Consumables for MIG/GMAW

Many factors influence gas metal arc welding (GMAW) consumable selection. Chief among the
factors is productivity. Because 85 percent of the cost of making a weld is for labor, you need to
choose consumables based on how well they improve welder productivity and minimize downtime.
To get the longest life out of GMAW consumables, you need to know what to look for when
making a decision. Three important consumables are contact tips, nozzles, and liners.
Contact Tips

GMAW employs continuously fed wire, and to transmit current to this wire, the welding gun must
make electrical contact with the wire. This electrical contact occurs through a contact tip that the
wire feeds through.
The contact tip's size corresponds to the wire diameter. For example, a 0.035-inch contact tip
corresponds to a 0.035-in. wire. However, this is not the only consideration. The contact tip size
you choose also depends on the application. Industrial applications require large diameter and
longer contact tips, which have more mass and help to keep tip temperatures lower than small tips
do.
Tapered and nontapered contact tips are available. Tapered tips typically are long and used with
tapered nozzles in applications with restricted access and limited space, such as pipeline welding.
Non-tapered tips have more mass in the front and tend to hold up heat better and last longer.
Contact tips also come in threaded and non-threaded varieties. Some styles of contact tips tend to
seize the diffuser, making them difficult to remove and replace. Seizing is less likely to occur with
nonthreaded contact tips. Nonthreaded designs typically have more area and conduct heat and
electricity better than threaded contact tips, and often take less time to change after a burnback.
Threaded tips have traditionally been the most common-welders are accustomed to using them,
and removal and installation is intuitive. Using tapered, nonthreaded contact tips, nozzles and
diffusers can help welders fit into spaces that have limited accessibility.
Because non-threaded contact tips do not require tools to change, they are quicker to replace after
burnback. Some fabrication shops use tips that have just four settings, such as flush with the end of
the nozzle, 1/8-inch recess, 1/4-in. recess, or 1/8 in. stick out. Fewer choices improve consistency
among welders.
When contact tips start to wear, an oval hole can start to develop. This phenomenon of key holing,
can lead to irregularities in the arc from poor electrical pickup. Irregularities in the arc can increase
spatter, which in turn leads to more postweld grinding. This is an inefficient use of a welder's labor-
every additional minute of grinding time is one less minute of valuable production time.

Remember that all consumables are not created equal. From materials to cost and design quality,
each brand on the market varies and so does their performance.
Nozzles

The nozzle directs the shielding gas to the weld. Like contact tips, nozzles are either threaded or
nonthreaded and come in many different shapes and sizes for various applications. Nonthreaded
nozzles are easier to change than threaded nozzles, but because they have no threads, they don't fit
as tightly as threaded nozzles do. Threaded nozzles are more secure, yet many require more effort
to change. Threaded nozzles generally stay on the gun better and offer better tip-nozzle
concentricity. Slip-on nozzles generally are a bit quicker to change and clean.
For spray arc transfer or pulse spray of solid wire, the nozzle should extend past the contact tip,
which helps deliver the shielding gas closer to the arc when longer electrode stickout is required. It
also helps the contact tip run cooler. In spray transfer a longer stickout is affordable.
In short-circuit transfer mode, the contact tip should be flush or extend only slightly past the
nozzle, allowing for the short electrode stickout required. Since a certain amount of spatter with
this type of transfer occurs, extending the contact tip can help to decrease the spatter buildup on
the nozzle. This in turn allows the gas to flow unrestricted.
The size of the nozzle opening depends on the size of the weld puddle, the volume of shielding gas
required, and the difficulty in reaching the area that needs welding. For example, for welding deep
V-groove butt joints, a small, tapered nozzle may be necessary to get the contact tip close enough
to the weld puddle. In contrast, high-voltage, high-amperage applications usually require high gas
flow rates, so a nozzle with a large inside diameter gives better shielding gas coverage of the larger
weld pool.
A good rule of thumb is to use the largest nozzle that fits the application. For an application that
has restricted clearance or limited visibility, a small nozzle might be the best choice. But generally,
bigger tends to be better because the larger the nozzle, the more gas coverage it provides. Some
nozzles have built-in orifices that help direct gas, smoothing the gas flow and covering the weld
better.
Nozzles typically are made from brass or copper. Copper nozzles are well-suited for use in heavy
industrial applications because of their ability to withstand intense heat. Brass nozzles resist spatter
better than copper, but tend to melt or burn when exposed to extreme heat. Chrome Zirconium
nozzles are also available.
Nozzles are typically available in brass or copper, although chrome-plated nozzles are also available.
Brass nozzles tend to resist spatter well and are good for lower-amperage applications (100 to 300
amps), whereas copper nozzles are better for high-amperage applications (above 300 amps) or for
those with longer arc-on time.
For high-amperage water-cooled applications, there are also nozzles available that circulate coolant
around the nozzles, but these tend to be much more expensive.

