Mastering MIG welding with adjustments, equipment and techniques
Discover essential adjustments, equipment tips, and expert techniques to accelerate your MIG welding game by reading our article in the October issue of The Welder. You’ll learn how to balance voltage and wire feed speed for flawless welds, select the right welder and shielding gas, and master gun angle and travel speed. Plus, we’ll guide you through troubleshooting common challenges to ensure consistent, high-quality results. Don’t miss out on transforming your welding skills—dive into the full article now!
Introducing The Bernard® Clean Air E™
Introducing The Bernard® Clean Air E™
Welding professionals face daily challenges in keeping their work environment clean and safe. With strict weld fume regulations, effective fume control is more important than ever. The Bernard® Clean Air E™ fume extraction MIG gun helps by capturing welding fumes directly at the source without sacrificing performance.
Why Source Capture Matters
Capturing weld fume as close to the point of generation as possible, also known as source capture, is one of the most effective ways to reduce exposure. Unlike general ventilation or ambient air systems that dilute fumes, source capture methods like fume extraction guns immediately remove hazardous particles, helping improve air quality for operators and surrounding workers.
The Clean Air E™ captures up to 95% of fume at the source. The gun is built with adjustable extraction control through interchangeable shroud lengths and a slider allowing operators to fine-tune suction levels without affecting shielding gas coverage. This balance is critical for maintaining weld quality while maximizing fume capture.
Key Benefits of the Clean Air E™
Efficient Extraction
By removing up to 95% of fumes directly at the arc, the Clean Air E™ helps reduce exposure risks and contributes to a cleaner workspace.
Enhanced Ergonomics
With a lightweight handle design, the Clean Air E™ allows you to weld longer without fatigue. The ball swivel at the rear of the handle makes maneuvering easier, even in difficult positions.
Engineered for Endurance
This fume gun is built to withstand the toughest working environments. Made from durable, tested materials, it features a robust and straightforward design for easy maintenance.
Designed for Demanding Applications
Ideal for high-amperage and high-deposition rate applications, the Clean Air E™ is well-suited for industries such as: Shipbuilding, Heavy equipment manufacturing, General fabrication and manufacturing
Ergonomic and Easy to Use
Unlike bulky ventilation systems, fume extraction guns like the Clean Air E™ seamlessly integrate into a welder’s workflow. With a lightweight, ergonomic design and a user-friendly adjustment slider on the guns handle, it operates much like a standard MIG gun while providing the added benefit of fume extraction.
Customizable
We know every welder has their own preference when it comes to welding style. That’s why we designed two trigger options—a button and a lever, plus an extended lever for added comfort. We also made the shrouds interchangeable, offering three lengths to optimize either weld visibility or fume extraction, depending on your application.
A Smarter Step Toward Safer Welding
No single solution eliminates all welding fume exposure, but using a fume extraction gun alongside a compatible extraction unit like the Miller® Filtair®215 can significantly improve a workplace environment. The Bernard® Clean Air E™ provides a practical, effective way to prioritize welder safety and performance.
It starts at the source™
The Occupational Safety and Health Administration (OSHA) and other safety regulatory bodies set the allowable exposure limits for weld fumes and other particulates, including hexavalent chromium, with the aim of protecting employees against potential health hazards in the workplace. Providing welding operators with proper ventilation during the welding process is an important step companies can take to help meet the standards — and to help provide a safe and comfortable work environment. Companies may opt to invest in centralized fume extraction systems, which are designed to protect the entire shop area. These systems involve the installation of new ductwork and fans to remove fumes and are highly effective, but they are also more expensive than other options. A viable alternative for some companies is a fume extraction gun used in conjunction with a fume extraction device or localized filtration system. Fume extraction guns are available in a variety of amperages (typically 300 to 600), cable styles and handle designs. As with any welding equipment, they have their best applications, advantages and limitations, as well as recommended techniques for achieving the best results. Fume extraction guns operate by capturing the fume generated by the welding process right at the source, over and around the weld pool. The weld fumes removed by these guns are composed of a combination of the filler metal and base material. 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. A vacuum chamber suctions the fumes through the handle of the gun, into the gun’s hose and through to a port on the filtration system (sometimes informally referred to as a vacuum box). Typically, fume extraction guns are larger than regular welding guns, and include the vacuum and hose that are necessary to extract the fumes. Some manufacturers offer fume extraction guns with a vacuum hose swivel on the rear of the handle to make them easier to maneuver. Also, design advancements have minimized the handle weight and size to make the guns as light as possible for operator comfort, while still offering consistent fume extraction benefits. The Bernard® Clean Air E™ fume extraction gun is designed to efficiently capture welding fumes at the source, helping to create a cleaner work environment. This gun is particularly well-suited for applications using solid welding wire and for operations in confined spaces, where fume extraction directly in the welding operator’s breathing zone is essential. Industries that frequently benefit from this technology include shipbuilding, heavy equipment manufacturing, and general fabrication, especially when working with mild or carbon steel. Additionally, for applications in petrochemical industries or those involving stainless steel welding, where higher levels of hexavalent chromium are present, the Clean Air E™ gun provides an effective solution for improving air quality. Designed for high-amperage and high-deposition rate applications, this gun performs best in flat and horizontal welding positions, where it can effectively capture rising fume particles. While fume extraction in out-of-position welding can be more challenging due to the natural rise of fumes, proper technique and positioning can help maximize effectiveness. The Clean Air E™ fume extraction gun operates similarly to a standard MIG gun, making it easy for welding operators to adapt to. To achieve the best results, consider these best practices: By integrating the Bernard® Clean Air™ E fume extraction gun into your welding operations, you can enhance fume control while maintaining welding quality and efficiency. Fume extraction guns operate by capturing the fume generated by the welding process right at the source, over and around the weld pool. As with any piece of welding equipment, fume extraction guns benefit from preventive maintenance. Flux-cored wire allows vacuum adjustment Because flux-cored wire produces a slag, it generates more weld fume. However, one benefit of using self-shielded flux-cored wire, for example, is it allows the ability to increase the vacuum level of the gun. Welding operators can close off all the vents and utilize the long shroud. This action maximizes the vacuum at the front end of the gun without concern for disturbing the shielding gas, since there is none generates with self-shielded flux-cored wire. When using gas-shielded flux-cored wire, a 0 to 15-degree angle will help maximize fume collection. Pause at the end At the end of the weld, welding operators can pause for 10 to 15 seconds, holding the fume extraction gun in place without depositing weld metal. This action allows the gun to capture residual fumes as the weld bead is cooling. Wire type determines stickout The contact tip to work distance can be longer — about 1/2 inch to 3/4 inch — when welding with flux-cored wire and a fume extraction gun. With solid wire, welding operators should try to keep the stickout to 1/2 inch or less to maximize fume capture. These lengths are comparable to the stickout lengths used with standard MIG guns. Experiment with the air control regulator Some guns, like the Clean Air E™, incorporate a slider or toggle mechanism conveniently located on the gun handle, while others integrate this function internally. This adjustability is essential for balancing fume extraction with shielding gas coverage. Too much suction can disrupt the protective gas flow, leading to weld defects like porosity, while too little may not effectively capture harmful fumes. By using the built-in adjustment feature, operators can increase or decrease suction as needed to maintain optimal fume control while ensuring proper weld protection. Finding the right balance may require some trial and error. To optimize performance, welding operators should test the air control setting on scrap material before welding on a final product. This ensures that fume extraction is maximized without negatively affecting weld quality. With the Clean Air E™ and other adjustable fume extraction guns, operators have greater control over their work environment—helping to improve air quality while maintaining welding efficiency. As with any piece of welding equipment, fume extraction guns benefit from preventive maintenance. Caring for them is similar to caring for a standard MIG gun. Also note that using flux-cored wire with these guns requires more frequent gun maintenance than solid wire because of the slag and fumes it generates. Regular maintenance is important to help prevent a clog or spatter buildup, which can limit the fume capture rate. Inspecting and maintaining the front end of the gun is key to optimizing fume extraction. Frequently inspect the nozzle and contact tip for signs of spatter buildup, which along with blocking the fume extraction can also obstruct shielding gas flow and cause weld defects. Spatter buildup also can cause consumables to fail prematurely. Replace the consumables if spatter buildup appears, or clean them according to the manufacturer’s recommendations. Also, inspect the vacuum hose regularly for damage such as cuts or kinks, which can lead to loss of suction. Replace a damaged vacuum hose as necessary. Regarding consumables, using the manufacturer’s recommended consumables package with a fume extraction gun helps optimize performance, as the guns are engineered to get the best results with specific consumables. When in doubt about maintenance or any other aspect of using a fume extraction gun, consider working with a trusted welding distributor, certified industrial hygienist and/or the gun manufacturer to address any questions or concerns. In combination with many other variables in the welding operation — wire selection, specific transfer methods and welding processes, welding operator technique, and base material selection — fume extraction guns can help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment. Proper use and maintenance of the equipment is important to get optimal results.
