to Select Your MIG Gun
Understanding Gun Ratings: What You Need to Know to Select Your MIG Gun
Gun ratings explained
How do you operate?
Understanding the impact of heat
Radiant Heat
Resistive Heat
As an air-cooled MIG gun increases in amperage, the size of the cable, connections and handles also increases. Therefore, a MIG gun with a higher rated capacity almost always has greater mass. If you are an occasional welder, that weight and size increase may not bother you; however, if you weld all day, every day, it is better to find a lighter and smaller MIG gun suited to your application. In some cases, that may mean switching to a water-cooled MIG gun, which is smaller and lighter, but can also provide the same welding capacity. Deciding between air- and water-cooled
Final thoughts to keep you comfortable
Considerations for Consumables in Robotic Welding Applications
Considerations for Consumables in Robotic Welding Applications
Space and duty cycle factors
Consumable materials and sizes
good defense against premature consumable
failure and poor shielding gas coverage,
and can help extend the life of front-end
consumables.Heavy- versus standard-duty
Welding mode and wear
Consider the impact of welding wire
Maintaining Consumables
New Reverse Part Number Lookup Function for Online MIG Gun Configurators Saves Time
New Reverse Part Number Lookup Function for Online MIG Gun Configurators Saves Time
Gain Efficiencies and Extend Consumable Life with Anti-Spatter Compound
Gain Efficiencies and Extend Consumable Life with Anti-Spatter Compound
Although it resembles water in its consistency, anti-spatter compound (when applied correctly and in the appropriate volume), will not drip like water. It simply creates a sacrificial barrier between the nozzle and any spatter generated during the welding process; the spatter easily falls off when the nozzle cleaning station performs the reaming cycle, thereby leaving the nozzle and other front-end consumables clean. The compound must be reapplied frequently to help maintain that barrier. tt
Positioning the robotic GMAW gun and front-end consumables in the correct location for the ream cycle and anti-spatter application helps the compound to be applied uniformly. To gain optimal spray coverage, always follow the manufacturer’s instructions for proper setup based on the nozzle bore size. If the sprayer is too far away from the nozzle, it will not provide adequate coverage to prevent spatter buildup. If the nozzle and sprayer are too close, too much spray may saturate the nozzle insulator, which can lead to premature failure.Adding a spray containment unit
This 3- to 4-inch unit fits over the spray head on the anti-spatter compound sprayer. Additional tips for effective nozzle cleaning station operation
Bernard and Tregaskiss to Attend FABTECH 2016
Bernard and Tregaskiss to Attend FABTECH 2016
Tips for Optimizing Reamer Usage
Tips for Optimizing Reamer Usage
This article has been published as an exclusive with The Fabricator. To read the entire article, provided by Ryan Lizotte, Tregaskiss field technical support specialist, please click here.
Customizing Your GMAW Gun for the Job
Customizing Your GMAW Gun for the Job
This article has been published as a web-exclusive on thefabricator.com. To read the entire story, please click here.
