Spatter in Welding: Should You Consider Anti-Spatter Liquid?
Are you losing money and arc-on time for excessive contact tip changeovers? Anti-spatter liquid may be an option to help.
What is anti-spatter liquid?
This compound protects the front-end consumables on your robotic MIG gun from spatter accumulation, reducing downtime for tip replacements and helping to prevent shielding gas flow restrictions that could lead to porosity. This liquid also:
• Prolongs the life of the nozzle, contact tips and gas diffuser
• Lowers cost for consumable inventory and management
• Reduces operating costs by improving weld quality and lowering rework
Although it resembles water in its consistency, anti-spatter liquid (when applied correctly and in the appropriate volume) will not drip like water. Rather, it creates a barrier between the nozzle and any spatter generated during the welding process. The spatter easily falls off when the nozzle cleaning station or reamer performs the reaming cycle, leaving the nozzle and other front-end consumables clean. Note, you must reapply the compound frequently to help maintain that barrier.
Does my operation need to use anti-spatter liquid?
Constant-voltage (CV) applications and those utilizing solid wire and/or the welding of galvanized steel tend to produce high levels of spatter and often benefit the most from the use of anti-spatter liquid. Anti-spatter liquid also benefits high-volume, high-production operations where the goal is to minimize potential weld quality issues, extend consumable life and reduce downtime. Its application can easily be programmed so that it is sprayed onto the consumables after each ream cycle, during routine pauses in production for part changeover.
Learn about TOUGH GARD® anti-spatter liquid.
This article is the first in a three-part series focused on the use and benefits of anti-spatter liquid. Read article two, How to Select and Use Anti-Spatter Liquid, and article three, Anti-Spatter Sprayer: How to See the Best Results.
Optimizing the robotic weld cell helps improve productivity, allowing a manufacturing facility to save time and money. It can be especially beneficial in applications that use pulsed gas metal arc welding (GMAW-P), a process that results in rapid wear to the welding gun’s front-end consumables. While the choice of contact tip for the GMAW gun may seem like a small factor in the entire operation, consider how much time it takes for an operator to enter the weld cell and change the contact tip — and how many times per day the tip is changed in most robotic welding operations. For example, copper contact tips are changed on average four times per shift. In a three-shift operation averaging 10 minutes per tip change, that equates to spending two hours per day changing contact tips. What else could a welding operator be doing with this time to create value in the manufacturing operation? There are contact tip innovations that help significantly reduce the downtime spent on changeover — time that can be spent on other tasks in the operation, such as increasing production up-time. In addition, when the operator spends less time in the weld cell, it reduces the potential of health and safety incidents and the possibility of weld quality issues through altering weld settings and parameters such as tool center point. For these reasons, it’s important to consider the total cost of ownership when selecting the right contact tip for a robotic welding operation. As more manufacturing applications use thinner, lighter and more corrosion-resistant materials to meet industry demands, this increases the use of GMAW-P processes, which offer benefits for welding thin-gauge materials. Pulsed waveform technology continues to develop, offering faster travel speeds, reduced spatter levels and high weld quality in many robotic applications. However, pulsed processes typically require a higher frequency of contact tip changeover due to the energy of the process. Faster contact tip deterioration is caused by peaks in pulse waveforms where the energy/heat is five times greater than in traditional constant voltage (CV) GMAW. Because of this, arc erosion is a common failure for contact tips in GMAW-P. Contact tip failure increases an operation’s costs, due to the increased frequency of downtime related to tip changeover. A new contact tip design has resulted in tips with improved resistance to arc erosion that last much longer in pulsed welding. Contact tips made from copper or copper chrome zirconium are commonly used in many welding applications. However, adoption of a GMAW-P process can double contact tip replacement frequency and related downtime when using copper or chrome zirconium tips. A new innovative technology on the market today can significantly extend the time between contact tip changeover, thanks to a combination of proprietary materials and tip design. HDP contact tips from Tregaskiss last more than 10 times longer than copper or chrome zirconium tips, allowing operations to go from changing contact tips two to four times each shift to only changing the tips once every third shift or longer. HDP contact tips are engineered to resist wear better than other materials and designs previously used for contact tips, providing increased resistance to arc erosion in pulsed welding, as well as spray transfer and CV GMAW. The precise fit between the tip and the wire also results in good arc stability to help produce high-quality welds, and because the degradation of welding current from the power source to the contact tip is reduced, it provides a truer representation of the pulsed waveform program. The tips currently come in .035, .040 and .045 sizes and can be used with standard nozzles and TOUGH LOCK® retaining heads as well as with air-cooled guns or water-cooled guns. HDP contact tips can be used with Tregaskiss guns, as well as guns from other MIG welding gun manufacturers. Because the tip bore is sized so tightly to the welding wire, it’s best to use the HDP Contact Tip with good-quality welding wire that has a large cast. A high-quality wire typically has a consistent wire diameter, which promotes better feeding and optimized performance. Typically, operations conduct contact tip changeovers on a preventive maintenance schedule to avoid unplanned downtime in the manufacturing process. The necessary frequency of contact tip changeover varies based on many factors including application, wire type and quality, waveform and base material. Many robotic welding operations have 100 welding arcs or more and run three shifts per day. In robotic welding operations, copper tips are changed on average four times per shift — or 12 times per day. Chrome zirconium tips are changed about half as often, or six times per day. A scheduled contact tip change typically takes 10 to 15 minutes to complete. Compare this to real-world results from several manufacturing operations using HDP contact tips. For example, one manufacturing operation converted to HDP contact tips in a solid wire GMAW-P application. The operation produces 600 parts per shift, and the previous chrome zirconium contact tip required changeover every 60 to 80 parts — or about 10 times per shift. In the company’s trial, one HDP contact tip was still running after 2,500 parts under the same parameters. Another manufacturing operation running a standard GMAW process tried HDP contact tips on a line of 18 robots. Where previous contact tip usage for the operation was 216 per day — or about 1,500 tips per week — one HDP contact tip lasted an entire week on each cell, totaling 18 tips per week. In addition to the significant productivity gains the new contact tip design provides, there are other benefits for arc stability, productivity and operator safety. Reduced frequency in contact tip changeover not only increases throughput while saving time and money due to downtime, it also reduces the risk of safety incidents, since every time an operator enters the weld cell it increases the risk of injury. Also, each time someone touches the welding gun, there is the risk putting it out of alignment. The less frequently an operator must enter the cell, the less chance there is for human error that can disrupt tool center point that reduces part quality. Frequently changing the contact tip can cover up other issues within the weld cell. When the contact tip is changed less often, other issues such as wire feeding problems, wire routing or a loose ground can come to the forefront. With standard contact tips, changing the tip out is often the first go-to fix when there is a problem in the weld cell — even if something else is the root cause. With a longer-lasting contact tip that is not changed as frequently, other issues that may not have been noticed before can now be fixed to improve the overall efficiency of the weld cell. It’s important to consider total cost of ownership when evaluating contact tips and other consumables. The upfront cost of a contact tip is just one factor in total overall costs. A longer-lasting contact tip may be more expensive upfront, but it can provide significant payback in time and labor savings and reduced downtime. In considering a switch in consumables, an operation should also be sure there is time to conduct a trial, which should always be part of changing the type of consumable or contact tip. The numbers will often speak for themselves when vetting the option and analyzing return on investment. An operation may think the welding process is optimized, but that may not be the case if operators must frequently enter the weld cell to change the contact tip. As manufacturing operations look for ways to improve production efficiency and throughput in automated welding, choosing the right contact tip for the gun is one solution. A contact tip designed to provide significantly longer tip life saves time and money in necessary changeover and reduces the frequency of people entering the weld cell. New contact tips on the market can last days in GMAW-P applications compared to standard copper tips that may only last a few hours. *Other parameters: 450 ipm wire feed speed, 40-45 ipm travel speed, 90/10 mixed gas, 240-260 average amps on a Tregaskiss robotic MIG gun with a 22-degree neck.