New industry standards from the Occupational Safety and Health Administration (OSHA) are protecting employees against potential health hazards in the workplace. These regulations, which dictate allowable exposure limits of welding fumes and other particulates (including hexavalent chromium), have led many companies to invest in fume extraction equipment. An increased desire to maintain optimal welding operator safety and to attract new skilled welding operators to the field is also a consideration in investing in this equipment — companies want to create the most comfortable and healthy work environment possible. The Clean Air E™ MIG fume extraction gun, as shown here, operates by capturing the fume generated by the welding process right at the source, over and around the weld pool. With interchangeable shroud options to help customize your extraction for your application. Some companies may opt for centralized fume extraction systems, which are designed to protect the entire shop area. These systems involve the installation of new ductwork and can be a costly investment for capturing fume particulate in the air. Fume extraction guns are available in a variety of amperages, cable styles and handle designs. As with any welding equipment, they have their advantages and limitations, best applications, maintenance requirements and more. 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 — fume extraction guns can help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment. Fume extraction guns operate by capturing the fume 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, into the gun’s hose through to a port on the filtration system (sometimes informally referred to as a vacuum box) like the Miller FILTAIR® 215 High-Vacuum Fume Extractor. The welding fumes that these guns remove are composed of a combination of the filler metal and base material. Some fume extraction guns feature adjustable extraction control regulators at the front of the gun handle, which allow welding operators to increase suction as needed (without affecting shielding gas coverage), while others provide this function internally. Regardless of the manner, the ability to balance between the downward flow of shielding gas and the upward flow of the suctioned air is critical. The fume extraction gun needs to provide the appropriate amount of shielding gas to protect the weld from defects such as porosity, without sacrificing the ability to suction fumes efficiently enough to protect the welding operator. The balance allows the weld pool time to react and solidify, and gives the fume particles time to decelerate so they are easier to extract. Typically, fume extraction guns are larger than regular welding guns and tend to be bulky due to the vacuum and hose necessary to extract the fumes. For that reason, some manufacturers create fume extraction guns with a vacuum hose swivel on the rear of the handle to make them easier to maneuver. Manufacturers have also, since fume extraction guns were first introduced (in the late 1960s and early 1970s), found ways to engineer internal components to minimize the handle weight in order to reduce operator fatigue. Fume extraction guns are well-suited for applications using solid welding wire and those 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 stainless steel applications, as this material generates greater levels of hexavalent chromium, and on mild and carbon steel applications. The guns also work well on high amperage and high deposition rate applications and are available, typically, in 300 to 600 amp ranges. Fume extraction guns attach to a localized filtration system, as shown here. Fume removal occurs by way of a vacuum chamber in the fume extraction gun that suctions the fumes through the handle of the gun, into the gun’s hose through to a port on the filtration system. For the best results, fume extraction guns should be used for in-position welding, such as on flat butt welds. In this position, they can most effectively capture fume particles as they rise from the weld pool. In out-of-position welds, the energy of the fume particles causes them to rise at a high rate, making it more difficult for the fume extraction gun to draw them downward and through the vacuum hose. One distinct advantage to fume extraction guns is that they remove the fumes at the source. This will minimize the amount that enters the welding operator’s immediate breathing zone. As with any piece of welding equipment, fume extraction guns benefit from preventive maintenance. Caring for them is similar to caring for a standard GMAW gun. Regularly check for tight connections throughout the length of the fume extraction gun to ensure good electrical flow. Minimizing electrical resistance helps ensure consistent weld quality and prevent premature failure of the front-end consumables — contact tip, nozzle and diffuser. Frequently inspect the nozzle and contact tip for signs of spatter build-up, too, as such build-up can obstruct shielding gas flow and cause weld defects that ultimately will need to be reworked. Spatter build-up can also cause consumables to fail prematurely. Replace the consumables if spatter build-up appears or clean them according to the manufacturer’s recommendation. In some cases the shroud that surrounds the nozzle may also have to be replaced or cleaned free of spatter. To ensure optimal fume extraction capabilities, inspect the vacuum hose regularly for damage, including cuts or kinks that could lead to loss of suction. Replace a damaged vacuum hose as necessary and dispose of it according to the manufacturer’s and/or an industrial hygienist’s directions. Visually inspect the handle for cracks or missing screws, and also check that the gun’s trigger is not sticking or otherwise malfunctioning. Replace or repair these components as necessary. Finally, maintenance on the liner is also important. As with the vacuum hose, use compressed air to clear out any potential blockages during welding wire changeovers or when removing the wire from the gun. Spending an extra few minutes clearing out any debris from the liner can save considerably more time than troubleshooting the weld defects and equipment problems that can result from blockages. Also, track the amount of time that it takes for a liner to wear during the course of the welding operation. Replace the liner prior to that in the future to prevent downtime for replacement during shifts or problems with wire feeding or quality. When in doubt about maintenance or any other aspect of using a fume extraction gun, consider working with a trusted welding distributor, certified industrial hygienist and/or the fume extraction gun manufacturer to address any questions or concerns. Proper use of this equipment can help provide optimal results, and improve the safety and comfort of the welding environment. For the past 40 years, 4-Star Trailers in Oklahoma has built high-quality aluminum stock and horse trailers. Aluminum is lightweight, corrosion-resistant, and strong—ideal for trailers designed to endure tough road conditions. However, welding aluminum with a push-pull gun has its challenges. The heaviness of the tool can make it difficult to maneuver in tight angles, and the added weight can lead to welder fatigue, especially when working on large parts or frames. Additionally, this setup can cause delays in production timelines due to discomfort and inefficiency during long hours of use. Before switching to the Bernard® BTB Semi-Automatic Air-Cooled MIG Gun, the team regularly faced feeding issues. The feeding problems were especially noticeable when working on large aluminum parts, causing disruptions and affecting their ability to keep up with demanding production schedules. The difficulty in maneuvering the push-pull gun, coupled with the physical strain it placed on welders, contributed to frequent delays and a slower pace of work. The BTB Gun has been a game-changer. It pushes aluminum wire long distances with ease, something that wasn’t possible with the previous system. Its design is lightweight and maneuverable, making it far easier for welders to handle, especially in tight spots. This has significantly reduced fatigue, allowing the team to work longer and more comfortably without sacrificing quality. The customizable neck lengths of the BTB Gun are another huge advantage, allowing welders to reach into tight angles or handle bigger components with greater ease. The Easy Feed Liner in the BTB Gun reduces friction, making it simpler to feed aluminum wire and minimizing downtime—critical for maintaining a steady workflow in a busy shop. With fewer interruptions, the team is able to stick to production goals and meet deadlines more effectively. The use of AccuLock consumables also contributes to less maintenance, as they last longer than other options, cutting down on the frequency of replacements and the time spent on maintenance tasks. The biggest benefit? The team is more productive and satisfied with their work. With fewer interruptions and smoother operations, they’re able to produce high-quality welds faster. The BTB Gun has not only made their jobs easier but also helped the business run more efficiently. It’s become an indispensable tool in their shop, enabling them to build even tougher, more dependable trailers while improving overall productivity and welder satisfaction. MIG welding is a common welding process especially useful for beginner and DIY welders due to its easy-to-learn nature, shorter lead times and lower production costs. The versatility of MIG welding allows users to work on a wide range of materials with less stopping and restarting. The process features a continuous consumable wire electrode being fed through a welding gun and into a weld pool. The gun also feeds a shielding gas alongside the wire to protect the weld pool from contaminants. While there are different types of MIG guns that have unique parts (e.g., water-cooled, air-cooled, fume extraction), all MIG guns have some parts in common. Understanding the components of a MIG gun and the