Posts Tagged ‘MIG Gun’

“All it takes is one time” welding with the Tweco Fusion MIG gun and you can see the difference!

Gene’s Paint & Body Shop of Denton, Texas, performs collision repair work, and it also specializes in emergency vehicle repair. Welder Brent Culley has more than 25 of experience, including oilfield work. We asked Brent to put the Tweco Fusion MIG with Tweco Velocity consumables to the test, and he reports they delivered better performance and longer consumables life.


By Ross Fleischmann, Senior Brand Manager, Victor Technologies

tools-yeildWhen the GMA welding arc becomes erratic, should the operator adjust the power source? Not necessarily. If the voltage and wire feed speed values currently used previously worked well, and if the correct shielding gas and flow rates have been selected, worn components are likely at the root of the problem.

Liners, tips and other gun components need routine inspection to ensure consistent GMAW performance. Good maintenance also prevents rework, eliminates unplanned downtime and maximizes gun life. The following maintenance practices apply to most brands of guns. Before working on a gun, review the operator’s manual and follow appropriate safety precautions to prevent burns or electric shock.

Cleaning Liners
Erratic GMA performance occurs when excessive friction causes the electrode stick or slip. When wire feed speed slows, yet voltage remains constant, the electrode will melt back from the weld puddle more quickly and produce an erratic arc. One of the most common culprits is a gun liner that has become clogged with wire shavings and other particulates.

Operators everywhere should get in the habit of blowing out the liner with compressed air when installing a new spool of wire. For GMAW systems with a high arc-on time, operators might consider blowing out the liner more frequently (experience will dictate the need).

How rapidly a liner clogs varies greatly. Over-tensioning the drive rolls on flux cored electrodes can clog a liner quickly. Electrodes exposed to the elements, especially humidity and salt air, can quickly clog a liner, as can a poor quality electrode. Different electrode manufacturers use different drawing compounds and substances to coat and finish the electrode. As a result, some clog liners faster than others — sometimes in half a spool or less. To keep liners cleaner longer, consider installing cleaning pads during the next scheduled maintenance. Use good cleaning pads and secure them properly, otherwise bits of the pad may end up clogging the liner.

For a clearer indication of particulate volume inside the gun liner, place a sheet of paper or cardboard under the gun to provide better contrast. If the arc is erratic and blowing out the liner reveals only small amounts of particulate, the liner is worn and should be replaced. For example, in the Tweco test lab, using a leading brand of 1/16-in. diameter ER70 S-6 electrode, applying these guidelines, we most frequently replace the liner after two 60-lb. spools.

Replacing Liners
blowing_out_linerTo replace a liner, remove the old liner, lay the new liner next to it on the floor and cut the new liner to the exact same length. A liner that is too short can interfere with feeding performance and lead to an erratic arc. Further, if a void exists between the liner and the diffuser, it could create a spot that traps the wire and leads to a bird nest.

When trimming the new liner, use sharp, premium quality side cutters. To produce a clean cut, place the cup side of cutters against the liner and orient the cutters so that they cut against the curl of the liner. Cutting with the curl tends to produce a burr on the inside edge of the liner, where it could drag against the wire. Never use dull cutters or whelpers to trim a liner. Rather than cleanly cut through the tough piano wire used for liners, they will most likely deform the liner and/or spread out the coils.

Never use a cutting disc (e.g., RotoZip® or similar tool), as it can leave a sharp edge that drags against the electrode and creates shavings. Should the cut liner have a burr, use a hand file to remove it. Otherwise, discard it and try again.

trim_linerAs with any mechanical system, don’t use excessive force when installing a new liner. If the liner hangs up, twist it in a counter clockwise direction so as not to uncoil the liner. If the liner doesn’t fit, the liner could be too long (in which case, trim it) or it could be bent. If the liner is bent, discard it, as a bent liner can promote erratic feeding.