PRODUCT UPDATE – Replacement Parts Availability for the TOUGH GARD Spatter Cleaner
PRODUCT UPDATE —
Replacement Parts Availability for the TOUGH GARD Spatter Cleaner
Discontinued Replacement Parts
Part Number Description PER-2510 Motor
Available Replacement Parts
Part Number Description ER-2241 Control Valve ER-2242 Sprayer Valve ER-2560 Reed Switch ER-2609 Wiring Interface Receptacle ER-2700 Spatter Cleaner Pneumatic ER-500-15 Spray Head PER-220 Valve Assembly PER-2599 Spatter Cleaner Kit (motor not included) PER-2680 Rear Shroud PER-2685 Front Shroud PER-500-15-6 Reservoir Mount
New TOUGH GUN Reamer Stand Offers Customizable Height and Quick Installation at a Lower Cost
New TOUGH GUN Reamer Stand Offers Customizable Height and Quick Installation at a Lower Cost
Getting the Most Out of Peripherals
Getting the Most Out of Peripherals
Clutches
Wire cutters
Neck inspection fixtures
Nozzle cleaning stations and sprayers
No peripheral decision
PRODUCT UPDATE – TOUGH GUN TA3 MIG Gun Offering Available for Panasonic TM-2000
PRODUCT UPDATE —
TOUGH GUN TA3 MIG Gun Offering Available for Panasonic TM-2000
Available Resources
DISCONTINUED PRODUCT – PER-2510 Motor
DISCONTINUED PRODUCT — PER-2510 Air Motor for the TOUGH GARD Spatter Cleaner
Fiam® Air Motor Model Number Part Number 28M100D-3/8-24UNF 185609008
Vendors:
Revised PER-2599 Kit Parts Breakdown
Item Part Number Description Qty Length 1 PER-2511 Motor Clamp Detail 1 3 PER-2611 Spatter Shield Plate, Inner 1 4 F1-M6X1-25B M6x1x25mm LG SHCS, Black Oxide 3 5 F2-M4X.7-6B M4x.7x6mm LG SHCS, Black Oxide 4 7 TR-2231 5/16″ x 1/8″ NPT QC 1 8 ER-2700 ER Reamer Pneumatic Kit 1 Not Shown Red Tape Electrical Red Tape, 18mm Wide 4.5″
Click here to download the archived M075 TOUGH GARD spatter cleaner technical guide. What You Should Know About Robotic MIG Gun Clutches
What You Should Know About Robotic MIG Gun Clutches
7 Tips for Improving MIG Welding
7 Tips for Improving MIG Welding
1. Remember that the best MIG welding operator is a safe one.
2. Do your research before you set up your equipment.
3. Make sure all of your connections are sound before getting started.
4. Select the proper drive roll and tension setting to effectively feed wire.
5. Use the correct contact tip recess for the application.
6. Use the shielding gas best suited to your wire.
7. Keep the wire directed at the leading edge of the weld pool.
Common Causes and Solutions to GMAW Gun Overheating
Common Causes and Solutions to GMAW Gun Overheating
This article has been published as an exclusive with Practical Welding Today on thefabricator.com. To read the entire story, please click here.
Through-Arm Robotic MIG Guns: Top 10 Things to Consider
Through-Arm Robotic MIG Guns: Top 10 Things to Consider
1) Look for a gun that offers good power cable rotation.
2) Look for power cables constructed of durable components and materials.
3) Select the proper amperage of gun.
4) Identify whether the robot has collision software.
5) Consult the manufacturer’s instructions when installing a through-arm robotic MIG gun.
6) Be sure the power cable position is correct and avoid making it too taut.
7) Always install the stud into the front housing before bolting the front end onto the robot wrist.
8) Position the wire feeder close enough to the power cable that it will not be unnecessarily stretched.
9) Regularly conduct preventive maintenance and check for clean, secure connections.
10) Visually inspect consumables and the gun on a regular basis for signs of spatter.
New Robotic Nozzle Cleaning Station Reduces Integration Costs, Helps Increase Productivity
New Robotic Nozzle Cleaning Station Reduces Integration Costs, Helps Increase Productivity
Best Practices and Troubleshooting Tips to Optimize Robotic Welding
Best Practices and Troubleshooting Tips to Optimize Robotic Welding
This article has been published as a web-exclusive on thefabricator.com. To read the entire article, provided by Ryan Lizotte, Tregaskiss field technical support specialist, please click here.
NEW PRODUCT – TOUGH GUN Reamer Stand
NEW PRODUCT —
TOUGH GUN Reamer Stand
NEW PRODUCT – TOUGH GUN TT3E Reamer
NEW PRODUCT —
TOUGH GUN TT3E ReamerPreventive Maintenance Helps Optimize MIG Gun Performance
Preventive Maintenance Helps Optimize MIG Gun Performance
Proper inspection
Liner
Consumables
Final thoughts
Criteria for Selecting a MIG Gun
Criteria for Selecting a MIG Gun
What’s the right amperage?
Water- versus air-cooled
Heavy- versus light-duty
Fume extraction guns
Other considerations: Cables and handles
Conclusion