process by which it works will help you make decisions on the consumables and gun type you select for your job. Here’s what you need to know. 1. Nozzle 2. Contact Tip 3. Diffuser 4. Liner 5. Neck 6. Handle and Trigger 7. Cable Assembly 8. Insulator 9. Power Pin Mastering preventive maintenance, timely consumable replacements, and proper liner trimming are key to prolonging the lifetime of MIG welding equipment. Discover proactive measures to follow for enhancing durability and performance while decreasing downtime, boosting productivity, and cutting operating costs by reading our full article in the March 2024 issue of MetalForming Magazine. MIG welding is considered one of the easiest welding processes to learn and is useful for a variety of applications and industries. To maximize the benefits this versatile process offers, it is imperative to select the right MIG gun for the job. Choosing the right MIG gun directly affects efficiency, quality and safety — a trifecta every operator is trying to master to create a more comfortable and effective environment. There are five key factors when choosing the right MIG gun for your needs. Regardless of your skill level, you need to make sure that the equipment you use, works as hard as you do. Consider these components of your welding system to help weld conistency. Could it be time to take a good look at your equipment? Read our article published in the November issue of Fabricating & Metalworking. South Louisiana Community College (SLCC) has made a game-changing decision to enhance its welding education program by incorporating Bernard semi-automatic welding guns and AccuLock consumables into its classrooms. This shift marks a significant departure from the MIG guns and consumables they had been using for decades. The transition began within the last year after SLCC’s welding technology instructors began noticing some challenges the students were facing with the welding guns and consumables that they were using. They noticed it took students 20 minutes to change a liner with their current welding guns and consumables. Enter Bernard. After meeting with the instructors and listening to their pains points and need for improvement – Bernard configured a lightweight MIG welding gun with the AccuLock S dual-locked liner consumable system to test in the classrooms. Instructors and students immediately saw the benefits. The AccuLock S dual-locked liner system makes liner installation error-proof by eliminating the guesswork and potential errors that can occur when trimming a liner. More importantly, it maximized their limited time in the classroom. The superior performance of AccuLock contact tips stood out most. SLCC saw a remarkable 50% improvement in tip life compared to the products they were using previously. AccuLock contact tips lasted twice as long. The school found the benefits of using Bernard’s MIG welding guns and AccuLock S consumables for instructional purposes were clearly evident. The lightweight and durable design, coupled with the extended consumable life delivered a substantial return on investment. Not only does the switch to Bernard provide cost savings, but it also equips inexperienced welders with the tools that can withstand the rigors of training and real-world applications. Tregaskiss and Bernard, manufacturer of semi-automatic, fixed automatic, cobot and robotic MIG welding guns, consumables and peripherals exhibited at FABTECH 2023, September 11-14 in Chicago. FABTECH is North America’s largest metal forming, fabricating, welding and finishing event that brings over 1,500 world-class suppliers worldwide together in one place. This year Bernard and Tregaskiss presented its latest technology and cost-effective welding solutions to help manufacturers and fabricators improve weld quality and productivity. This year’s product showcase included: Additional options include nozzle detect and wire cutter, and installed on the TOUGH GUN® reamer stand. , plus all TOUGH GUN TT4 reamer robotic nozzle cleaning stations come with an industry-leading 2 year warranty that can be extended to 3 years with exclusive use of TOUGH GARD anti-spatter liquid. Estimated reading time: 6 minutes While MIG is widely used, some operations may still run into issues that require troubleshooting. Understanding the basics of MIG welding and following best practices for operator technique as well as gas and consumable selection can help optimize results with the process. MIG offers productivity benefits when compared to some other welding processes such as TIG and Stick, thanks to its higher travel speeds and deposition rates. MIG is also considered easier for new welders to learn, so it can be a good option for operations that struggle to find skilled welders. MIG could be utilized with either solid filler wires or tubular wires such as Metal Cored and when used with Flux Cored wires it is referred to as Flux Cored welding. Tubular wires in general can be run at higher speeds and deposit more weld metal, so they even offer higher productivity gains than Solid wires. There are many factors to consider when choosing the right welding process for your application. These include base material type and thickness, weld appearance requirements, productivity requirements, the welding environment and available skilled labor. TIG welding is generally used in niche applications, such as those that require high-precision welds or extremely high aesthetic quality. TIG is frequently used with special-grade materials like titanium or stainless steel. In comparison, MIG can be used in higher production applications where increased throughput is important, and it’s a good option for a wide variety of metals. A typical travel speed in TIG welding is 4-6 inches per minute. With MIG welding, travel speeds are much higher; 6 inches per minute are considered slow, and 15 to 20 inches per minute are common. Deposition rates are also much higher with MIG welding. Regarding training, TIG is considered the most difficult welding process to learn and master since it uses both hands. An operator may take a few months to become proficient in TIG, while a new welder could be proficient in MIG within a week or two. Shielding gas plays an important role in determining weld penetration profiles, arc stability, mechanical properties of the finished weld, the transfer process you use and more. The filler metal manufacturer often provides shielding gas recommendations for the type of wire being used, so it’s a good idea to first consult the wire specification sheet. When using flux-cored wire, 100% CO2 or an 80/20 Argon/CO2 mix are common choices. When it comes to solid wire or metal-cored wire, the right gas is dependent on the transfer mode being used. A short-circuit transfer mode works with 100% CO2 gas in most cases but can still run on mixed gas. While using a pulse or spray transfer, a higher Argon content is needed, and an 80/20 Argon/CO2 is the right choice. The base material also plays a role in choosing the right gas. Aluminum requires 100% argon, while stainless steel requires at least 98% argon. The technique choice may come down to operator preference in most cases, but there are some best practices. For example, when welding aluminum, a push angle is generally better because it helps the cleaning action of the oxidation layer on aluminum, similarly uphill position, a push angle is good for visibility and penetration. While if you use Flux Cored wire to weld carbon steel then a pull angle is going to work better in this case to give enough time to the slag not to be entrapped in the weld metal. Maintaining a proper stick-out is important to achieving the best results in MIG welding, a too-long or a too-short stick-out will affect the weld quality and appearance. A 3/8-inch stick-out is a good starting point, but operators can deviate from that based on preference, wire diameter and accessibility to the weld. To choose the right MIG welding gun, consider the specifics of the application. The wire feed speed and wire diameter are two of the most important factors in determining proper gun amperage. Are you welding heavy wall materials, like heavy equipment or heavy steel structures? Those jobs will likely require a high deposition, hence a high-amperage welding gun — such as an Air-cooled 400-amp gun with at least a 60%-80% duty cycle or above, and in some cases a water-cooled gun. If you weld lighter walls and shorter beads, you may consider a 200 to 300-amp gun. The most common amperage choice in the industry is a 300- to 400-amp, air-cooled MIG gun. This gun can address the majority of the MIG welding applications and can run the most common wire sizes such as 0.045” and 0.052”. A good starting point would also be the welding procedure in place that specifies the amperage needed for the weld, which would help in choosing the gun’s amperage. Another easy way is to match the welding machine amperage output, a 400-amp welder would run well with a 400-amp gun in most cases, but this might not be the most effective way to select the right amperage gun when compared to the other methods mentioned above. Using the OEM consumables designed to be used with a specific MIG gun and welding system is important. Because these consumables are machined to very tight tolerances and go through high-quality measures which in turn is translated into higher quality welds and longer consumable life. Be sure to choose a contact tip that is the appropriate size for the wire diameter — an oversized or undersized contact tip will wear faster and result in poor performance. In addition, follow the gun manufacturer’s recommendations for consumable installation and changeover, check connections regularly, install and trim to the right length, select the right nozzle material, size and recess/extension, and finally clean your consumables regularly and change them when needed. Written by Mostafa Hanafy (mostafa.hanafy@tregaskiss.com) , Market Segment Manager, Tregaskiss and Bernard. Republished with permission from Fabricating and Metalworking (August 