Uptime is key in any robotic welding system. Not only does it help companies increase productivity, but it also supports a solid return on investment in the equipment. The addition of peripherals, like a nozzle cleaning station or reamer, can help further those goals. A reamer cleans the consumables on a robotic gas metal arc welding (GMAW) gun to prevent spatter buildup that could lead to porosity. This consumable cleaning reduces downtime for changeover, improves weld quality and minimizes costs. There are two main styles to choose from: standard- or Ethernet-based. Both provide the same function of cleaning the nozzle free of spatter, with the Ethernet-based reamer providing additional functionalities that some companies find beneficial to their robotic welding operation. During cleaning, the robot is programmed so that it will dock the nozzle of the GMAW gun against a v-block on top of the reamer, typically during routine pauses in welding cycles. Once the nozzle is in place, a signal is relayed to the reamer to close its clamps. When the clamps hold onto the nozzle, concentric to the cutter blade, another signal is sent to the unit telling the spindle to rise and spin the cutter blade, removing the spatter from the nozzle and gas diffuser. Many companies also employ an anti-spatter sprayer that applies a coating of anti-spatter compound to the front-end consumables after every cleaning cycle. Usually this spray only lasts a half second to avoid saturating the nozzle and wasting the anti-spatter compound. A standard reamer features inputs and outputs that are plugged into a Program Logic Controller (PLC), including the inputs that control the nozzle clamping, cutter actions and anti-spatter spray process. These are the traditional reamers used by many companies. A standard reamer must be plugged in with a power cord, in addition to having several leads connected to several inputs and outputs, so it may require cord management to minimize clutter. Ethernet reamers, a newer style, feature a single Ethernet cable that serves as a multipurpose input/output and connects to the PLC. Due to their connectivity, they enable robotic welding system operators to set a program that handles complex equations so they can easily duplicate that program to another weld cell. Consider a robotic welding operation featuring 100 weld cells that require 50 reamers total. If there are two robots per cell sharing the same reamer, and the reamer program for all 100 weld cells is virtually identical to the first cell, operators can set the program in the first cell to alternate between the two robots and then essentially “copy and paste” that program into the next 99 cells. For this reason, an Ethernet reamer can offer time savings, especially at the integrator level. With an Ethernet reamer, robotic welding operators can also program a double stroke. If one cleaning cycle wasn’t quite enough to remove spatter from the nozzle, a signal is sent, as the spindle unit and cutter retract, to clean again. Ethernet reamers can come with an additional Ethernet port, which can be used to daisy chain to other Ethernet devices. This means an operator does not require an individual Ethernet cord run from the reamer to the PLC, from the robot to the PLC, or from the power source to the PLC. He or she can instead run them in a series, together. This cuts down on the number of wires and cords in the cell, further reducing clutter. They also allow operators to monitor the cycle times carefully and more easily troubleshoot any issues that arise. That said, some older robotic welding operations are not Ethernet-ready because they use standard-based signals, and some facilities simply do not have the infrastructure, resources, capabilities or knowledge necessary to justify the higher investment of an Ethernet reamer. As with the implementation of any robotic welding system, having a champion with a certain skillset who can oversee the implementation of an Ethernet reamer and know how to program it is incredibly helpful, and it can ensure the success of the investment. Regardless of which style of reamer is used, standard- or Ethernet-based, it should always be programmed with the gun docking to the reamer and the height set properly, following the instructions outlined in the owner’s manual. Always dock the nozzle concentric to the cutter, and always supply the reamer with clean, dry air. Almost all reamers function the same way, but accessories can be added to make them behave differently or optimize them for a welding operation. Wire cutter attachments, for example, cut the wire stick out to a set distance so that the robot can employ wire-touch sensing. Most operations that use a wire cutter on the reamer also use a wire brake on the GMAW gun. The wire brake then holds the wire in place at that set distance so it can’t move — keeping it from extending or retracting as the robot moves. The wire brake works well in combination with robots employing touch sensing, as it keeps the wire in a set position while the robot searches and accurately locates the weld joint. Lubricators are yet another valuable reamer attachment. A lubricator applies oil to the air motor impeller, coating the blades so they will not absorb moisture that might be present in the air. Keeping these blades lubricated helps extend the life of the motor and protect a company’s investment in a reamer. Reamer stands are another accessory that can be useful. They are essentially a pedestal that an operator can mount the reamer to, with a stand bolted into the floor. Options exist in the marketplace that can be customized to a specific height to help streamline the weld cell layout and those that feature quick-change base plates to facilitate reamer change-outs when necessary. Spray containment units are also common reamer attachments designed to keep the welding cell clean of anti-spatter compound. A spray containment unit is a cylinder that mounts on top of the sprayer head to keep excess anti-spatter spray from bleeding into the open environment in the weld cell. Another useful reamer accessory is a nozzle detect, which is a proximity switch that detects whether a nozzle is present or not. Occasionally, when a robot enters its ream cycle, there may not be a nozzle present on the GMAW gun; it may have been bumped off during routine movement of the robot arm or from accidentally hitting a fixture. Nozzle detect will recognize the absence of the nozzle or if a nozzle is pulled off during a cleaning cycle. These occurrences are especially prevalent when an operation is using a slip-on nozzle, which is more likely to disconnect. For large robotic welding operations, a multi-feed anti-spatter sprayer system may also be useful. This attachment allows up to 10 reamers to be working off one larger container of anti-spatter compound, eliminating the need for an operator to go into the cell and fill up the smaller sprayer reservoirs attached to every reamer. This reduces how often anti-spatter levels must be checked and the associated downtime. Although all these accessories, and the reamer itself, do add to the cost of a robotic welding system, they can also lead to measurable cost savings and profits in the long run. Remember, the goal in robotic welding is repeatability and increased productivity, and any additional equipment that can help achieve these results may be worth the investment. In the end, reamers help clean GMAW gun consumables and prevent porosity. They also reduce downtime and labor for changeover. Since cleaner nozzles and other consumables produce cleaner welds, they can help a robotic welding system produce higher-quality products and be more productive. While reamers and their attachments are often afterthoughts for many operators, maintaining them properly and ensuring parts are replaced promptly can greatly improve a robotic welding operation’s overall efficiency, quality and productivity. All limit switches on a reamer have a life expectancy and must be replaced if they don’t activate any longer, for the reamer to work properly. Cutter blades also need to be replaced, since the edges will become dull over time and will no longer cut as effectively. In some cases, an operator might visually see that one of the flutes on the cutter is broken. Operators must also monitor the reservoirs in anti-spatter sprayers regularly, to ensure they have anti-spatter compound in them. Similarly, if an operation is running a lubricator over an extended period, operators will need to refill the oil reservoir on the lubricator.
August 10, 2018 Tregaskiss is pleased to announce that the TOUGH GUN® TA3 robotic air-cooled MIG gun offering has now been expanded to include configurations for the following robot models: Click here to learn more about the TOUGH GUN TA3 robotic air-cooled MIG gun, or configure your gun at Tregaskiss.com/ConfigureMyGun today.
MIG welding offers numerous benefits for productivity without sacrificing quality of the finished weld, but there are many factors that can interfere with successful MIG welding performance. You can improve performance and results in your MIG welding applications — and save money through reduced consumable waste — by taking steps to avoid common mistakes related to the MIG gun and consumables. Consider these common causes of poor performance in MIG welding and learn how to prevent them, for a positive impact on productivity and the bottom line. Cutting the liner the wrong length is a common issue in MIG welding. In many cases, it’s a matter of the liner being cut too short. When the liner is the wrong length, it can cause poor wire feeding, an erratic arc and/or wire chatter. For conventional liners, use a liner gauge as a guide when trimming and installing the liner. Another option is to employ a consumable system designed for error-proof installation that eliminates incorrect liner trimming and requires no measuring. The liner loads through the MIG gun neck and is then locked in place at the front and back of the gun while also being concentrically aligned to the contact tip and the power pin. Once locked, the welding operator simply trims the liner flush with the power pin. In addition to accurate trimming, by locking the liner at both ends of the gun, it isn’t able to extend or contract. The result is a smooth wire-feeding path. When a MIG gun’s consumables become overheated, they can be the source of many problems. To prevent consumables from overheating, use the proper wire stickout, mind the gun’s duty cycle and employ the right contact-tip-to-work distance. Any steps that keep consumables cooler will help limit the amount of vibration in the gun and reduce issues with burnback. While a wire stickout that is too long is not desirable, keep in mind that too short of a stickout can result in the nozzle and contact tip being too close to the weld pool causing them to overheat. This impacts productivity by causing burnbacks and wire sticks, and can significantly shorten consumable life. Also, look for consumables with a tapered design, as this helps lock conductive parts together, resulting in less electrical resistance, lower heat and a longer life. Some consumable