Nozzles are typically available in heavy-duty or standard styles, and in slip-on or thread-on varieties.
Heavy-duty nozzles have thicker walls, as well as thicker insulators, and are designed for use in
applications ranging from 400 to 600 amps. Due to their heavier construction, these nozzles resist
heat better than standard varieties. Standard nozzles tend to have a thinner wall and are better for
100- to 300-amp applications. Slip-on nozzles, as their name implies, simply slip on to the front end
of the MIG gun. These nozzles are quite prevalent in the industry, compared to thread-on nozzles
that need to be twisted to install, and they offer the advantage of being able to change over more
quickly. A note of caution: when installing slip-on nozzles, be certain that they are fully seated on
the retaining head to prevent shielding gas leaks that could lead to poor weld quality.
 Welding Application Nozzles Considerations
The higher the welding current, the larger the bore size of the
Welding Current nozzles should be. Consider standard duty nozzles for low
welding current applications to save money
Use a heavy-duty, copper nozzle for the high heat applications.
For extreme heat applications, consider water cooled
nozzles/guns. Brass nozzles have good spatter resistance and can
High Heat
take more manual abuse than copper nozzles at medium and low
heat applications. Brass loses most merits when the temperature is
above 450 degrees Celsius (840 F).
The general rule of thumb is to use as long nozzle as possible to
save gas and get sufficient gas coverage. However, if weld access
Limited Weld Access
is an issue, use a short nozzle. Taper or bottleneck nozzles shapes
can also help.
If heavy spatter is expected (i.e. galvanized base metal, or, oily
surface, or, short circuit weld, 100% CO2, etc.), use a short nozzle
Heavy Spatter Generation
with a larger bore size. Brass material is also a good choice
depending on head (see above).
Using Nozzle Cleaning Straight bore nozzles are recommended to achieve the most
Stations effective cleaning with a robotic nozzle cleaning station or reamer.
Liners

The electrode wire is fed to the welding gun through a cable liner, and typically you need spring
steel coiled liner for steel applications. Because these liners are steel, they are rigid, resist buckling,
and have a long life.
Aluminum applications typically require liners made from nylon, Teflon(r), or some type of plastic,
because these materials have lower friction than steel and they help keep contamination out of the
weld. When aluminum wire is pushed through a steel liner, the wire can pick up little bits of steel
that can contaminate the weld.
Liners need to be replaced because they wear out from continuous use or become kinked from
improper use. Decreasing the friction between the liner and the wire and preventing improper use
both help to minimize liner replacement and maximize welder uptime. Kinks in the liner cause the
wire to catch and can result in erratic arc performance, which can lead to more operator downtime
caused by more spatter cleanup.
To maximize liner life and reduce postweld cleanup, you can blow out the liner with compressed
air. The liner can be blown out from the contact tip end or from the feeder end to remove dirt or
copper flaking.
Liners usually need to be changed when you switch electrode size. Although some liners may be
used for more than one wire size, if they are either too big or too small, they can cause poor
feeding. One of the biggest causes of poor feeding is an improperly trimmed liner, such as one that
is (trimmed too short or trimmed so a burr on the liner impedes electrode feeding). Patented jump
liner technology allows a toolless change of the most common liner wear point, which is at the
radius of a GMAW gun's body tube, instead of the entire liner.
The liner size needs to match wire size, usually within a specific range. For example, a 0.035-in.
wire typically is used in a liner capable of running 0.035-in. to 0.045-in. wire.

Cost Considerations
The optimal consumable is one that provides the best quality and the longest life. The better the
consumable quality is, the less postweld work is needed, and the less downtime is incurred. Also,
the longer the consumable lasts, the less time you spend replacing it. Time is money, and whether
you are choosing a large power source or a small consumable, choosing the right equipment is
essential to maximizing productivity.
Shielding gas blends for carbon steel GMAW
Select the right argon/Co2 blend for your weld requirements
PRACTICAL WELDING TODAY SEPTEMBER / OCTOBER 2015
SEPTEMBER 28, 2015
BY: SAMANTHA NOLAND
Argon and CO2 are the most commonly used gases in gas metal arc welding (GMAW). Alone, each has
pronounced advantages. Together they combine to neutralize each other’s weaknesses and capitalize on each other’s
strengths, all while providing you with your desired weld requirements.

