Based On A Tip - Welding Productivity

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WELDING PRODUCTIVITY
Based on a tip MAGAZINE
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CONTACT TIP RECESS IS OFTEN OVERLOOKED AS A VARIABLE THAT CAN
AFFECT THE QUALITY OF A WELD VIEW ARTICLE IN READER
By: Susan Woods, managing editor Tweet (HTTP://MAGAZINE.WELDINGPRODUCTIVITY.CO
While often overlooked, the consumables used in the MIG welding process play a key role in overall weld quality.
Zeroing in even further, the contact tip recess, or the position of the contact tip within the nozzle, is key to producing a
quality weld. The proper recess can affect productivity and help minimize the need for secondary operations. ARTICLES BY TYPE
Knowing when to use a recess, flush or protruding contact tip can help the welding process. A welder having trouble Welding
with excessive spatter, burnthrough, porosity or insufficient penetration should check the contact tip position. It could (https://weldingproductivity.com/type/welding/)
be an easy fix. (43)
Robotics
(https://weldingproductivity.com/type/robotics/)
In recess (29)
Contact tip recess is more or less Fume Extraction
what controls wire stickout, the (https://weldingproductivity.com/type/fume-
length the wire extends from the extraction/) (24)
end of the contact tip. The greater Systems & Equipment
the recess, the longer the wire (https://weldingproductivity.com/type/systems-
sticks out. equipment/) (21)
Cutting & Prep
The most widely used type of tip, (https://weldingproductivity.com/type/cutting-
recessed contact tips are prep/) (21)
generally for higher heat Sawing
applications. They are also used (https://weldingproductivity.com/type/sawing/)
in applications where the nozzle (18)
may touch the workpiece, such as Consumables
tack welding. (https://weldingproductivity.com/type/consumables/
(17)
Recessed contact tips are used Plasma
for spray transfer, pulse and other (https://weldingproductivity.com/type/plasma-
higher current applications cutting-prep/) (15)
(greater than 200 amps). The tip Training
is typically recessed from 1/8 in. (https://weldingproductivity.com/type/training/)
to 1/4 in., which makes for a wire (14)
stickout from 1/2 in. to 3/4 in. Laser
(https://weldingproductivity.com/type/laser-
A longer stickout gives the wire welding/) (13)
time to heat up before it is Safety
consumed by the arc. It helps (https://weldingproductivity.com/type/safety/)
smooth out the arc and stabilize (13)
the spray transfer. It also helps Abrasives and Deburring
reduce the occurrence of (https://weldingproductivity.com/type/abrasives-
burnback (where the wire melts and-deburring/) (13)
and fuses to the contact tip), which helps extend tip life. Filler Metals
(https://weldingproductivity.com/type/filler-
A recessed contact tip and longer wire stickout help to keep the tip away from the high heat of the arc. Heat buildup metals/) (11)
leads to an increase in electrical resistance in the consumables (the nozzle, diffuser and tip), which reduces the Automotive
contact tip’s ability to pass the current to the wire. This poor conductivity can cause insufficient penetration, excessive (https://weldingproductivity.com/type/automotive/)
spatter and other problems. (10)
Arc
Contact tip recess affects shielding gas coverage, as well. A recessed contact tip provides consistent gas flow. (https://weldingproductivity.com/type/arc-
welding/) (10)
“When the contact tip positions the nozzle farther away from the arc and weld pool, such as with protruded contact PPE
tips that stick out of the nozzle, the welding area is more susceptible to airflow that can disturb or displace shielding (https://weldingproductivity.com/type/ppe/)
gas without it getting to the weld,” says Travis Hall, Lightning MIG product manager, American Torch Tip Co. (7)
“Insufficient shielding gas coverage leads to porosity, spatter and insufficient penetration.” Wire
(https://weldingproductivity.com/type/wire/)
(7)
Flush and extend
Flush contact tips have a shorter wire stickout, roughly 1⁄4 to 1/2 in., bringing the tip closer to the workpiece. These Oxyacetylene
tips are used with short-circuit transfer and low-current pulse welding. The shorter stickout along with the lower (https://weldingproductivity.com/type/oxyacetylene/
voltages mean the wire does not heat up before it is consumed. This allows short-circuit transfer to weld thin (6)
materials without risking burnthrough and excessive spatter. TIG
(https://weldingproductivity.com/type/tig/)
Protruding, or extended, contact tips typically have a 1/8-in. extension; wire stickout is 1/4 in. These tips are generally (6)