systems feature a contact tip that is buried in the gas diffuser, which helps reduce overheating.This design also allows the shielding gas flowing through the gun to cool the tail of the contact tip for added protection against overheating. Shortened life of the contact tip and other front-end consumables can also result if a solid ground isn’t in place when MIG welding. Without a solid ground, the arc can become erratic and ultimately cause more heat buildup in the front of the gun. Any problem that creates more heat will also create more resistance and more wear — damaging the contact tip and other front-end consumables and possibly impacting weld quality. To prevent these problems, place the ground cable as close to the workpiece as possible. If allowable, hook the ground cable on the weldment. If that is not feasible, hook it to a bench. But remember: The closer it is to the arc, the better. An erratic arc can also be caused by setting the wrong voltage or the wrong wire feed speed. Setting the voltage too high can create too much heat in the handle of the gun, which in turn can eventually wreak havoc on the contact tip. When the wire feed speed is too fast, it can cause the wire to pile up instead of melting properly into the weld pool. This can also cause burnback or birdnesting. A wire feed speed that is too slow doesn’t feed the weld pool, so there is not proper penetration for a quality weld. Always follow the manufacturer’s recommendations for the proper voltage and wire feed speed for the filler metal and thickness of the base material being welded. Poor power cable management can lead to performance problems and cable damage. To help prevent damage or other issues, don’t pull the welding machine around using the cable. When the gun is hot, everything is more pliable. Yanking or pulling on the cable can stretch the cable or the liner and even cause the conduit to pull away from the gas pin, which can result in shielding gas issues. It’s also important to let the gun cool in a flat position, rather than draping or hanging the cable over a piece of plate or some other object. When a hot gun is draped or hung over something, it can bend the conduit. When the gun and consumables cool, they can be misshapen, leading to marginal shielding gas coverage. Take care to lay the gun out properly to let it cool. Also, be sure to store the gun and cable properly when they aren’t being used to avoid damage that can occur if a cable is run over by a forklift or other heavy equipment. A key step to prevent a MIG gun from overheating is to choose the right gun for the application. Be mindful of the requirements of the job and select a gun with enough duty cycle and amperage capacity. If the application requires you to weld at 300 amps all day and you choose a 200-amp gun with a 30 or 40 percent duty cycle, this gun will not be up to the task. Exceeding the gun’s duty cycle leads to overheating — and doing this frequently will shorten the life of the gun. In addition to choosing a MIG gun that has a high enough amperage rating and duty cycle rating for the job, you can also take breaks to let the gun and consumables cool to help avoid gun overheating. A change in shielding gas can also help reduce the heat produced during welding. If you’re using an argon shielding gas, the higher the percentage of argon, the less cooling the shielding gas provides. However, keep in mind that many applications use argon shielding gas because it provides a cleaner process with much less spatter for reduced cleanup. So while reducing the argon can help the process run cooler, there are other tradeoffs that can impact productivity. Using the wrong type of drive roll or setting improper drive roll tension can also be common causes of erratic or poor wire feeding in MIG welding. Consider the size and type of wire being used and match it to the correct drive roll. Because flux-cored wire is softer — due to the tubular design and flux inside — it requires using a knurled drive roll that has teeth that can grab the wire and help push it through. Knurled drive rolls typically should not be used with solid wire, since the teeth can cause shavings to break off of the wire, clogging the liner and creating resistance in wire feeding. Instead, use U-groove or V-groove drive rolls with solid wire. Setting proper drive roll tension is another important step. Without proper tension, erratic feeding can cause burnback or other issues. To set the proper drive roll tension, start by releasing the drive rolls. Then increase the tension while feeding the wire into your gloved hand until the tension is one half-turn past wire slippage. Always keep the gun as straight as possible to avoid kinking in the cable that could lead to poor wire feeding. Avoiding common mistakes helps you get the best results in MIG welding. It is just as important to properly maintain the MIG gun and consumables, including the contact tip, nozzle and liner. Whenever you change consumables, check that the gas holes in the nozzle are clean and that the seat that holds the contact tip isn’t filled with spatter or debris. A clogged contact tip or nozzle can cause overheating in the gun and handle. Also check frequently that all connections are tight and as concentric as possible. Keeping the gun and cable as straight as possible during welding — and laying them flat to cool — makes for an effective and efficient MIG gun. Follow these tips to minimize downtime, improve productivity and quality, and save money in your MIG welding operation.
Optimizing MIG welding gun performance in specific applications can be a matter of choosing different components for the gun. Selecting the right MIG gun neck improves access to the weld joint, increases operator comfort and can reduce costs in the operation. The biggest factor when choosing a gun neck is to ensure it provides proper access and visibility to the work. In some applications, the weld joint may be difficult to reach, or it may require you to reach down into a groove. A gun neck should provide optimal access to the weld joint — so you can do your best work while maintaining proper ergonomics. In addition to joint accessibility, several other factors play a role in the decision, including the welding process and parameters, the welder’s height and whether the gun has a curved or straight handle. Keep the following considerations in mind to choose the right MIG gun neck for your application. Certain welding processes and filler metals generate much greater heat during welding, so take that into account when choosing a gun neck. Pulsed welding processes, the use of metal-cored wires and even certain materials, including stainless steel and aluminum, all generally create more heat during welding. The welding parameters — including amperage, volts, joint configuration and distance from the welder to the joint — also impact the amount of heat produced and felt by the welder. In applications with high heat, a standard short gun neck can cause the heat to radiate through the glove and into the welder’s hands. It’s recommended to use a longer gun neck in these situations to keep the heat farther away. Another good rule of thumb to remember is the larger the wire diameter being used, the longer the gun neck should be. Standard necks for MIG guns are available in a range of options, with varying angles and material types. • Aluminum armored necks can withstand abuse and offer outstanding heat dissipation. They are typically available in fixed and rotatable styles, and some models require no tools to rotate. These necks, which come in 30-, 45-, 60- and 80-degree angle options, are a good all-purpose choice for many welding applications. • Black polymer armored necks, available in a 60-degree angle, contain a thick copper wall with a conductor tube interior, so they don’t radiate or reflect heat as quickly. This insulation from the heat makes them a good choice for higher-amperage welding applications. Be aware that black polymer armored necks can become brittle and break since the high temperatures, over time, can break down the exterior tube. Choosing between these standard neck options is often a balance of application requirements and welder preference. The same is true for choosing a neck angle. The style of the gun handle, however, is also a determining factor in selecting the right neck angle. When using a curved handle, it’s often more comfortable to use a 60-degree neck than a 45-degree neck. With a straight handle, a 45-degree neck is typically better suited due to natural hand placement. A welder’s height also impacts proper neck angle: A taller welder may want to use a 60-degree neck, while a shorter welder may prefer a 45-degree neck for comfort. A neck coupler is an accessory that allows a flex neck to be added to the top of an existing standard neck. This can be used when a longer neck with flexibility is needed to get into hard-to-reach areas. to-reach or narrow areas. Some flex necks have a bend radius up to 80 degrees. These necks are typically available in 6- and 8-inch lengths for straight and curved handles. Because flex necks can be changed, rotated or bent without tools, this saves time and labor. In applications where a standard neck can’t provide proper access to the weld joint, consider using a flex neck, which can be bent into a desired shape or angle to access hard-to-reach areas. Some flex necks can also be used with an easily removable jump liner for quick changeover. Jump liners replace only the most commonly worn and clogged liner area in the neck bend, to reduce downtime for liner changeover. A jump liner connects the standard liner at the back of the neck and runs through the neck up to the contact tip. Because a jump liner allows for quick and easy neck change-out, the gun can be easily adapted to fit multiple applications. For example, flex necks and rotatable necks are frequently used in shipbuilding. A welder may be in the ship’s hull and need multiple neck styles to access different weld joints. Instead of bringing several welding guns to the work area, a jump liner allows the welder to quickly unscrew one neck and thread another one on without changing or trimming the liner. An operation can also reap cost savings, since jump liners are less expensive than standard liners and quicker to install. When available standard or flex necks don’t provide proper weld joint access, specialty necks can be created. Multiple lengths and bends are available for limited access positions and improved operator comfort. These necks are specially designed by manufacturers to fit the specifications of the application. Because producing a quality weld hinges on optimal access to the joint, in some cases a custom neck can provide the best accuracy and results. Many neck options are available for MIG welding guns, including rotatable, flex, various bend angles and lengths, neck couplers and custom necks. Choosing the right style can improve your comfort and maneuverability — especially with hard-to-access welds. When you’re unable to reach your weld joints comfortably using a standard neck, consider adding a specialty or custom neck to your toolkit.