Some gun models use small screws to keep the liner from twisting. Do not remove or discard those screws. First, if the liner twists independently from the gun cable, it can increase or decrease the length of liner relative to the length of the gun cable. Second, an absent screw may permit shielding gas to escape through the hole instead of coming out the diffuser, which may lead to insufficient gas coverage or excessive gas flow to compensate for lost gas.
consumables_drawerSpatter and Tips, Nozzles And Diffusers
The GMA process, especially short circuit transfer, inherently produces spatter.

A percentage of operators inherently feel compelled to knock spatter off by banging the gun on the welding table or work piece. Banging the gun doesn’t do much to remove spatter, but it’s a great way to loosen component connections at the front of the gun. Don’t bang the gun!

With the economy still providing mixed signals, Victor Technologies is approaching business with optimism. Our branding
effort is in full swing, and we are enthusiastic about our newest product offerings both in the U.S. and around the globe.
Beginning with the company name change in May of 2012, and following in October with the alignment of our cutting
brands under the Victor name, we have focused on optimizing the performance of our brand portfolio. This is reflected in the
introduction of new packaging and displays for Victor, along with new “Victor green” trade dress and packaging for Victor Thermal
Dynamics manual and automated product lines.
To our valued distributors, business partners and end users, we share the message that coupled with our brand changes, our
resolve in the pursuit of strong product solutions, innovation and technology remains unchanged.
For example, Victor has introduced its new line of 400 Series oxy-fuel torches that offer better ergonomics and end-user driven
features such as a new contoured handle, three-tube cutting attachment design and color-coded valves for clarity and enhanced
safety. The 400 Series boasts a contoured, high-strength alloy torch handle that, while lighter than a brass handle, balances better
in operators’ hands and better resists wear and abuse.
In Victor Thermal Dynamics Automation, the rollout of the AutoCut XT and UltraCut XT lines represent the next generation in
precision plasma cutting. Ultra-Cut XT systems provide the flexibility to increase cutting power and the assurance of superior
quality, higher productivity and lower cutting costs. And because of its expansion capabilities, there is never a concern about
choosing the right system.
In specialty welding, Tweco also boasts a new logo and refreshed packaging. In addition to the new Tweco Velocity MIG
consumables and light-duty Tweco Fusion MIG guns, Tweco has also announced its scheduled launch of the Tweco Classic Series
MIG guns, an enhancement to the original “numbered series” that is arguably one of the most popular gun designs in the world.
Tweco Classic enhancements will include interlocking joints for superior toughness, an angled trigger for a more comfortable pull
and refined, modernized lines.
In addition to these exciting announcements, we invite you to help us celebrate this year’s 100th anniversary of the Victor brand.
Please read about our 100th Anniversary contests in this issue of NewsUpdate, and we invite you to share in a special celebration
with us later this year at the 2013 Fabtech. Stay tuned for additional details, and again, thank you for your valued role in delivering
Victor Technologies cutting, gas control and specialty welding products that set the standard for versatility and performance.






Joseph F. Mueller
Sr. Vice President, GM Sales, Americas

Catch up with the latest in cutting, gas control and specialty welding with the latest edition of the Victor Technologies’ News Update.

In this issue, find out about the newest products including the Victor 400 Series of cutting torches and handles, the Victor G Series regulators, Tweco Fusion MIG guns and more.

We’ve also got some great articles on welding education, safety and best practices.  Check it out!



Tweco_Classic_MIG_Gun_4The MIG Gun That Built America™ – Tweco is excited to announce the introduction of the Tweco Classic No. 4 MIG gun, which replaces the legendary Tweco No. 4.

We took the legendary No. 4 and just made it better!

The Tweco Classic No. 4 is an air-cooled MIG gun with a rating of 400 amps at 60% duty cycle.  Enhancements include higher impact resistant materials, interlocking handle design for superior toughness, an angled trigger for a more comfortable pull and refined, modernized lines.
New Series
The Tweco Classic No. 4 is the first in a new series of enhanced air-cooled MIG guns that will roll out in 2013. The Tweco Classic Series will carry on the tradition of the Tweco No. Series platform, which has stood the test of time since its introduction at the AWS Welding Show in 1969.
Millions of welders will be familiar with the way the paddle shaped handle of a Tweco Classic gun fits in their hand and enables them to manipulate the arc. With these enhancements, they’ll be able to enjoy its heavy-duty, industrial-grade performance for years to come.