used when the welder needs to get into a tight weld joint, such as inside corners or deep and narrow V-groove joints. GMAW
The downside is these tips increase the chance of arcing the tip to the workpiece, which could damage the (https://weldingproductivity.com/type/gmaw/)
consumables. (5)
Aluminum
Overall, the general rule is the best wire stickout length is typically the shortest one allowable for the application. (https://weldingproductivity.com/type/aluminum/)
(4)
“Everyone should use the shortest wire stickout they can in the application,” Hall says. “We always say some of it Trade Shows
comes down to preference, but more so, you should use what is best for the application. Typically, the shortest one is (https://weldingproductivity.com/type/trade-
the best one.” shows/) (4)
Aerospace
It should be noted that the welder’s preference also plays a role. Welding problems can occur if the contact tip to (https://weldingproductivity.com/type/aerospace/)
workpiece distance is too short or too long. It’s important to hold a consistent distance for good arc stability. (3)
Military
“Some of it depends on the welder’s technique,” Hall says. “Wire stickout is affected by the nozzle depth, but it’s also (https://weldingproductivity.com/type/military/)
affected by the welder’s hand and how far way he keeps the nozzle. Whether recessed or protruded, if someone is (3)
pulling back further than they should, the welder is making more wire stick out. Keeping the nozzle 1/4 in. to 1/2 in. Gases
away is recommended.” (https://weldingproductivity.com/type/gases/)
(3)
Making Steel
(https://weldingproductivity.com/type/steel/)
adjustments (3)
Tube and Pipe
Two style of consumable are
(https://weldingproductivity.com/type/tube-
available – fixed and
and-pipe/) (3)
adjustable. Fixed nozzles,
Friction Stir Welding
whether they are threaded
(https://weldingproductivity.com/type/friction-
or slip on, are meant for a
stir-welding/) (3)
specific recess. With
Shop Floor Productivity
adjustable nozzles, the
(https://weldingproductivity.com/type/shop-
welder can adjust the recess
floor-productivity/) (2)
or stickout to what is
Electric Resistance Welding
needed.
(https://weldingproductivity.com/type/electric-
resistance-welding/) (2)
Threaded nozzles offer a
Heavy Equipment
more secure connection, but
(https://weldingproductivity.com/type/heavy-
are typically a little harder to
equipment/) (2)
remove. Slip-on nozzles are
Resistance Welding
typically quicker to change
(https://weldingproductivity.com/type/resistance-
and clean.
welding/) (2)
Power Tools
“We offer both styles, but in most cases, we recommend a non-adjustable recess,” Hall says. “With the adjustables,
(https://weldingproductivity.com/type/power-
there’s a lot of room for error. Issues can come up because of inconsistencies through the shop when the welder
tools/) (1)
adjusts the recess to his preference or needs by maneuvering the nozzle or tip to where he wants it (wrong or right)
Post Processing
instead of using the best setup for the application.
(https://weldingproductivity.com/type/post-
processing/) (1)
“The threaded and fixed slip-on nozzles fit properly and match the recess,” he adds.
Underwater Welding
(https://weldingproductivity.com/type/underwater-
When it comes to the contact tip recess, the size and shape of the tip matter. For example, a large contact tip and a
welding/) (1)
nozzle with a small opening where the tip is almost touching the nozzle can cause problems.
Agriculture
(https://weldingproductivity.com/type/agriculture/)
“Get a bit of spatter in there and all the sudden you’re touching tip to nozzle and arcing out,” Hall says. “The situation
(1)
calls for a tapered contact tip.”
Quality Control
(https://weldingproductivity.com/type/quality-
It can affect the gas flow, as well. With a protruding tip, for example, a smaller nozzle opening is better. A large
control/) (1)
opening provides too much area for the gas to go. It needs to be more focused.
General Fabrication
(https://weldingproductivity.com/type/general-
Many other factors can affect the nozzle, diffuser and contact tip trifecta. One factor is the materials the components
fabrication/) (1)
are made from. The materials alone can affect resistance to spatter and prevent heat buildup. Again, taking a look at
these overlooked consumables might result in an easy fix for MIG welding quality issues.
ISSUES
American Torch Tip Co. (http://americantorchtip.com/)
June 2019
(https://weldingproductivity.com/issue/june-
2019/) (7)
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