Limiting exposure to welding fumes is an increasingly important issue for many welding operations, as it provides a cleaner, more comfortable work environment and helps companies stay compliant with changing regulations. 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. Some companies may choose a centralized fume extraction system designed to protect the entire shop area. However, these systems can be a substantial investment and often require installation of new ductwork. In some welding applications, they are not a feasible or efficient fume extraction option. A fume extraction gun is a viable alternative in certain welding applications, including when the welder is in a tight or confined space or must move often to complete welds on a large part. Welding guns with built-in fume extraction are commonly used in heavy industrial welding, such as truck and trailer, rail car and heavy equipment manufacturing. Fume extraction welding guns capture the fumes generated by the welding process right at the source, over and around the weld pool, and they can be tailored to best meet the needs of a specific application or to welder preferences. Consider these key factors to help choose the right type of fume extraction gun for the job — and learn more about available features that can help improve gun flexibility and performance in certain applications. Fume extraction guns are available in a variety of amperages and handle designs. Common amperages for fume extraction guns range from 300 to 600. Keep in mind that amperage is tied to gun weight. The higher the amperage, the more copper required in the power cable and therefore the heavier the gun will be. Due to this additional weight, use the lowest amperage gun possible that will still allow the job to be completed. Along with the added weight, higher-amperage guns typically cost more than lower-amperage guns, so it may be a waste of money to buy more gun than necessary for the application. However, automatically buying the lightest gun available may not provide the amperage or durability needed for the application. Some lighter and more flexible guns aren’t durable enough for heavy industrial applications. Always consider a gun’s duty cycle rating, and keep in mind that it’s a balancing act between gun weight and durability when choosing a fume extraction gun. Some fume extraction guns on the market offer features and capabilities that help optimize fume capture while also providing benefits for operator comfort and ergonomics, gun performance and ease in producing quality welds. When choosing and configuring a fume extraction gun, consider these options: As with any fume extraction equipment, proper use and maintenance of fume extraction guns is important to achieve optimal results. Operating a fume extraction gun is similar to using a standard MIG gun, with many of the same recommended best practices. However, there are some techniques that welders can follow to help get the best performance from a fume extraction gun: Some fume extraction guns are designed using a common consumable platform, which means any consumables used on a standard MIG gun or even a robotic MIG gun can also be used on a fume extraction gun. When fume gun replacement parts — nozzles, contact tips and gas diffusers — can be the same as those used on standard MIG guns, this offers greater flexibility and helps reduce a company’s consumables inventory. Additionally, it may be important for some companies to choose a fume extraction gun that is compatible with vacuum systems from most major manufacturers. In the right applications, fume extraction guns can help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment for employees. When choosing fume extraction guns for MIG welding, look for features and accessories that will provide additional flexibility, time savings and advantages for welder comfort.
July 19, 2018 Tregaskiss is pleased to announce that the TOUGH GUN® TA3 robotic air-cooled MIG gun offering has now been expanded to include configurations for the FANUC® 100iD robot model. Click here to learn more about the TOUGH GUN TA3 robotic air-cooled MIG gun.
BEECHER, Ill./WINDSOR, Ontario. July 17, 2018 – Bernard and Tregaskiss announced the companies will showcase their products at FABTECH 2018 in Atlanta from November 6 to 8 in booth C12828. Bernard semi-automatic MIG guns and consumables will be on display and also featured in live welding demonstrations with power sources from Miller Electric Mfg. LLC. Tregaskiss will showcase its robotic MIG guns, consumables and peripherals and feature them in Miller pre-engineered automated welding cells. Welding demos will feature Hobart filler metals. The companies will have representatives available to answer questions and plans to unveil new products for the fabrication and manufacturing industries.
BEECHER, Ill./WINDSOR, Ontario. July 17, 2018 – Bernard and Tregaskiss announced the companies will showcase their products at FABTECH 2018 in Atlanta from November 6 to 8 in booth C12828. Bernard semi-automatic MIG guns and consumables will be on display and also featured in live welding demonstrations with power sources from Miller Electric Mfg. LLC. Tregaskiss will showcase its robotic MIG guns, consumables and peripherals and feature them in Miller pre-engineered automated welding cells. Welding demos will feature Hobart filler metals. The companies will have representatives available to answer questions and plans to unveil new products for the fabrication and manufacturing industries.
A MIG gun liner is an important consumable because it can make a significant difference in gun performance and the time and money an operation spends in unplanned downtime. Proper installation of the liner is critical to its ability to guide the wire through the welding cable and up to the contact tip. Improper liner installation — which includes trimming the liner too short or having a liner that is too long — can result in a number of problems, such as birdnesting, wire feeding issues and increased debris in the liner. These issues can result in costly rework and operator downtime for maintenance and repairs, which impacts productivity. Also, wasted wire due to issues like birdnesting can drive up costs for a company. The installation process is somewhat similar for all types of MIG gun liners, with some variations. Here are some general steps to consider when installing a new MIG gun liner. There are some variances in the installation process, depending on the type of liner being used. Follow these steps when installing a front-loading liner. The only difference in this installation process is that there is no receiver in the back of the power pin. The receiver is built into the module pin. The installation process also varies when retrofitting a gun from a conventional liner to a front-loading liner. Here are a few additional things to remember: The quality of the liner also can impact welding performance, productivity and operator downtime, so it’s important to buy quality liners from a trusted manufacturer. Choosing the correct size of liner for the wire being used is another way to help maximize performance. While liners may seem like a small part of the welding operation, it’s important to be mindful of the impact they can have on quality, performance and costs. Liners perform a vital function in the MIG welding process, and the proper installation and maintenance of liners can help reduce costly rework, operator downtime and wasted wire.
BEECHER, Ill., April 3, 2018 – Bernard has announced changes to its fume extraction gun offering. Effective immediately, Bernard® FILTAIR™ fume extraction MIG guns are transitioning to the Bernard Clean Air™ brand name and will become Bernard Clean Air curved handle series fume extraction MIG guns. In addition, several upgrades have been made to the former FILTAIR fume extraction guns. “This transition offers improved functionality, performance and ease of maintenance to our fume extraction guns — to bring flexibility and value to users,” said Jerome Parker, product manager, Bernard. Designed to produce a cleaner, more compliant work environment, Clean Air fume extraction guns are ideal for large weldments and confined space welding applications, and they range in models from 300 to 600 amps. The name change was made due to feature and performance similarities between the two gun offerings. In addition, several upgrades from the Clean Air gun line are now available for the former FILTAIR gun models, including: • Reduced overall weight, stemming from the eliminated need for a protective cover thanks to a new high-performance, crush- and snag-resistant extraction hose. • Adjustable nozzle shroud with a front vacuum chamber that adjusts to one of four positions for optimized fume capture, gas flow and weld access. • Additional neck options of 30-, 45- and 60-degrees are now available for the curved handle model. • Inclusion in the Clean Air gun online configurator with expanded options. The curved handle guns are now available with Centerfire™, Quik Tip™ and TOUGH LOCK® consumables and are compatible with QUICK LOAD® liners and the QUICK LOAD liner AutoLength™ system. Along with the name change, the FILTAIR gun part numbers have been converted to Clean Air gun part numbers for a seamless transition. Legacy products can be identified from updated products by visible changes in neck and shroud color. The fume extraction components that previously were chrome now have a black finish. Learn more about Clean Air fume extraction MIG guns, or configure you gun today.