2023). Estimated reading time: 4 minutes While it may be tempting for companies to purchase MIG welding guns and welding consumables based on price, lower upfront costs don’t always add up to savings. Less expensive products often lack in quality and bring risk to the profitability of the welding operation. This can come in the form of: For these reasons, it’s important to look at MIG guns and consumables as more than simple commodities. Welding engineers, production managers and purchasing agents, along with other stakeholders, should instead look at the total cost of ownership of these products. Those with a higher upfront cost can help reduce risks and save money in the long term. When considering the total cost of ownership of a MIG gun, there are several factors to keep in mind. For example, less expensive guns may require more maintenance and repairs over the life span of the product. Parts like necks, handles and triggers may need frequent attention, resulting in increased expenses for replacement and downtime for changeover. With labor being the largest expense in a welding operation, time spent on activities other than welding come at a price. Lower quality guns may also require more downtime for troubleshooting issues like poor wire feeding. This not only stops production, preventing parts from moving out the door, but it also keeps welding supervisors or others from more important tasks. When an employee’s job is to keep the weld cells running smoothly, any distraction for troubleshooting can negatively affect the productivity and profitability of the welding operation. To lower the total cost of ownership of a MIG gun, companies should look for quality products with a long life span. Guns that offer the ability to repair the power cables are a good option. In this case, the downtime and cost for replacement is a benefit. It is less expensive to repair the cable than to buy a brand-new gun. Companies should also look at a gun’s warranty. With heavy industrial use, a high-quality MIG welding gun typically lasts one to two years and those, like Bernard® BTB guns, include a one-year warranty. Some Bernard guns also have a lifetime warranty on triggers, switches and handles. Poor quality, cheaper consumables — contact tips, gas diffusers, nozzles and liners — can lead to a host of problems that increase downtime and costs. These include an erratic arc, burnbacks, birdnests and a short life span (particularly for contact tips) that can lead to rework. Such issues also increase instances of troubleshooting and make less expensive consumables pricier in the long term. Cheaper contact tips can be prone to keyholing, or an uneven wear of the bore, and may not be as consistent in terms of electrical conductivity. Both can affect welding performance and shorten product life. Conversely, premium consumables can lower the total cost of ownership in a welding operation. The longer they last, and the easier they are to install, the less downtime for changeover and the less expense for replacement. AccuLock™ contact tips feature a coarse thread that eliminates cross-threading and 60% of this consumable is buried in the diffuser, so it is away from heat during welding. As a result, these contact tips last two to three times longer than competitive ones. For robotic applications, AccuLock HDP contact tips last six to 10 times longer. This extended life can help increase production by reducing the number of scheduled changeovers. QUICK LOAD™ liners are also a good option for robotic applications, as they load from the front of the robotic welding gun — safely out of the weld cell — in less than half the time needed for a conventional liner. The liner in the AccuLock S consumable system offers error-proof liner trimming without measuring, to prevent issues with wire feeding. When it comes to MIG guns and consumables, time is money. Repairs, replacements and rework all add up and affect the total cost of ownership of these products — not to mention the company’s bottom line. Making a conversion to higher quality options can yield good results and the benefits can be verified with a MIG gun and consumables trial prior to implementation. These trials help establish a baseline for improvements and provide data that allows companies to assess the upfront cost of products compared to the cost of downtime. With this information in hand, companies can make an informed decision about alternative MIG welding guns and consumables. Whether it’s a high amperage application, high or low ambient temperatures, or humidity, harsh manufacturing environments can be tough on welding equipment — including MIG guns and consumables. Confined, cluttered or dirty weld cells can also negatively affect this equipment. Cleaning and organizing the weld cell, plus areas upstream and downstream, can help prevent some issues — for example, damage to welding gun cables caused by forklifts running over them. However, operators can’t change factors such as heat or cold or the amperage required for the job. For that reason, it’s important to look for a durable MIG welding gun and consumables and know how to protect them. Not only does that help minimize costs for replacement, but it also supports productivity by reducing downtime for changeover. One of the best defenses against the elements in a harsh manufacturing environment is to choose a MIG gun with robust components and make certain it’s the best option for the job. Consider these factors. This is the most important factor in selecting a MIG gun for any operation, but especially in a harsh environment. Duty cycle is the amount of arc-on time within a 10-minute period that a gun is capable of being used. Manufacturers in the U.S. rate their MIG welding guns according to the National Electrical Manufacturers Association (NEMA), with the rating reflecting the temperatures at which the gun or cable becomes too warm for use. For example, a gun may be rated at 400 amps and 100% duty cycle, meaning it can weld the entire 10 minutes at 400 amps (or even longer at a lower amperage) without discomfort to the operator. In areas of high heat and humidity, it is helpful to use a MIG gun offering 100% duty cycle and higher amperages than needed for the application. If a welding shop is experiencing 80% humidity and it is 100 degrees F outside, that ambient temperature will reduce the duty cycle — a 400-amp gun may drop from 100% duty cycle to a 60% duty cycle range. MIG gun handles should be manufactured with materials designed to withstand heat. Those with added glass in the plastic mold material are particularly adept at resisting wear in harsh environments. Tubular handles are also an option, as they tend to be a bit larger, and they have a slight air gap between the handle and the power cable that adds to its durability and heat tolerance. However, each handle material and design can have its own pros and cons. High glass content will create a more brittle handle, while more malleable materials may withstand less heat but not break as easily if abused. Trigger designs vary by manufacturer. The best option to protect against harsh elements is a micro-switch trigger, which is sealed. MIG guns with straight handles typically have a trigger that is enclosed to protect against dirt and debris. Avoid contact triggers, as these feature a spring and two contacts that touch each other when the operator presses down on it. Dirt can get inside of these triggers and break the contacts, preventing good electrical connections. A MIG welding gun neck with aluminum armor on the outside is a durable choice. This type of neck is also lightweight, so it is more comfortable for the operator. MIG gun neck grips can also increase comfort, as well as control. Look for a power cable with a thick rubber outer jacket. While this type of cable may add some to its stiffness and weight, it will last longer. It can better take the abuse of being dragged on the floor, run over edges and exposed to hot materials. There are also power cable jackets that further protect power cables in harsh environments. A good jacket option is one with a tubular design versus one with Velcro or buttons. A power cable with higher-quality grades and higher amounts of copper adds to its durability and performance, as well. Welding contact tips, nozzles and gas diffusers made from quality copper or chrome zirconium are reliable complements to a sturdy MIG gun. Typically, higher-quality welding consumables cost more upfront; however, they last longer. Having fewer changeovers during shifts can save money for labor and replacement consumables in the long run. Contact tips, like those in AccuLock™ S consumable systems, have 60% of the tip buried within the gas diffuser. This keeps heat from the weld away from the tip, so it lasts longer. Shielding gas also cools the contact tip tail to protect it. Preventive maintenance is critical in any welding operation, but especially in harsh manufacturing environments. Purchasing a gun that is repairable and can be maintained versus thrown away is a smart investment. In the long term, operators and maintenance personnel can gain more life from the gun even when exposed to heat, humidity and other elements. Periodically, remove the welding gun liner and blow out any dust or debris that accumulated with compressed air. Take care not to drag the liner on the ground, where it can pick up more dirt or inadvertently become damaged. At the start of every shift, especially when operators share MIG guns, check all connections. Tighten connections along the length of the gun — between the welding contact tip, gas diffuser, neck, power cable and power pin. Also check that the screws on the handle are tight and the trigger is functioning. When using a MIG welding gun with a rotatable neck, be certain to tighten it to avoid wire feeding problems. The best defense to protect a MIG gun used in a harsh manufacturing environment is to make sure to select a durable one in the first place. Look for quality components and take care to schedule preventive maintenance. Treat