Professional Documents
Culture Documents
Criteria For Selecting A MIG Gun
Criteria For Selecting A MIG Gun
1-855-MIGWELD (644-9353)
Enter keyword
The versatility and speed of MIG welding also make it a good option for all-position welding on various metals, including mild and stainless steels, in a
range of thicknesses. In addition, it produces a cleaner weld that requires less cleanup than stick or flux-cored welding.
To maximize the benefits this process offers, however, it is imperative to select the right MIG gun for
the job. In fact, this equipment’s specifications can significantly impact productivity, downtime, weld
quality and operating costs — as well as welding operators’ comfort. Here is a look at different types of
MIG guns and some key factors to consider when making the selection.
What’s the right amperage?
It is important to select a MIG gun that offers adequate amperage and duty cycle for the job in order to
prevent overheating. Duty cycle refers to the number of minutes in a 10-minute period that a gun can
be operated at its
full capacity without overheating. For example, a 60 percent duty cycle means six minutes of arc-on
time in a
10-minute span. Because most welding operators don’t weld 100 percent of the time, it is often To maximize the benefits of MIG welding, it is imperative to select the
right MIG gun for the job. This equipment’s specifications can
possible to use a lower amperage gun for a welding procedure that calls for a higher-amperage one; significantly impact productivity, downtime, weld quality and operating
costs — as well as welding operators’ comfort.
lower-amperage guns tend to be smaller and easier to maneuver, so they are more comfortable for the
welding operator.
When evaluating a gun’s amperage, it is important to consider the shielding gas that will be used. Most guns in the industry are tested and rated for duty
cycle according to their performance with 100 percent CO2; this shielding gas tends to keep the gun cooler during operation. Conversely, a mixed-gas
combination, such as 75 percent argon and 25 percent CO2, makes the arc hotter and therefore causes the gun to run hotter, which ultimately reduces
duty cycle. For example, if a gun is rated at 100 percent duty cycle (based on the industry-standard testing with 100 percent CO2), its rating with mixed
gases will be lower. It is important to pay attention to the duty cycle and shielding gas combination — if a gun is rated at only 60 percent duty cycle with
CO2, the use of mixed gases will cause the gun to operate hotter and become less durable.
Applications that involve welding sheet metal for only a few minutes every hour have little need for the benefits of a
water-cooled system. On the other hand, shops with stationary equipment that repeatedly weld at 600 amps will likely
need a water-cooled MIG gun to handle the heat the applications generate.
A water-cooled MIG welding system pumps cooling solution from a radiator unit, usually integrated inside or near the
power source, through hoses inside the cable bundle, and into the gun handle and neck. The coolant then returns to the
radiator, where a baffling system releases the heat absorbed by the coolant. The ambient air and shielding gas further
disperse the heat from the welding arc.
Conversely, an air-cooled system relies solely on the ambient air and shielding gas to dissipate the heat that builds up
along the length of the welding circuit. These systems, which range from 150 to 600 amps, use much thicker copper
cabling than water-cooled systems. By comparison, water-cooled guns range from 300 to 600 amps.
Choosing a MIG gun that offers the best comfort Each system has its advantages and disadvantages. Water-cooled guns are more expensive upfront, and can require
and operates at the coolest temperature allowed
by the application can help improve arc-on time more maintenance and operational costs. However, water-cooled guns can be much lighter and more flexible than air-
and productivity — and, ultimately, increase the cooled
guns, so they can provide productivity advantages by reducing operator fatigue. But because water-cooled guns
profitability of the welding operation.
require more equipment, they can also be impractical for applications that require portability.
These guns operate by capturing the fumes generated by the welding process right at the
source, over and around the weld pool. Various manufacturers have proprietary means of
constructing guns to conduct this action but, at a basic level, they all operate similarly: by mass
flow or the movement of material. This movement occurs by way of a vacuum chamber that
suctions the fumes through the handle of the gun and into the gun’s hose through to a port on
the filtration system (sometimes informally referred to as a vacuum box).
Fume extraction guns are well-suited for applications that use solid, flux-cored or metal cored One distinct advantage to fume extraction guns is that they remove the fumes at
welding wire as well as those conducted in confined spaces. These include, but are not limited the source, minimizing the amount that enters the welding operator’s immediate
breathing zone.
to, applications in the shipbuilding and heavy equipment manufacturing industries, as well as
general manufacturing and fabrication. They are also ideal for welding on mild and carbon steel applications, and on stainless steel applications, as this
material generates greater levels of hexavalent chromium. In addition, the guns work well on high amperage and high deposition rate applications.
However, sometimes a longer cable is necessary if the part being welded is very large or if welding operators must move around corners or over fixtures to
finish the task at hand. In these cases, where operators are moving back and forth between long and short distances, a steel mono coil cable might be the
better choice. This type of cable doesn’t kink as easily as standard industrial cables and can provide smoother wire feeding.
A MIG gun’s handle and neck design can impact how long an operator can weld without experiencing fatigue. Handle options include straight or curved,
both of which come in vented styles; the choice often boils down to welding operator preference.
A straight handle is the best choice for operators who prefer a trigger on top, since curved handles for the most part do not offer this option. With a straight
handle, the operator can rotate the neck to place the trigger on top or on bottom.
Conclusion
In the end, minimizing fatigue, reducing repetitive motion and decreasing overall physical stress are key factors that contribute to a safer, more comfortable
and more productive environment. Choosing a MIG gun that offers the best comfort and operates at the coolest temperature allowed by the application can
help improve arc-on time and productivity — and, ultimately, increase the profitability of the welding operation.
Technical Resources
Spec Sheets, Replacement Parts and Operations Manuals
Tech Connection Product News
How-To Guides and Videos
Article Library
Technical Resources
Get Connected
Enter your email
Sign up here to receive the following electronic communications from Bernard and Tregaskiss: Amperage eNews (quarterly), special company
announcements, event invitations, contests/sweepstakes, and information about our products and services!
You can unsubscribe at any time. Please refer to our Privacy Policy or Contact Us for more details.
Bernard semi-automatic welding products, consumables and accessories combine quality and rugged durability to provide you with all the welding supplies your project requires.
Whether it's a welding consumable, nozzle, MIG welding tip, welding tip, welding torch, welding cable, welding company, Centerfire, butt connector, wire feeder, splicer, self-shielded
flux-cored gun, FCAW gun, GMAW gun, stick welding gun, manual gun, fume extraction gun, smoke gun, MIG gun, MIG welding gun, terminal lugs, MIG gun, Bernard welding gun,
welding gun, MIG torch, or a Bernard MIG Gun, Bernard has it for you.