What is ergonomics? While this term has several definitions, its practical meaning is “to adapt a task and work environment to a human.” Despite what some think, the importance of ergonomics far surpasses comfort. A workplace environment or task that causes a welding operator to repetitively reach, move, grip or twist in an unnatural way — or even stay in a static posture for an extended time without proper rest — can do much more than become a literal pain in the neck. Over time, it can lead to repetitive stress injuries with life-long impacts that may even prevent the welding operator from working. People are built with certain limitations, and when the design of work exceeds normal limitations, excessive wear and tear on the body occurs, accelerating damage that can lead to Work-Related Musculoskeletal Disorders (WMSDs) — injury to the muscles, tendons, ligaments, joints, nerves and/or spinal discs. Although many welding operators may start with a dull pain that they dismiss as “just getting conditioned” or “tweaking something that will go away,” it can become more intense — and more expensive — and difficult to treat as time goes on. For example, early treatment for pain may require only ice, heat or some anti-inflammatories, and it might cost $200. However, waiting months or years to address the problem could result in invasive treatment and cost thousands of dollars. That is especially true with wrist and shoulder injuries that require surgery. Ergonomics not only protects welding operators from injuries, but it can also improve the productivity and profitability of a welding operation. Stressful postures and motions tend to be inefficient. Lifting boxes from floor level or reaching outward beyond arm’s length, for example, takes extra time. These posture and motions repeated throughout the year by multiple employees can have a significant impact on earnings for the company. By proactively reducing the risk of injury, companies can improve productivity, while also reducing employee absences and eliminating overtime pay for replacement workers who may not be as efficient or proficient. Eliminating stressful postures and motions can also help reduce employee turnover and training costs for replacing welding operators who quickly decide “this job isn’t for me.” According to the Bureau of Labor statistics, WMSDs account for 29 percent of all lost workday injuries and for about 34 percent of all workers’ compensation claims — and they cost employers $20 billion each year in workers’ compensation. Injuries ranging from mild and short-term to serious and chronic can result when the demands of a task do not naturally align with the capabilities of the welding operator. Most WMSDs develop when repetitive micro-traumas occur to the body over time. WMSDs include strains or sprains, which can result in pain, decreased productivity, disability, medical treatment, financial stress and even a change in the quality of life for those affected. The most common symptoms among welding operators are shoulder pain, range of motion loss and reduced muscle strength. The most common injuries for welding operators include back and shoulder injuries, wrist injuries (such as tendinitis) and various knee joint disorders. Today WMSDs are the fastest-growing disorder in the aging workforce because these illnesses have developed over time, before welding operations were as aware of them as they are today. As a result, there is the potential for an increase in claims costs in the coming 10 years as welding operators seek treatment. There are three primary risk factors that increase the likelihood of developing WMSD injuries: 1) Highly repetitive tasks that keep an operator in a static posture for too long or use the same motion over and over, such as pulling a MIG gun trigger. 2) Tasks that require an operator to apply significant force or pressure, such as pushing, pulling or heavy lifting. 3) Poor or awkward postures, such as bent wrists or necks tilted backward. In addition, environmental conditions such as extreme temperatures can also contribute to the development of WMSDs. Personal risk factors that increase the likelihood of incurring WMSDs include physical conditioning, pre-existing health problems, gender, age, work techniques and stressful hobbies. Some common welding postures that are considered awkward and stressful include kneeling, squatting, torso twisting, leaning on a hard surface, holding the arms away from the body or above shoulder height for long periods of time, hunching or bending over, and looking upward too long. In general, the best postures are those that are as close to neutral as possible — a natural position that the body would rest in if it were not doing anything. The use of proven ergonomic principles can dramatically improve the way a welding operator performs a task, thereby reducing the exposure to risk factors and simultaneously increasing productivity. A simple work station adjustment or the use of different tools can make a big difference on an operator’s long-term health and wellbeing, as well as on the company’s bottom line. For example, operators who weld with pistol grip tools, such as a welding gun, and use their finger to apply pressure for an extended length of time can develop “trigger finger.” This problem can be easily resolved by using a welding gun with a locking trigger. Welding operators should position their work between the waist and shoulders, whenever possible, to ensure they are working in a close to a neutral posture. Achieving this posture may mean using work stools or height-adjustable chairs, as well as lifting tables and rotational clamps or other material-positioning equipment. All these solutions can reduce awkward postures and allow employees to work in more neutral positions. Welding guns with rear swivels on the power cable can help reduce the stress of repetitive motions. Different combinations of handle angles, neck angles and neck lengths can also keep an operator’s wrists in a neutral position. In some cases, a welding gun with a rotatable neck can help the welding operator more easily reach a joint, with less strain on the body. Manipulators, lighter-weight welding guns, lighter power cables with low stiffness and cable supporting balancers can also be invaluable. Remember, the working height of a welding operator’s hands should typically be at elbow height or slightly below. The engineering controls described above are effective because they reduce or eliminate risk factors in the workplace. Administrative control measures, such as job rotation and stretching programs, can also be used to reduce the exposure time for welding operators or at least prepare their bodies for the work-related stress. An effective and sustainable ergonomics process provides a structured approach to reducing risk in the workplace and preventing WMDs over the long-term. It typically includes: 1) A formal ergonomics risk assessment process to identify and prioritize high- risk work. 2) A structured task analysis process to define the causes of the risk factors, leading to the development of practical engineering controls. 3) An action plan developed by management stakeholders to set expectations and allocate resources for ergonomics in the workplace. 4) An ergonomics team trained to implement the ergonomics process and empowered to implement the action plan. 5) A formal process for developing, implementing and validating ergonomics solutions for high-risk tasks. 6) Ergonomics training for management, supervisors, the ergonomics team and other production staff members. Once an ergonomics solution has been implemented, it is important to provide frequent reinforcement to the welding operators to ensure that the solution is utilized effectively. It can be difficult, initially, for a welding operator to get comfortable with new work practices if the job has been done a specific way for years. Therefore, it is important for welding operators to use any new welding gun and implement new best practices for at least 30 days. At that point, they can provide valid feedback on how well the new equipment or practices work for them. After all, gaining the benefits of proper ergonomics is only possible if they are used and the welding operator also sees the results. In the end, the goal is to secure the safety of the welding operator, which requires an active commitment on the part of both the individual and management. Gaining the benefit of ergonomics is a team effort — one that ultimately provides a comfortable work environment, leads to a more productive and profitable welding operation, and provides for the long-term health of the welding operator.
BEECHER, Ill./WINDSOR, Ontario. Feb. 19, 2018 – Bernard and Tregaskiss have earned upgrades in their quality certifications. The quality management systems of both Bernard and Tregaskiss for the design, manufacture and service of semi-automatic and robotic welding guns, respectively, have been registered to Quality System Standard ISO 9001:2015, as have components and related accessories. The ISO 9001:2015 standard sets out the criteria for a company’s quality management system and using the standard helps ensure that an organization’s customers receive consistent, high quality products and services. The standard is based on several quality management principles, including a strong customer focus, the motivation and implication of top management, the process approach, risk assessment, and continual improvement. The International Organization for Standardization (ISO) develops international standards such as ISO 9001 and is an independent, international agency with a membership of more than 160 national standards bodies. Bernard was previously certified to the ISO 9001:2008 standard in 2014 and Tregaskiss was certified to that standard in 1996 before upgrading to ISO 9001:2015 in recent months. “Our certification illustrates our dedication to our products around the globe and is just another reason why our customers know that they can always trust Bernard to provide the welding guns and consumables they require to achieve their goals,” said Nashonne Newman, quality engineer, Bernard. “This standard involves documented operating procedures, internal and third-party audits, management review, and advanced product quality planning — all to ensure that Tregaskiss products meet a very high standard of quality, safety and reliability for customers,” said Jatinder Singh, quality engineer, Tregaskiss. BEECHER, Ill./WINDSOR, Ontario. Feb. 19, 2018 – Bernard and Tregaskiss have earned upgrades in their quality certifications. The quality management systems of both Bernard and Tregaskiss for the design, manufacture and service of semi-automatic and robotic welding guns, respectively, have been registered to Quality System Standard ISO 9001:2015, as have components and related accessories. The ISO 9001:2015 standard sets out the criteria for a company’s quality management system and using the standard helps ensure that an organization’s customers receive consistent, high quality products and services. The standard is based on several quality management principles, including a strong customer focus, the motivation and implication of top management, the process approach, risk assessment, and continual improvement. The International Organization for Standardization (ISO) develops international standards such as ISO 9001 and is an independent, international agency with a membership of more than 160 national standards bodies. Bernard was previously certified to the ISO 9001:2008 standard in 2014 and Tregaskiss was certified to that standard in 1996 before upgrading to ISO 9001:2015 in recent months. “Our certification illustrates our dedication to our products around the globe and is just another reason why our customers know that they can always trust Bernard to provide the welding guns and consumables they require to achieve their goals,” said Nashonne Newman, quality engineer, Bernard. “This standard involves documented operating procedures, internal and third-party audits, management review, and advanced product quality planning — all to ensure that Tregaskiss products meet a very high standard of quality, safety and reliability for customers,” said Jatinder Singh, quality engineer, Tregaskiss.