the MIG welding gun just like any other piece of equipment in the welding operation, caring for it with regular inspections. Doing so can increase its lifespan and help prevent downtime and the cost for replacement. Estimated reading time: 6 minutes Improving productivity in semi-automatic operations isn’t simply about welding faster and working harder. Instead, there are ways to create consistency in the process and support quality so that companies can avoid downtime that adversely affects throughput. When training new welders, it’s important to provide a solid foundation of knowledge to achieve the best results. Taking the time to establish and expand welders’ skill sets shows welders companies are invested in them, and as welders gain more experience, they become more confident. The aim is to empower them and provide all the information necessary to be productive. To instill good habits from the start, consider some key training tips. A safe welder is a productive welder. By training new welders to follow welding safety protocols, there is less risk of lost productivity due to injury. Wearing the appropriate personal protective equipment (PPE) is important. This includes a properly fitted helmet, safety glasses, flame-resistant jacket or sleeves, welding gloves and steel-toed, rubber-soled boots. If the process is prone to higher levels of fume generation, correct use of a respirator is necessary. Train welders to read and follow all equipment labels and their owner’s manual carefully before operating welding equipment. Training also includes checking the power source ground, securing workpieces in the best possible manner and keeping their heads out of the weld plume when welding. Following best practices for weld prep supports high weld quality, reduces rework and scrap, and improves productivity. As part of new welder training, welders should understand their power source settings, type and levels of the shielding gas being used, and how to clean the base material. Checking that all welding consumable connections are tight can minimize electrical resistance that could lead to burnbacks (the formation of a weld in the contact tip) and downtime for tip changeover. Downtime to address liner issues is common in semi-automatic welding operations and is typically caused by incorrect installation. This can lead to bird-nesting (a tangle of wire in the drive rolls), poor wire feeding, an erratic arc, wire chatter, burnbacks and more. Always use a liner gauge when trimming a liner; or consider a consumable system like AccuLock™ S, which provides error-proof liner installation without measuring. The liner locks and is aligned to the power pin and the contact tip to ensure proper wire feeding. New welders should also learn to install and tighten contact tips according to the consumable manufacturer’s recommendation. Training welders to pay attention to their posture and the angle they hold their MIG welding gun can help reduce fatigue and the risk of welding-related musculoskeletal disorders that lead to lost productivity. Whenever possible, welders should position themselves so they are welding the workpiece in the range between their waist and shoulders. This may require a work stool or adjustable chair. Welders should also keep their hands and welding gun at or slightly below elbow height. Gaining good visibility to the weld joint can encourage proper posture. Welding procedure specifications (WPS) are a means to create consistency in the welding operation by taking the guesswork out of the process. This document outlines welding parameters, filler metal type and diameter, wire feed speed (WFS), weld pass sequence and more. Training new welders to follow the details in a WPS can help ensure that they produce quality welds and remain productive. New welders should be trained to use the best equipment and tools for the job — and ones that best suit them. A MIG welding gun that fits the welder’s hand comfortably will help maximize their time when welding. Using a hammer for repositioning a part, as opposed to the MIG gun itself, can prevent damage to the gun that leads to downtime for repairs or replacement. Likewise, having the correct wrench for installing gas diffusers or welpers for tightening contact tips helps ensure snug connections and lessens the opportunity for issues. Using the wrong tools or not tightening parts properly leads to loose connections that cause electrical resistance. This, in turn, increases heat and wears out the equipment prematurely. Welding techniques vary according to the process, the welding position and the thickness of the base material. For example, when MIG welding with solid or metal-cored wire, welders need to learn to use a push technique, while a flux-cored process requires a drag technique. Train welders on the proper gun angles for flat, horizontal and out-of-position welding applications so they are able to fill the joint with the appropriate amount of weld metal and avoid issues like lack of fusion. Training new welders to quickly identify issues in the welding process can minimize downtime for troubleshooting. They should be given the guidance to identify the causes of common problems like porosity, burnbacks, poor deposition and more, along with their solutions. Welders should also be able to recognize signs that equipment needs to be repaired or replaced — for example, a welding contact tip that is keyholing (wearing at the bore unevenly) or a gun that has nicks in the power cable. Companies can provide troubleshooting cards with quick checklists to keep in the weld cell as reminders. Clearly communicating expectations to new welders and having supervisors who are responsive to questions are vital parts of training. It is about both learning and listening. As training continues and welders grow their skill sets, it’s important to establish two-way feedback. This way everyone can find common ground on what best practices could be. In some cases, new welders may identify a way to improve the operation based on experience they have from another job. When companies commit to providing thorough new welder training, the aim is to establish skills that lead to consistency in quality and reduce downtime. The more they can avoid secondary work or additional processes, the better productivity will be. Plus, supporting the comfort and safety of welders can help make sure they perform their best every day, build confidence and help retain them as employees. Estimated reading time: 7 minutes Establishing consistent levels of weld quality is important for attaining production goals and a better bottom line in semi-automatic welding operations. However, there are many factors that can negatively impact those efforts, including a lack of skilled labor, inadequate or aging equipment or using the wrong welding consumables. To avoid costly rework associated with poor weld quality, it’s critical to implement proper welder training. Evaluating the welding operation on a regular basis for issues can also help, along with following these key tips. Welding contact tips are available in a range of diameters — typically 0.023 to 1/8 inches — to accommodate different welding wire sizes. The wire packaging, in part, determines what size contact tip is appropriate to support good weld quality. Welding wires in larger drums — 500 pounds or more — have a larger cast and are flatter so there is less degree of arc. This means there is less opportunity for the wire to make consistent contact when feeding down the bore of the contact tip, resulting in an erratic arc and weld quality issues. To avoid problems when using copper and chrome zirconium welding contact tips (with Bernard and Tregaskiss consumables), undersize them for the diameter of wire. For example, match an 0.045-inch wire to a 0.039-inch contact tip. For other manufacturers’ contact tips, request recommendations. Copper and chrome zirconium contact tips can be matched size for size with wire on spools or in drums less than 500 pounds since the wire has a tighter cast. For AccuLock™ HDP contact tips, the wire and tip size can be matched regardless of the welding wire drum or spool size. As with contact tips, welding liners are available in various diameters and ranges, from 0.035 to 0.045 inch or from 0.045 to 1/16 inch. To avoid issues like burnback (the fusing of a weld in a contact tip), poor wire feeding and an erratic arc that can be detrimental to weld quality, match the diameter of welding wire to that of the liner. This supports the wire as it feeds through the liner. It’s equally important to trim the liner properly. A liner that is too short can create wire chatter, an erratic arc and bird-nesting (a tangle of wire in the drive rolls). If the liner is too long, it can cause the wire to weave. Both situations can cause poor welds and, potentially, rework. Always use the gauge provided by the manufacturer to ensure that the liner is trimmed correctly. The AccuLock S consumable system is also a good option, as it provides error-proof liner replacement. The liner loads through the neck at the front of the gun and is locked and trimmed flush with the power pin at the back of the gun, which eliminates the need to measure. Electrical resistance — or interference with the flow of electricity in a semi-automatic MIG gun’s circuit — generates heat and can impede weld quality by negatively impacting the gun’s components. There are several causes that can be rectified to prevent issues such as inconsistent weld appearance or an erratic arc. Through ongoing use, connections begin to wear and loosen, leading to electrical resistance. Address this problem by tightening connections between the gas diffuser, gun neck and handle, as well as the connections from the power cable to the power pin and wire feeder. Power cable wear that results in hotspots can also lead to electrical resistance. This wear may not always be visible, so as a course of troubleshooting, operators should consider this problem as a cause of poor weld quality. Replace the cable as necessary to prevent