One of the most frequently asked questions pertaining to shielding gases is which gas blend should
be used. Unfortunately, there is no definitive answer because different metals, thicknesses, weld
requirements, and processes can use a number of possible gas blends.
Shielding gas is important to the welding process for a couple of reasons. First, it prevents
atmospheric air from entering into the weld pool and causing porosity, cracking, and nitriding that
could destroy the strength of the weld joint. Second, shielding gas acts as a medium to help the
flow of electrons in the arc, allowing the electrons to continue to flow and giving the weld different
properties based on which gas is selected.
Two of the most commonly used gases for gas metal arc welding (GMAW) carbon steel are carbon
dioxide (CO2) and argon (Ar). Let’s look at the various qualities each individual gas brings to the
weld and how they work together when combined.
CO2
Using CO2 as the sole shielding gas yields a weld bead that is wide and fairly deep. It is most
commonly used in gas-shielded flux-cored arc welding (FCAW) and must be run at a relatively high
voltage compared with other gases because of its atomic structure and the release of electrons,
which can lead to problems when welding thin materials. The best attribute of CO2 is that it is a
deep-penetrating gas, which is why it’s included in the mixes most of the time.

CO2 is a reactive gas, which means it produces oxygen and carbon monoxide during the welding
process, leading to oxidizing of the weld metal. Using a welding wire with high manganese or
silicon content will prevent this from happening, but both will be deposited in the weld pool and
will appear on the surface of the metal after welding. Remember to perform the necessary cleanup
before you paint or galvanize your component.
Generally speaking, using pure CO2 produces a lot of spatter because of its interaction with the
high voltage, the flow of electrons, and the material you are using. That, paired with the fact that it
tends to generate more fume, often leads people to seek other options.
Argon
Welding with pure argon yields a concentrated and focused arc, resulting in a narrow profile and
deep penetration. The bead profile generally has a higher peak in the center of the weld with better
wet-in at the toes compared with CO2.
Unlike CO2, argon is nonreactive, eliminating the potential for oxidation in the weld pool. This
means you can use a wire with low silicon and manganese content if the metal itself does not
require the additional cleaning elements. It also requires little energy (a lower voltage setting) to
continue the electron flow across the arc, which results in a cleaner arc start and more stable flow
of electrons across the gas than CO2.
Argon is the standard for gas tungsten arc welding (GTAW). In GMAW, however, argon is used in
conjunction with other gases.
Ar/CO2 Mixtures
Separately, argon and CO2 possess desirable and undesirable qualities. But together these gases can
complement each other’s strengths while equalizing each other’s weaknesses, so to speak.
For example, pure argon is not recommended for GMAW on ferrous materials because of the
penetration profile (that is, the shape of the fusion zone within the base metal). Pure argon
produces a narrow and fingerlike weld, so it is easy to miss joints and fail to penetrate as deep as
needed in the right direction. However, when CO2 is added to the mix, the characteristics of the
two gases combine to provide excellent weld quality.
Argon and CO22 cannot be mixed and properly delivered via cylinders in mixtures with much more
than 25 percent CO2. Co2 is pumped as a liquid and, because of the way it and the compressed
argon flows out of the cylinder, only partial cylinder use is possible and the quality of the mix
cannot be guaranteed. These mixes, therefore, are usually 75 to 95 percent argon and 5 to 25
percent CO2.
75 Percent Argon/25 Percent CO2.This is the most commonly used gas blend for short-circuit
GMAW. The CO2provides a wider-penetration bead than argon can on its own. On the flip side,
the argon lends stability to the CO2that helps reduce spatter and control the weld profile. It is a
short-arc process, so some spatter, even at optimal settings, is still present. This mixture also can be
used effectively on flux-core wires made to operate with a mixed gas.
85 Percent Argon/15 Percent CO2. If your application requires a faster and cleaner weld, using a
minimum of 85 percent argon with 15 percent CO2 combined with higher voltages allows for spray
transfer. The amount of argon must be at this 85 percent or more level for the spray action to
occur correctly.
Spray transfer propels small droplets of molten metal into the weld puddle as opposed to
contacting the metal and shorting (short-arc) or transferring a large, difficult-to-control droplet
(globular). Because of the more fluid puddle and higher deposition rates in spray transfer, this
process is not recommended for out-of-position welding. If a part requires out-of-position welding
with high deposition, pulse or globular transfer modes are recommended. Globular transfer modes
should be used only for out-of-position welding. For both pulse and globular transfer modes, gases
comprising 85 percent or more argon are recommended.
90 Percent Argon/10 Percent CO2. This is a very common mix for spray transfer often used in
robotics because it provides the fastest travel speed. It is also commonly used with metal-core wire.
Asking the Right Questions
Selecting the right argon/CO2 mix requires you to ask certain questions regarding the desired weld
specifications and production requirements. What bead profile is required? Where is the joint
located? What are our cleanup requirements?
Getting answers to these questions is critical to selecting the appropriate gas for your application.
This is where it is important to ask an expert and run some tests. You may find that less cleanup or
faster travel speeds result from a simple bump in argon content. With the current shortage of
welders, any productivity gains using the existing workforce are useful.