For many fabricators, the choice between an air-cooled and water-cooled robotic MIG welding gun is easy. Their heavy-duty applications simply demand a water-cooled model due to the high amperage and duty cycle requirements of the job — an air-cooled gun would overheat and fail prematurely under such conditions. In the right application, a water-cooled robotic MIG gun can often prove beneficial by minimizing downtime, increasing productivity and reducing consumable costs. These guns typically have higher duty cycles than air-cooled models and operate at higher amperages, which means they can run for longer periods of time. Still, deciding whether an operation would benefit from converting to a water-cooled MIG gun involves a careful analysis of several factors. In addition to considering the amperage requirements and duty cycle, a fabricator should consider the upfront costs, potential return on investment (ROI) and the specific application. For example, some fabricators may choose a water-cooled robotic MIG gun because of the length of their welds — they need a long arc-on time to produce long welds, which generates more heat in the gun. Similarly, critical start-and-stop points along a longer weld joint typically require a gun that can handle extended weld times. The weld joint design and type or thickness of the material can also help determine whether to switch to a water-cooled MIG gun. For instance, heavy plate sections that have been preheated can generate substantial radiant heat that impacts how well a gun cools, and can adversely affect the life of the front-end consumables. In this scenario, a water-cooled gun would be better suited for the job. When deciding whether a water-cooled robotic MIG gun is the best choice for an application, it’s important to keep in mind some maintenance and replacement costs. While a water-cooled gun costs more upfront, there is the possibility to conduct maintenance on each individual component within the cable assembly (e.g. water lines, gas hose, etc). However, an air-cooled cable combines all its components into one common part and if any single component fails, the entire cable needs to be replaced, resulting in higher replacement costs. It is necessary to weigh those factors against each other. Welding guns — whether air or water-cooled — must stay cool to protect the power cable, gun body, neck and consumables from heat damage during welding. That heat takes three forms: radiant heat from the arc; resistive heat from the electrical components in the welding circuit; and reflective heat from the welded part, particularly aluminum or preheated parts. Whereas an air-cooled MIG gun relies on the ambient air, shielding gas and arc-off time to dissipate heat, a traditional water-cooled robotic MIG gun circulates a coolant from a radiator unit through cooling hoses inside the power cable and into the gun body and neck. The coolant then returns to the radiator, where the radiator’s baffling system releases the heat absorbed by the coolant. There are also guns available on the market today that cool only the front of the gun, where heat is generated, and still use an air-cooled cable. Air-cooled MIG guns also use much thicker copper cables and inner neck tubes, whereas water-cooled robotic MIG guns use much less copper in the power cables and thinner wall sections in the necks because the coolant carries away the resistive heat before it builds. Water-cooled MIG guns, however, do have multiple inner lines that run through the neck to the front-end consumables, making this portion of the gun heavier than an air-cooled neck. There are three key indicators that signify a welding operation could benefit from converting to a water-cooled MIG gun: 1. Excessive consumable usage All these factors are interconnected, because if the weld is too hot, excessive consumable usage and gun temperature will automatically result. In general, water-cooled robotic MIG guns are most beneficial for high-amperage applications and are typically available in 350 to 600 amp models. Closely related to amperage is duty cycle, which refers to the amount of time during a 10-minute cycle that the gun can operate at its rated capacity without overheating. Water-cooled robotic MIG guns have varying duty cycle capacities depending on the manufacturer and model. It is important to make the appropriate comparison during the selection process, as some guns may be rated at either 60% or 100% duty cycle, which results in different amperage ratings. Fabricators who plan to change from an air-cooled to a water-cooled robotic MIG gun should follow these three steps to help ensure a smooth conversion. Match the existing tool center point (TCP) and approach angle. Be sure to have access to all the weld joints with the new water-cooled MIG gun. Make sure that the tooling will work with the new system. The gun may require a special neck or special mounting arm to achieve the desired TCP. Often, converting to a water-cooled gun will require a new mounting arm and insulating disk to maintain or achieve a specific TCP while changing the dimensions of the neck itself to create better access. Ensure overall clearance. A 3-D simulator can help determine whether all parts of the new system will clear all tooling or any other obstructions. In addition to having front-end clearance and access – once installed, it’s important that the gun body and cable bundle fits properly to avoid getting caught on tooling or other equipment. Get a water cooler. It is necessary to invest in a radiator for the new water-cooled robotic MIG gun. Ensure that the water-cooler has been installed and maintained, as per the manufacturer’s specifications. Because all the lines and hoses in a water-cooled robotic MIG gun are separate, it is possible to conduct maintenance on individual components if they become damaged. However, due to the lines being internal to the gun, it is difficult to perform preventive maintenance on them. There are options though to care for a water-cooled gun. As with an air-cooled MIG gun, it’s important to inspect a water-cooled robotic MIG gun to ensure that all consumables and connections are tight and working properly. Inspect the water lines frequently to make sure they are tight and have no leaks, and replace the O-rings when necessary (e.g. when cracks or wear appears). Ensure there is a flow switch installed in the return line from the gun and the radiator to indicate any leaks within the system — this component will save time and money in the event of a failure. Using a reamer or nozzle cleaning station adds significant benefits to the preventive maintenance of water-cooled robotic MIG guns. A reamer eliminates the need to manually clean out the front-end consumables and can, with the addition of an automated sprayer, add anti-spatter compound to help further extend consumable life. This feature adds to the overall cost of the equipment, but it helps increase uptime for production since there is less manual intervention. The ROI is typically worth it. It is important to always use the correct coolant — do not fall prey to the notion that it is cheaper to use tap water in a water-cooled gun. Doing so can cause algae growth or mineral build-up and, eventually, lead to costly clogging. Instead, use deionized water or the specially treated coolant solution recommended by the manufacturer. These coolants contain special additives to lubricate internal pumps and O-rings, as well as to prevent algae growth. Although converting to a water-cooled robotic MIG gun is often more of a necessity than a choice (because the application demands it), this type of gun has its value. Applying a water-cooled gun to the appropriate application can result in a more efficient system performance and lower overall operating costs. Consider the various costs, specific application needs and joint accessibility to determine whether a water-cooled robotic MIG gun is the best option for the specific robotic application — and don’t hesitate to consult a trusted welding distributor, welding equipment manufacturer or robotic welding system integrator with questions.
November 20, 2019 Effective November 29, 2019: All replacement parts for the previously discontinued TOUGH GUN® G2 and ThruArm G2 series robotic air-cooled product will be discontinued and no longer available for sale. Visit the TOUGH GUN CA3 or TOUGH GUN TA3 robotic air-cooled MIG gun page to learn more about replacement solutions. The following part numbers have been discontinued: Want to convert from your TOUGH GUN G2 or ThruArm G2 series MIG gun to a TOUGH GUN CA3 or TA3 MIG gun? Find what you’re looking for below:
March 9, 2018 We are proud to announce that effective immediately, you will notice some important changes to the Bernard® fume extraction MIG gun offering. Bernard FILTAIR™ fume extraction MIG guns are transitioning under the Clean Air™ brand name and will become our Bernard® Clean Air™ curved handle series fume extraction MIG guns. This product transition offers improved functionality, performance and ease of maintenance. Learn more about Bernard Clean Air fume extraction MIG guns or click here to configure your gun online.
November 30, 2017 Effective immediately, all 8- and 12-foot length options in the BTB semi-automatic air-cooled MIG gun product lineup will be discontinued. BTB MIG guns will continue to be available in lengths of 10-, 15-, 20- and 25-feet. No other configurable options have been affected by this change. View available options or configure a BTB MIG gun today!
Tregaskiss® by DINSE™ CWD robotic water-cooled MIG guns are designed for conventional robots, while TWD robotic water-cooled MIG guns are for through-arm robots. Both guns are available as part of the five-year Master Distribution Agreement between Tregaskiss and DINSE GmbH announced in September 2017. The new robotic water-cooled guns are available in a variety of amperages ranging from 350 to 600 amps at 100 percent duty cycle. Designed with a dedicated gas line that runs from the back of the guns directly to the gas diffuser, the guns deliver cost savings since shielding gas has zero opportunity to escape. The guns also use a unique dual-circuit cooling system that runs the length of the front end, providing more effective cooling and lower operating temperatures. This feature results in longer MIG gun and consumable life, as well as less downtime for consumable changeover. Cooler operating temperatures also reduce the amount of spatter that adheres to the nozzle, saving time and money in cleanup, extending nozzle life and lowering overall consumable costs. CWD and TWD Robotic Water-Cooled MIG Guns are available in clutch and solid mount models, with a variety of mounting arm and neck options to achieve Tool Center Point (TCP). They also include integrated air blast and a simple liner design, with one end pre-dressed at the factory to minimize the opportunity for operator variation in liner trimming.
WINDSOR, Ontario. November 14, 2017 — Tregaskiss has introduced its new TOUGH LOCK® HDP contact tips, designed to significantly extend contact tip life in pulsed MIG Precision engineered with a special alloy that provides a higher resistance to wear and arc erosion, the TOUGH LOCK HDP contact tips allow operations to regain as much as 95 percent of the productivity lost during typical contact tip changeovers. TOUGH LOCK HDP contact tips can do so by lasting six to 10 times longer than copper and chrome zirconium tips, which often need to be replaced twice as frequently during pulsed MIG welding due to its high heat input. The new contact tips also feature a tight bore tolerance, provide increased arc stability to improve weld quality and reduce spatter, along with its associated cleanup. TOUGH LOCK HDP contact tips are available in packages of 5, 25 or 100 and can be used with .035-, .040- and .045-inch solid copper-coated wires. They are compatible with TOUGH LOCK Consumables, including nozzles and retaining heads, and require no change to Tool Center Point (TCP). The contact tips also benefit from compatibility with the TOUGH GUN reamer robotic nozzle cleaning station, which helps extend the life of robotic MIG guns and consumables by automatically removing spatter.
BEECHER, Ill. November 16, 2017 — Bernard has introduced a new model to the Clean Air™ fume extraction gun family and has updated the entire Clean Air offering with a new look. A 300 amp MIG gun has been added to the Clean Air family, which allows users to reduce smoke at the source with an industrial-duty fume extraction gun that is comparable in size and weight to a regular welding gun. In addition, Bernard has changed the finish from chrome to black on all Clean Air fume extraction gun vacuum tubes and chambers. This aesthetic change has been made on all new guns, replacement vacuum tubes and replacement chambers. The expansion of the Clean Air fume extraction gun offering provides more choices and greater flexibility for operations seeking to establish a cleaner, more compliant work environment. Clean Air fume extraction guns are also available in 400-, 500- and 600-amp models and can be used with solid and flux-cored wire. The guns are compatible with high performance consumables from Bernard, including Centerfire™, Quik Tip™ and TOUGH LOCK®, as well as the conventional liner or QUICK LOAD® liner. Users can make their selection and customize their Clean Air fume extraction gun when configuring their gun online. All Clean Air fume extraction guns have a small vacuum chamber that provides good joint access and visibility, along with a 360-degree vacuum hose swivel on the rear of the handle that improves flexibility and reduces operator wrist fatigue. The guns are ideal for large weldment and confined space welding applications.