issues. Likewise, increased electrical resistance can occur in the gun handle, since it is an area of high use and bending. Look for signs of wear and replace as needed. There are various aspects of cleaning and weld prep that can help support good weld quality. Always follow proper procedures for cleaning the base material to prevent defects like porosity that can be caused by welding through dirt, oil and debris. It’s also important to be proactive about cleaning consumables. For example, weld spatter buildup in the nozzle or in the ports in the gas diffuser can hinder shielding gas coverage, which also leads to porosity. Clean or replace these consumables when excessive spatter is evident. Operators can also apply anti-spatter compound to the consumables by dipping the front inch and a half of the nozzle into the liquid. Use the anti-spatter compound sparingly to avoid damaging the nozzle insulator. Storing consumables in a clean area minimizes the opportunity for dust, oil or other contaminants to adhere to the surface of the welding contact tip, nozzle and diffuser and adversely affect weld quality. A covered container with compartments for each welding consumable is a good option to protect them. Also consider how to handle the welding liner during changeover. Be careful not to drag the liner on the floor while feeding it into the gun, since doing so can cause debris to collect on it and be pulled into the gun. Preventative maintenance and ongoing care of the MIG gun and consumables can go far in supporting high weld quality. Set a schedule to inspect, maintain and repair the components. Although often overlooked during regular inspections, the O-rings found throughout the gun are important to assess. If they start to degrade or break, they can cause shielding gas leaks that lead to porosity and potentially extra costs for shielding gas if the operator increases gas flow to compensate for the leak. Check O-rings on the power pin, gas diffuser and liner during routine preventive maintenance and replace these components as needed. Look for damage to the power cable, such as nicks or tears that can impede gas flow. Visually inspect the gun handle for cracks or missing screws and the trigger for sticking or malfunction. Repair or replace as necessary. Last, inspect the welding contact tip for keyholing (an oblong wear of the bore); this can cause drifting wire and arc start failures that affect weld quality. Improving weld quality is a matter of ongoing evaluation. Supervisors and managers overseeing semi-automatic welding operations should regularly consult with welding operators to make sure they are following best practices. Ongoing training and quickly troubleshooting issues can also support good weld quality and prevent costly downtime and rework. Estimated reading time: 4 minutes Human error can take its toll on welding operations, leading to downtime and lost productivity, poor quality and increased costs. It can result from a variety of factors. An operator may know how to manage a process, but periodically misses a step or forgets to complete a task. Or an operator may believe he is conducting a task in the correct manner, but it is wrong. To reduce problems, it’s important to provide proper training to semi-automatic and robotic welding operators. This includes not only training on the welding process, but also on how to spot errors when they occur. Companies may want to rely on principles of poka-yoke to help. These principles could be applied in several ways in a welding operation. With these high-level, error-proofing ideas in mind, it’s possible to put them into action in several specific ways. Investing in welding consumables with color-coded parts can help eliminate confusion during installation. AccuLock™ S liners and power pin caps are color coded to make it easy to identify which power pin cap is compatible with which liner. For example, power pin caps with red washers are compatible with liners that have red shrink tube and so on. Implementing a welding procedure specification (WPS), and training operators to follow it, can help ensure consistent, high-quality welds. A WPS outlines details on the welding process and parameters, weld pass sequences, filler metal type and size, and more. For operations with a mix of welding arcs or for all automated welding operations, AccuLock R consumables are designed to prevent errors associated with cross threading during installation. They feature a long contact tip tail that aligns in the diffuser prior to the thread engaging. This allows operators to install the tip easily and accurately. The AccuLock S welding gun liner also offers error-proof liner trimming with no measuring required for semi-automatic welding operations. Consumables that last longer require less changeover, which means less interaction by the welding operator in the welding cell and less potential for errors. AccuLock contact tips offer a longer lifespan, particularly the AccuLock HDP tips. These last up to ten times longer than standard contact tips and are designed for use in pulsed MIG welding applications, where waveforms tend to be harsher on tips. Taking steps to simplify inventory by having a lower variety of consumables can help prevent errors during changeover. The AccuLock S and AccuLock R consumable systems share a common contact tip, so the tip can be used in Bernard semi-automatic MIG guns and Tregaskiss robotic and fixed automatic guns. Keeping open lines of communication among welding operators and with management is an important way to minimize and rectify errors. Knowing what is expected in the welding process is a good start, as is reporting errors when they occur so that they can be fixed and don’t lead to further complications. Preventing errors in a welding operation requires attention to detail, a commitment to making improvements, and collaboration among welding operators and management. Everyone needs to take a vested interest in the process, knowing that it will help improve quality and productivity — and ultimately make everyone’s job easier. Estimated reading time: 3 minutes When it comes to MIG welding, it’s important for new welders to start with the basics to set a solid foundation for success. The process is generally forgiving, making it simpler to learn than TIG welding, for example. It can weld most metals and, as a continuously fed process, offers greater speed and efficiency than stick welding. The very first consideration for new welders is welding safety. It is imperative to read and follow all labels and the equipment Owner’s Manuals carefully before installing, operating, or servicing welding equipment. Welders must wear proper eye protection to avoid arc flash burns and sparks. Always wear safety glasses and a welding helmet set to the appropriate shade level. Proper personal protective equipment attire is also critical to protect the skin from electric shock and burns. This includes: Adequate ventilation is also an important safety factor. Welders should always keep their head out of the weld plume and be sure that the area in which they are welding has adequate ventilation. Some type of fume extraction may be needed. Fume extraction guns that remove the exhaust at the arc are also helpful, and are very efficient compared to floor or ceiling capture. Depending on base material and shielding gas, welders can weld in various welding transfer modes. Short circuit is common for thinner materials and operates at lower welding voltage and wire feed speed, so it is slower than other processes. It also tends to produce spatter that requires post-weld cleaning, but overall, it is an easy process to use. Globular transfer operates at higher wire feed speeds and welding voltages than short circuit and works for welding with flux-cored wire with 100% carbon dioxide (CO2) (see details on CO2 in next section). It can be used on 1/8-inch and thicker base materials. Like short-circuit MIG welding, this mode produces spatter, but it is a fairly fast process. Spray transfer offers a smooth, stable arc, making it appealing to many new welders. It operates at high welding amperages and voltage, so it is fast and productive. It works well on base materials that are 1/8 inch or more. In addition to protecting the weld pool from the atmosphere, the type of shielding gas used for MIG welding impacts performance. Weld penetration, arc stability and mechanical properties depend on shielding gas. Straight carbon dioxide (CO2) offers deep weld penetration but has a less stable arc and more spatter. It is used for short circuit MIG welding. Adding argon to a CO2 mixture allows for use of spray transfer for higher productivity. A balance of 75% argon and 25% is common. Along with practice, knowing some key information can help new welders better understand the MIG welding process. It’s also important to be familiar with the equipment, including MIG welding guns and welding liners. Understanding how to select and maintain this equipment can go far toward establishing good welding performance, quality and productivity. This is the first article in a three-part series on welding basics. Read article two, MIG Welding Glossary: Terms to Know and article three, MIG Welding Techniques: What to Know. Estimated reading time: 2 minutes Understanding some proper techniques for MIG welding can help welders gain good weld quality and avoid the frustration and cost of rework. Everything from proper positioning of the MIG welding gun to travel angle and travel speed can make an impact. Consider these four recommended techniques: As with any welding process, practice is a large part of MIG welding success. Along with good techniques, it’s also important to properly prepare and clean the base material before welding and to maintain the MIG welding gun and consumables properly. This can reduce downtime for addressing equipment issues or troubleshooting weld defects and problems such as poor wire feeding. This is the third article in a three-part series on welding basics. Read article one, MIG Welding Basics