With Mike Balboni putting his 3-in-1 welders to the test on a daily basis, Victor Technologies asked him to test

the new Tweco Fusion series of light-duty MIG guns. He immediately recognized some of the gun’s unique features

Fusion Gun


“Simplicity of design. That’s what’s going to set these guys

apart from everybody else,” he says (view video).


Northeast Welding 3These guns now come standard on all 3-in-1 welders, and they feature Tweco’s new Velocity MIG consumables platform.

The non-threaded, “drop-in” style contact tip eliminates the need to use vice-grips, welpers or other tools to remove the tip,

even if the wire burns back and fuses inside the tip. The Velocity™ consumables design integrates the gas diffuser into the

conductor tube. This creates an improved all-copper conductor

path that provides better electrical conductivity and transfers heat

more efficiently away from the tip. As a result, the arc becomes

more stable and predictable.

The design also eliminates the insulator found on other MIG guns. Balboni says that insulators often become loose and worn, causing the nozzle to fall off in the middle of a job. The Tweco Fusion gun has eliminated that weak point, “so these guns will never hang on the wall. They will always be in operation.”


#   #   #

  • Velocity consumables include “drop-in” non-threaded contact tips that are simple and easy to change.
  • Superior electrical and thermal conductivity increases arc stability with reduced spatter and provides a wide window of operation.
  • Velocity consumables will be featured on new Tweco Fusion light-duty MIG guns and incorporated in all Thermal ArcFabricator  3-in-1 Series welders.

Tweco,  a Victor Technologies brand, introduces its new Velocity MIG consumables platform, which is integrated into the new Tweco Fusion series of light-duty MIG guns.

Speed Made Easy: New Tweco Velocity MIG Consumables Offer Quick Change Tip, Less Complexity, Improved Arc Stability and Reduced SpatterThe non-threaded, “drop-in” style Velocity contact tip eliminates the need to use vice-grips, welpers or other tools to remove the tip, even if the wire burns back and fuses inside the tip. The Velocity consumables design integrates the gas diffuser into the conductor tube. This creates an improved all-copper conductor path that provides better electrical conductivity and transfers heat more efficiently away from the tip. As a result, the arc becomes more stable and predictable.

Velocity consumables provide smoother arc characteristics, reduce weld spatter and make it easier for the operator to control the arc,” says David Wilton, Vice President – Welding Products. “This design eliminates all of the hassle associated with burn backs, as operators can change contact tips in seconds instead of fighting to remove a threaded tip.”

“Our field trials presented great results, across a broad cross-section of welders, from DIY’ers to code welders”, adds Ross Fleischman, Senior Brand Manager.

In addition, Velocity consumables reduce the number of replacement parts needed.  In a traditional MIG gun, the front end consists of a conductor tube, brass gas diffuser, threaded contact tip and slip on nozzle. Velocity consumables integrate the gas diffuser/contact tip seating area into the end of the conductor tube. A threaded nozzle secures the contact tip against the seating area, and it also directs and smooths shielding gas flow for excellent gas coverage of the weld puddle.

Fusion MIG GunsFusion Gun

At the end of 2012, Tweco will offer the Velocity consumables on its new Tweco Fusion Series of light-duty MIG guns, which include the following models: Tweco Fusion 140 (140A @ 20% duty cycle), Tweco Fusion 180 (180A @ 40% duty cycle), TTweco Fusion 220 (220A @ 40% duty cycle) and the Tweco Fusion 250 (250A @ 60% duty cycle). The Tweco Fusion Series will be available as an aftermarket gun starting in December 2012 and will be bundled with Thermal Arc’s Fabricator 3-in-1 Series of MIG-Stick-TIG welders starting in the first quarter of 2013.

Tweco Fusion is offered at a price point compatible with light-duty MIG welding systems, yet maintains the Tweco heritage of designing rugged, reliable products.

“We feel like operators will immediately notice the solid, more durable feel of a Tweco Fusion MIG gun.” notes Wilton.