Companies invest in robotic welding systems to improve productivity and gain efficiencies in their operation. But if the weld cell layout is not optimized, it can negatively impact those goals — along with the quality of the completed welds. Poor cell layout can create a bottleneck in the process or result in parts not being properly welded —problems that cost time and money in the long term. When considering proper layout for a robotic weld cell — whether it’s a pre-engineered cell or a custom cell —gun and consumable selection, robot reach, parts flow in and out of the cell, and weld sequencing are all important. Proper weld cell layout is important for both pre-engineered robotic welding systems or a custom-designed system. Determining which option is right hinges on several factors. A pre-engineered robotic welding cell is designed for welding specific parts in a certain size range. Pre-engineered cells offer benefits for easy and fast installation and a much lower first cost, but they do have their limitations regarding the type and size of parts that can be welded. Part size is often the key determining factor when choosing between the two systems. If there isn’t a pre-engineered weld cell available to fit the parts — perhaps there is a reach or weight capacity issue — then a custom robotic weld cell is the better option. Custom cells have a higher initial cost and typically a longer lead time for design and installation, but the upside is they can be customized to meet specific needs. When installing either type of robotic weld cell, the system integrator should be involved in planning and testing to ensure cell layout is optimized for the application. Having the right gun is a critical factor that can help reduce or eliminate the sources of common problems in the weld cell. Gun choice should not be an afterthought in robotic welding applications. The gun must have proper access and be able to maneuver around fixturing in the weld cell. Different choices in gun types and in consumables can help in achieving this. Robotic welding systems are available in two styles: through-arm or conventional. Through-arm systems are gaining popularity, and most through-arm robots allow for mounting either type of gun — providing more options and flexibility depending upon the needs of the application. As the name suggests, the power cable assembly of a through-arm MIG gun runs through the arm of the robot as opposed to over the top of it like in a conventional gun. Because of this design, the through-arm gun style is often more durable, since the power cable is protected. However, because conventional guns can be used on either type of system — a through-arm or a conventional robot — they can sometimes offer greater flexibility, and can be used with more robot makes and models. Consider which type of gun provides the best access to the welds when making the selection. With conventional robotic welding systems especially, proper cable management is important. Once the hardware is installed and the system is set up — but before full production begins — be sure to do a test run or two through the welding sequence to determine how the gun cable moves and if it gets caught on tooling. Another choice in selecting a gun is air-cooled versus water-cooled. This essentially comes down to the required duty cycle. The base material thickness, weld length and wire size all help determine the necessary duty cycle. Water-cooled guns are typically used in manufacturing heavy equipment and in the case of long cycle times and large wire diameters. Once the system type and gun is chosen, it’s all about proper fit and function of the gun. It’s critical to ensure the robot arm can access all the welds — ideally in one position with one neck if possible. If not, different neck sizes, lengths and angles — and even custom necks — as well as different consumables or mounting arms can be used to improve weld access. The choice of nozzle is another important consideration, since it can greatly hinder or improve access to the weld in a robotic cell. If a standard nozzle is not providing the necessary access, consider making a change. Nozzles are available in varying diameters, lengths and tapers to improve joint access. While many companies like to choose a nozzle with the smallest outside diameter available, it may be necessary to size the nozzle up to avoid spatter buildup and loss of shielding gas coverage. A nozzle with a 5/8-inch bore or larger is recommended because it allows the most access. Choosing the right gun is tied closely to proper weld cell layout — since different sizes and lengths of guns and nozzles can improve or hinder reach to the welds. However, there are also many other factors involved in proper weld cell layout. Think of weld cell layout as the footprint of the entire process. Some important issues to keep in mind: Weld cell layout and the chosen components that fit inside have a significant impact on productivity, efficiency and quality of the finished welds. Weld cell layout that is not optimized can even harm the tooling or consumables, and result in increased time and money spent on maintenance and repair. Protect the robotic weld cell investment by taking the time at the start of the process to test proper cell layout and equipment — to help ensure the end results and productivity gains being sought. The fabrication and manufacturing industries continue to experience demands for greater productivity, increased efficiencies and higher cost savings — often times with less labor to support the efforts. Every improvement companies can make to achieve these goals is beneficial, from offering more operator training to implementing lean practices. Managing MIG guns and consumables that meet the needs of multiple applications is also an important element in achieving those goals, both from an inventory perspective and as a matter of eliminating unnecessary downtime. There are rarely, if ever, welding operations that require only one type of MIG gun or a single consumable. In fact, it’s not uncommon for many companies to have multiple MIG guns and consumables in use as a routine part of their daily operations, especially within the automotive manufacturing and pressure vessel industries. Automakers, for example, often have handheld and automation weld cells all in the same building. Similarly, welding operators working on different-sized pressure vessels may have a 1,500 gallon tank being welded together with a larger, higher-amperage MIG gun, while welding operators are fabricating a smaller tank nearby with much smaller, lighter-duty MIG gun. Understanding how to pair the best gun and consumable with the job can pay off in workflow and cost savings, and help improve the quality of completed welds. In addition, minimizing the part numbers for MIG guns and consumables can simplify inventory, which ultimately saves time for management and saves storage space. It can save time during the welding process, too. In the shipbuilding industry, for instance, welding operators move around frequently so they do not have the capacity to swap out MIG guns to address multiple applications. Instead, they often standardize on one type of MIG gun and swap out the necks, installed with a jump liner that replaces the front part of the liner system (the rest seats in the power cable). Doing so allows them to keep the same gun for the job, while gaining access to a new joint with the appropriate neck length or configuration. Below are five tips to help streamline welding operations and remain competitive by managing MIG guns and consumables effectively. Using fewer power cable lengths throughout an operation is possible when there is a difference of two or three feet between each application. For example, it may be possible to standardize on a 15-foot cable for weld cells that need this or a slightly shorter length — without causing issues with kinking of poor wire feeding. Doing so minimizes inventory and storage space requirements. It also takes away the guesswork when it comes to replacing this part of the MIG gun, as it eliminates the risk that a welding operator or maintenance employee will install the wrong length power cable on a MIG gun. 2. Choose one type of liner, when possible. There are different styles of liners available for MIG guns, including steel liners, D-wound liners or Teflon® liners. Teflon liners are well-suited for wires that are difficult to feed, including stainless steel or aluminum. Standardizing liner types across multiple weld cells, when possible, can reduce downtime for changeover and costs for inventory. Always make sure the liner is properly installed; otherwise, problems like birdnesting and feeding issues can result. 3. Use the same contact tips, even across semi-automatic and robotic weld cells. Use one type of contact tip across applications whenever possible. For companies that have both robotic and semi-automatic welding operations, common consumables can be especially helpful to streamline processes and inventory — while also reducing costs. It is not uncommon in robotic welding applications for welding operators to change contact tips long before they become worn, as it helps ensure that there is minimal downtime for problems associated with failures. These contact tips, however, still have life in them and can be used on semi-automatic MIG guns to reduce part numbers and count in inventory, and overall costs. It can also reduce confusion as to which contact tips to use across the welding operations. Too many different types of contact tips, for instance, can be confusing and can lead to a welding operator using the wrong parts on the wrong MIG guns. That misstep can bring production to a slowdown or a halt. 4. Adapt the power pin. It is not uncommon for companies to have multiple types and brands of power feeders throughout the welding operation. When possible, standardizing the power pin used in every MIG gun, via an adaptor at the feeder, can help streamline the management of various power pins to match these feeders. If a company also has various types or brands of MIG guns, an adapter can also help with gun standardization. The guns can be ordered with the same power pin and plugged into any wire feeder throughout the facility, again streamlining ordering and inventory, and minimizing costs. 5. Review MIG gun amperage and select one to streamline. In some instances, it may be possible to use the same amperage of MIG gun for multiple applications. For example, if 200 amp and 300 amp guns are both part of the inventory, using 300 amp guns in each cell can make it easier to manage inventory. It can also help prevent the potential for overheating if a smaller gun is accidentally used in place of a larger, higher-amperage one for a higher duty cycle job.
New HDP Contact Tips Provide Robotic Pulsed MIG Welding Benefits
New HDP Contact Tips Provide Robotic Pulsed MIG Welding Benefits
Demands of GMAW-P
Contact tip advancements
Significant productivity gains
Additional benefits
Return on investment
Be sure to look at the big picture in terms of productivity and efficiency improvements for the entire operation.Improve productivity and efficiency
Ethernet vs. Standard Reamer: Making the Selection
Ethernet vs Standard Reamer: Making the Selection
Standard versus Ethernet
A standard reamer features inputs and outputs that are plugged into a Program Logic Controller (PLC), including the inputs that control the nozzle clamping, cutter actions and anti-spatter spray process.Robotic reamer accessories
Extra: Reamer maintenance
PRODUCT UPDATE – Expanded TOUGH GUN TA3 MIG Gun Offering
PRODUCT UPDATE —
Expanded TOUGH GUN TA3 MIG Gun Offering
Available Resources
7 MIG Welding Mistakes and How to Avoid Them
7 MIG Welding Mistakes and How to Avoid Them
No. 1: Improper liner length
No. 2: Overheated consumables
No. 3: A bad ground
No. 4: Improper voltage or wire feed speed
No. 5: Poor cable management
No. 6: Selecting the wrong gun
No. 7: Drive roll issues
Proper maintenance is also key
What MIG Gun Neck is Right for You?