and article two, MIG Welding Glossary: Terms to Know. Estimated reading time: 7 minutes Porosity, cavity-type discontinuities formed by gas entrapment during solidification, is a common but cumbersome defect in MIG welding and one with several causes. It can appear in semi-automatic or robotic applications and requires removal and rework in both cases — leading to downtime and increased costs. The major cause of porosity in steel welding is nitrogen (N2), which gets involved in the welding pool. When the liquid pool cools down, the solubility of N2 is significantly reduced and N2 comes out of the molten steel, forming bubbles (pores). In galvanized/galvanneal welding, evaporated zinc can be stirred into the welding pool, and if there is not enough time to escape before the pool solidifies, it forms porosity. For aluminum welding, all porosity is caused by hydrogen (H2), by the same way as N2 works in steel. Welding porosity can appear externally or internally (often called sub-surface porosity). It can also develop at a single point on the weld or along the entire length, resulting in weak welds. Knowing how to identify some key causes of porosity and how to quickly solve them can help improve quality, productivity and the bottom line. Poor shielding gas coverage is the most common cause of welding porosity, as it allows atmospheric gases (N2 and H2) to contaminate the weld pool. Lack of proper coverage can occur for several reasons, including but not limited to poor shielding gas flow rate, leaks in the gas channel, or too much air flow in the weld cell. Travel speeds that are too fast can also be a culprit. If an operator suspects poor flow is causing the problem, try adjusting the gas flow meter to ensure the rate is adequate. When using a spray transfer mode, for example, a 35 to 50 cubic feet per hour (cfh) flow should suffice. Welding at higher amperages requires an increase in flow rate, but it’s important not to set the rate too high. This can result in turbulence in some gun designs that disrupts shielding gas coverage. It’s important to note that differently designed guns have different gas flow characteristics (see two examples below). The “sweet spot” of the gas flow rate for the top design is a lot larger than that of the bottom design. This is something a welding engineer needs to consider when setting up the weld cell. Also check for damage to the gas hose, fittings and connectors, as well as O-rings on the power pin of the MIG welding gun. Replace as necessary. When using fans to cool operators or parts in a weld cell, take care that they are not pointed directly at the welding area where they could disrupt gas coverage. Place a screen in the weld cell to protect from external air flow. Re-touch the program in robotic applications to make sure there is a proper tip-to-work distance, which is typically ½ to 3/4 inch, depending on the desired length of the arc. Lastly, slow travel speeds if the porosity persists or consult a MIG gun supplier for different front-end components with better gas coverag Base metal contamination is another reason porosity occurs — from oil and grease to mill scale and rust. Moisture can also encourage this discontinuity, especially in aluminum welding. These types of contaminants typically lead to external porosity that is visible to the operator. Galvanized steel is more prone to subsurface porosity. To combat external porosity, be certain to thoroughly clean the base material prior to welding and consider using a metal-cored welding wire. This type of wire has higher levels of deoxidizers than solid wire, so it is more tolerant of any remaining contaminants on the base material. Always store these and any other wires in a dry, clean area of similar or slightly higher temperature than the plant. Doing this will help minimize condensation that could introduce moisture into the weld pool and cause porosity. Do not store wires in a cold warehouse or outdoors. When welding galvanized steel, the zinc vaporizes at a lower temperature than the steel melts, and fast travel speeds tend to make the weld pool freeze quickly. This can trap zinc vapor in the steel, resulting in porosity. Combat this situation by monitoring travel speeds. Again, consider specially designed (flux formula) metal-cored wire that promotes zinc vapor escape from the welding pool. Clogged and/or undersized nozzles can also cause porosity. Welding spatter can build up in the nozzle and on the surface of the contact tip and diffuser leading to restricted shielding gas flow or causing it to become turbulent. Both situations leave the weld pool with inadequate protection. Compounding this situation is a nozzle that is too small for the application and more prone to greater and faster spatter buildup. Smaller nozzles can provide better joint access, but also obstruct gas flow due to the smaller cross-sectional area allowed for gas flow. Always keep in mind the variable of the contact tip to nozzle stickout (or recess), as this can be another factor that affects shielding gas flow and porosity with your nozzle selection. With that in mind, make sure the nozzle is large enough for the application. Typically, applications with high welding current using larger wire sizes require a nozzle with larger bore sizes. In semi-automatic welding applications, periodically check for welding spatter in the nozzle and remove using welder’s pliers (welpers) or replace the nozzle if necessary. During this inspection, confirm that the contact tip is in good shape and that the gas diffuser has clear gas ports. Operators can also use anti-spatter compound, but they must take care not to dip the nozzle into the compound too far or for too long, since excessive amounts of the compound can contaminate the shielding gas and damage the nozzle insulation. In a robotic welding operation, invest in a nozzle cleaning station or reamer to combat spatter buildup. This peripheral cleans the nozzle and diffuser during routine pauses in production so that it does not affect cycle time. Nozzle cleaning stations are intended to work in conjunction with an anti-spatter sprayer, which applies a thin coat of the compound to the front components. Too much or too little anti-spatter fluid can result in additional porosity. Adding in air blast to a nozzle cleaning process can also aid in clearing loose spatter from the consumables. By taking care to monitor the welding process and knowing the causes of porosity, it’s relatively simple to implement solutions. Doing so can help ensure greater arc-on time, quality results and more good parts moving through production. Estimated reading time: 4 minutes The welding industry, like many others, is challenged by a labor shortage — and one that is growing. By 2023, the American Welding Society (AWS) anticipates the welder shortage to reach approximately 375,000, as an increasing number of experienced welders reach retirement age and leave the field.[1] With those statistics in mind, it’s more important than ever for companies to take steps to retain the welders they have. Employee retention is critical for several reasons. It helps support quality and productivity initiatives, which in turn makes it easier to meet customer demands. It also prevents overworking welders — an issue that can lead to low morale and a poor company culture. In addition, retaining welders helps maintain the bottom line. Turnover can cost companies significantly in terms of recruiting and retraining new welders, as well as for downtime in production due to lack of a full workforce. [2] Fortunately, there are some best practices that can help companies create a positive environment and keep welders interested in the job. Empowering welders is important to instill a sense of interest and pride in the job —and that process should start from the very beginning. It’s reported that strong onboarding and training can help companies retain 82% of new hires. [3] With proper training, welders can feel confident in their ability to do the job and help train new welders. Start with establishing good welding habits and creating a familiarity with the welding process. This includes training new welders on how to set up their power source accurately and safely and on what welding parameters to use. Equally important is providing guidance on the best technique for the process and application to minimize weld defects. Establishing a comfort level with following welding procedures is also a valuable part of welder training. [4] For more experienced welders, offering more advanced training opportunities can help keep them engaged. This could include training to weld on more complicated applications or complex parts, robotic welding programming and more. Along with providing appropriate personal protective equipment (PPE), such as helmets, gloves, safety glasses and jackets, it is also important that the environment is safe. That means ensuring the welding cell and surrounding areas are free of clutter and any tripping hazards. It also entails proper ventilation. Companies can achieve that by removing weld fume at the source with a fume extraction gun, or with a mobile, wall-mounted system or a centralized fume extraction system. A clean, safe welding environment is more appealing for welders to work in — and it can provide an edge over competitive companies when it comes to employee retention. Additionally, be certain to train employees on all company safety protocols and welding equipment manufacturer’s safety precautions. Doing so can help create a culture of safety in which everyone is contributing. [5] Complicated equipment can be difficult to use, especially for inexperienced welders, leading to frustration about errors and downtime. This holds true not only for power sources, but also MIG guns and consumables: contact tips, nozzles, gas diffusers and liners. Liners, in particular, can be troublesome to install since it’s easy to trim them too long or too short, the latter of which happens more often. When the liner is too short, it can cause burnbacks, an erratic arc and poor wire feeding. Look for a consumable system that offers error-proof liner replacement for easier installation. This leaves welders more time to hone their welding skills while spending less time on troubleshooting. In automated welding operations, it is important to have equipment that is easy and intuitive to maintain and program after the proper training. This includes teach pendants with easy-to-use controls for inputting new parameters and requirements for the application. Offering welders a chance to advance and learn new skills can be a good way to retain those who are interested in those opportunities. Growth can take many forms, whether it’s stepping into a new role or shouldering additional responsibilities within a current position. Certifications are another avenue for growth. The American Welding Society (AWS) offers its AWS Certified Welder performance-based program so welders can expand their knowledge and technique — from plate to pipe welding with a variety of processes. There are additional programs that support advancement, including one for a certified welding supervisor. [6] Along with these best practices, keeping open lines of communication with welders is key — as it is in any work environment. Staying involved and creating a sense of community in which everyone is contributing to the well-being of the company can go a long way in keeping welders interested and engaged. In both semi-automatic and automated welding cells, the upfront cost of welding consumables is low compared to the overall expense for equipment, materials and labor. Yet when companies accrue downtime for excessive welding contact tip changeover or troubleshooting poor wire feeding associated with liner issues, costs can quickly compound. At times, companies may try to mitigate consumable problems without a true sense of the root cause, implementing a solution without data to back up the decision. However, conducting a welding consumables trial can provide insight into whether an operation is using the best consumables for the application. Welding contact tips are the baseline for these trials since they are the most frequently changed consumable. Nozzles and diffusers that are compatible with the contact tip are included in a trial but not monitored in the same way since they last much longer. August 1, 2022 Bernard has discontinued the sales of the Q150 semi-automatic air cooled MIG guns as of August 1, 2022. Replacement MIG gun options would be a configured Bernard® BTB 200 amp or TGX 180 amp MIG gun. If you have any questions regarding this change, contact your local ITW representative. Estimated reading time: 5 minutes Knowing the common causes of MIG gun wear — and how to eliminate them — is a good step toward minimizing downtime and costs for addressing issues. Like any equipment in a welding operation, MIG guns are subject to routine wear and tear. The environment and the heat from the arc, along with other factors, impact their longevity. When operators follow best practices for their use, however, most quality MIG welding guns can last at least one year in a manufacturing environment. Routine preventive maintenance can also help extend product life. The welding environment and application can affect MIG gun life. Some of the most common causes of gun wear include: Extreme temperature fluctuations can affect the condition and expected life of the MIG gun jacket, which is typically a rubber-type composite material. If temperatures fluctuate from high to low, the jacket material will react differently — becoming softer or harder — which eventually leads to wear. Whether you’re welding inside a facility or on an outdoor jobsite, dirty conditions can introduce abrasives and debris into the MIG gun circuit and consumables. Guns can also be damaged if they are dropped, run over, walked on, or caught in a lift arm or boom. These actions can damage the cable or cause disruption of the shielding gas flow. Welding on or near abrasive surfaces can cause cuts to the gun jacket or cable. It’s not recommended to weld with a MIG gun that has a damaged jacket. Always replace worn, damaged or cracked guns or cables. When dirt and debris build up within the gun liner or on the contact tip, it increases resistance and causes additional heat buildup — the enemy of gun life. A wire feeder that isn’t feeding properly can also cause damage elsewhere in the gun. Consider these five tips to help optimize gun performance and longevity. Getting the most life out of your MIG welding gun involves numerous factors, from proper maintenance and care to using best practices when welding. Keeping an eye on MIG gun wear and changing consumables as necessary can help prolong gun life and deliver better performance for longer. Attacking Weld Fume at the Source
Attacking Weld Fume at the Source
The basics
Benefits of the Bernard® Clean Air™ E Fume Extraction Gun
Maximizing Performance
Proper maintenance and consumable usage
Fume extraction guns can provide results
Learn more about the Bernard® Clean Air E™
Fume Extraction Guns: Understanding the Basics
Fume Extraction Guns: Understanding the Basics
The basics of fume extraction guns
Applications, advantages and limitations
Maintenance tips
Bernard® BTB Gun Transforms Aluminum Welding for 4-Star Trailers
Bernard® BTB Gun Transforms Aluminum Welding for 4-Star Trailers
Key MIG Gun Components for Job Performance
Key MIG Gun Components for Job Performance
CONSUMABLES
ESSENTIAL GUN COMPONENTS
OTHER COMPONENTS
Extending the Life of Welding Guns and Consumables
Extending the Life of Welding Guns and Consumables
5 Factors to Consider When Choosing a MIG Welding Gun
5 Factors to Consider When Choosing a MIG Welding Gun
Click here to read the full article featured in the March 2024 issue of Fabricating and Metalworking Magazine.Five Equipment Adjustments to Improve Weld Quality
Five Equipment Adjustments to Improve Weld Quality
South Louisiana Community College Chooses Bernard® Semi-Automatic MIG Welding Guns and AccuLock™ Consumables for Welding Education | Customer Testimonial
South Louisiana Community College Chooses Bernard® Semi-Automatic MIG Welding Guns and AccuLock™ Consumables for Welding Education
Bernard® and Tregaskiss® offer welding solutions at FABTECH 2023
Bernard® and Tregaskiss® offer welding solutions at FABTECH 2023
MIG Welding FAQ: Best Practices for MIG Success
MIG Welding FAQ: Best Practices for MIG Success
MIG is the most frequently used welding process in general manufacturing and fabrication, thanks to its ease of use, versatility, and productivity benefits.
Q: What are the main advantages of MIG welding?
Q: What are the differences between MIG and TIG welding?
Q: What is the right shielding gas for MIG welding?
Q: Which is better: a push or a pull technique?
Q: What is the proper wire stick-out?
Q: What amperage MIG welding gun is needed?
Q: How can an operation make consumables last longer?
Upfront Cost vs. Total Cost of Ownership of MIG Guns and Consumables
Upfront Cost vs. Total Cost of Ownership of MIG Guns and Consumables
A look at MIG welding guns
Considerations for consumables
MIG gun and consumables trials
Making a MIG Gun Last in Harsh Manufacturing Environments
Making a MIG Gun Last in Harsh Manufacturing Environments
What to look for
Duty cycle
Handles
Trigger
Neck
Power cable
Consumables
Maintain and protect
Being mindful
Welder Training Tips to Help Improve Productivity
Welder Training Tips To Help Improve Productivity
Put safety first
Establish consistent weld prep
Install welding consumables correctly
Focus on comfort
Follow welding procedures
Use the right equipment
Employ proper techniques
Recognize signs of trouble
Keep communication open
Successful new welder training
5 Tips for Improving Weld Quality
5 Tips for Improving Weld Quality
No. 1: Size contact tips correctly
No. 2: Size and change over liners properly
No. 3: Keep electrical resistance low
No. 4: Be mindful of cleanliness
No. 5: Plan for inspection and maintenance
Long-term results
From Consumables to Communication: Reducing Human Error in Welding
From Consumables to Communication: Reducing Human Error in Welding
Color-coded parts
Welding procedures
Error-proof consumables design
Long-lasting consumables
Inventory reduction
Communication and reporting
MIG Welding Basics
MIG Welding Basics
Welding safety
Welding transfer modes
Welding shielding gas
Beyond the basics
MIG Welding Techniques: What To Know
MIG Welding Techniques: What To Know
Solving Common Causes of Welding Porosity
Solving Common Causes of Welding Porosity
Poor Shielding Gas Coverage
Base Metal Contamination
Clogged and/or Undersized Nozzles
Maintaining quality and productivity
Employee Retention: Best Practices for Keeping Welders Engaged
Employee Retention: Best Practices for Keeping Welders Engaged
Provide proper welder training
Create a clean, safe environment
Offer easy-to-use welding equipment
Provide growth and advancement opportunities
The Value of Welding Consumables Trials
The Value of Welding Consumables Trials
This article has been published as an exclusive with The Fabricator. To read the entire article, please click here. BERNARD DISCONTINUED PRODUCT — EFFECTIVE AUGUST 1, 2022
BERNARD DISCONTINUED PRODUCT — EFFECTIVE AUGUST 1, 2022
Click here for a list of discontinued part numbers.How to Reduce Welding Gun Wear and Extend Gun Life
How to Reduce Welding Gun Wear and Extend Gun Life
What causes MIG gun wear?
Temperature changes
Environmental damage
Lack of proper maintenance
A broken handle or noticeable chips or cuts in the gun jacket or cable are common indicators of MIG gun wear. But other signs aren’t always visible.
If a burnback, erratic arc or poor-quality welds are an issue during welding, these could be caused by inconsistent power being delivered to the weld circuit. Worn connections or components in the welding gun can cause these power fluctuations. To avoid downtime and additional wear on the gun, it is important to troubleshoot weld or arc issues and fix them as quickly as possible. 
Tips for preventing MIG gun wear
Optimizing MIG gun life