What MIG Gun Neck is Right for You?
Feeling the heat
Standard necks
Flex necks
Specialty necks
Final thoughts
Fume Extraction Gun: Features and Techniques to Improve Performance
Fume Extraction Gun: Features and Techniques to Improve Performance
Fume extraction gun options
Features to consider
Fume extraction gun best practices
Getting results
PRODUCT UPDATE – TOUGH GUN TA3 MIG Gun Offering Available for FANUC 100iD
PRODUCT UPDATE —
TOUGH GUN TA3 MIG Gun Offering Available for FANUC 100iD Robot Model
Features & Benefits
Part Numbers
560-600 Solid Mount Connector, air-cooled, no options 560-600I Solid Mount Connector, TOUGH GUN I.C.E., no options 560-600W-045 Solid Mount Connector, air-cooled, wire brake 0.030″-0.045″ 560-600W-116 Solid Mount Connector, air-cooled, wire brake 0.052″-1/16″ 560-600IW-045 Solid Mount Connector, TOUGH GUN I.C.E., wire brake 0.030″-0.045″ 560-600IW-116 Solid Mount Connector, TOUGH GUN I.C.E., wire brake 0.052″-1/16″ 58SF011 LSR Unicable, air-cooled, no options 58SF011W LSR Unicable, air-cooled, wire brake 58SF211 LSR Unicable, TOUGH GUN I.C.E., no options 58SF211W LSR Unicable, TOUGH GUN I.C.E., wire brake 560-500A Optional Air Blast Kit for guns equipped with Lincoln® power pins
Available Resources
Bernard and Tregaskiss to Display Products, Host Live Welding at FABTECH 2018
Bernard and Tregaskiss to Display Products, Host Live Welding at FABTECH 2018
Bernard and Tregaskiss to Display Products, Host Live Welding at FABTECH 2018
Bernard and Tregaskiss to Display Products, Host Live Welding at FABTECH 2018
Steps for Proper MIG Gun Liner Installation
Steps for Proper MIG Gun Liner Installation
Step-by-step installation
That way, once all of the consumables are back on at the front of the gun, the wire is already in the gun and ready to be pulled through.
Installing a front-loading QUICK LOAD Liner
1. Unravel the liner (which comes coiled) and stick the brass end — the end that goes into the receiver at the back of the gun — over the wire and through the neck.
2. Feed the liner through the front of the gun using short strokes, to avoid kinking the liner. The front-loading liner will click or snap into place once it hits the receiver in the power pin.
3. Once that is complete, put the liner gauge on top of the liner and follow the standard installation steps above.Installing a front-loading liner with the spring-loaded module
Retrofitting a gun
Proper liner installation can help optimize performance
Fume Extraction MIG Gun Offering Expands, Adds Improved Features
Fume Extraction Gun Offering Expands, Adds Improved Features
Proper Ergonomics Improve Welding Productivity, Protect Welders
Proper Ergonomics Improve Welding Productivity, Protect Welders
By Jack Kester, senior VP, Marsh Risk Consulting and Andy Monk, product manager, Bernard
Welding-related musculoskeletal disorders
The risk factors
Ergonomic solutions
The keys to an effective ergonomics program
Bernard and Tregaskiss Earn Stringent Quality Certification
Bernard and Tregaskiss Earn Stringent Quality Certification
Bernard and Tregaskiss Earn Stringent Quality Certification
Bernard and Tregaskiss Earn Stringent Quality Certification
Reduce Downtime and Costs with Water-Cooled Robotic MIG Guns
Reduce Downtime and Costs with Water-Cooled Robotic MIG Guns
Understanding water-cooled robotic MIG guns
When to switch to a water-cooled robotic MIG gun
2. Excessive gun temperature (overheating)
3. Excessive cycle time (high duty cycle)Converting to a water-cooled robotic MIG gun
Maintenance and usage tips
Lower operating costs
DISCONTINUED PRODUCT – All TOUGH GUN G2 and ThruArm G2 Series Replacement Parts
DISCONTINUED PRODUCT —
All TOUGH GUN G2 and ThruArm G2 Series Replacement Parts59U303.5 Unicable, G2 Series, 3.5 ft, 300 amp 59U304.5 Unicable, G2 Series, 4.5 ft, 300 amp 59U503.5 Unicable, G2 Series, 3.5 ft, 500 amp 59U504 Unicable, G2 Series, 4.0 ft, 500 amp 59U505 Unicable, G2 Series, 5.0 ft, 500 amp 59U505.5 Unicable, G2 Series, 5.5 ft, 500 amp 59U510 Unicable, G2 Series, 10.0 ft, 500 amp 59C Torch connector 59CW Torch connector 59S Torch connector, solid mount 593-22-A Neck, 22 degree, G2 Series, TOUGH GUN I.C.E.® 593-22-B Neck, 22 degree, G2 Series, TOUGH GUN I.C.E. 593-22L-A Neck, 22 degree, G2 Series, TOUGH GUN I.C.E. 593-35-A Neck, 35 degree, G2 Series, TOUGH GUN I.C.E. 593-45-A Neck, 45 degree, G2 Series, TOUGH GUN I.C.E. 593-45L-A Neck, 45 degree, G2 Series, TOUGH GUN I.C.E. 59G22 Neck, 22 degree, G2 Series 59G22L Neck, 22 degree, G2 Series 59G22L1 Neck, 22 degree, G2 Series 59G35 Neck, 35 degree, G2 Series 59G45 Neck, 45 degree, G2 Series 59G45L Neck, 45 degree, G2 Series 59G45L1 Neck, 45 degree, G2 Series 59G45L2 Neck, 45 degree, G2 Series 580-400 Connector assembly, G2 Series, FANUC® 58G2 Torch part, ThruArm G2 Series 58G2W Torch part, ThruArm G2 Series A58G2S Torch assembly, ThruArm G2 Series, ABB® A58G2SW Torch assembly, ThruArm G2 Series, wire brake, ABB F58G2S ThruArm G2 Series, FANUC IF58G2S ThruArm G2 Series, FANUC, TOUGH GUN I.C.E. 580-401-2 Hose, TOUGH GUN I.C.E., ThruArm G2 Series, FANUC 590-A Air blast kit, G2 Series 598G2-116 Holder, 0.052-1/16 59GI Neck insulator 59GI-02 Neck insulator 59GI-25 Neck insulator PRODUCT UPDATE – Changes to the Bernard Fume Extraction MIG Gun Offering
PRODUCT UPDATE –
Changes to the Bernard Fume Extraction MIG Gun Product OfferingFeatures and Benefits:
Additional Changes:
DISCONTINUED PRODUCT – 8 and 12 foot BTB MIG Gun Lengths
DISCONTINUED –
8′ and 12′ BTB MIG Gun LengthsNew Robotic Water-Cooled MIG Guns Offer Lower Total Cost of Ownership
New Robotic Water-Cooled MIG Guns Offer Lower Total Cost of Ownership
WINDSOR, Ontario. November 27, 2017 — Tregaskiss has introduced two new robotic water-cooled MIG guns that offer superior cooling power for longer gun and consumable life, in addition to zero gas loss for a lower total cost of ownership.Regain Up to 95 Percent of Lost Productivity for Tip Changes With the New TOUGH LOCK HDP Contact Tips
Regain Up to 95 Percent of Lost Productivity for Tip Changes With the New TOUGH LOCK HDP Contact Tips
welding applications — resulting in increased production throughput. Bernard Expands and Updates Clean Air Fume Extraction Gun Offering
Bernard Expands and Updates Clean Air Fume Extraction Gun Offering
Tips to Optimize the Robotic Weld Cell
Tips to Optimize the Robotic Weld Cell
Pre-engineered or custom welding cell?
Choosing the right gun and nozzle
Key considerations for proper layout
The right choices enhance productivity and quality
Managing MIG Guns and Consumables for Multiple Applications
Managing MIG Guns and Consumables for Multiple Applications
1. Standardize on a shorter power cable length across weld cells. As a rule of thumb, always use the MIG gun with the shortest power cable possible. A MIG gun with a longer power cable can cause welding operator discomfort since it is heavier, which can cost money and time if he or she has to stop to rest due to fatigue. Additionally, a shorter power cable minimizes the risks of kinks that could cause poor wire feeding and/or an erratic arc, and result in downtime to address birdnesting or rework.
