Tip #6: Lighten up

When appropriate, switching from heavy-duty contact tips to standard-duty ones can help lower your overall consumable costs, while still providing you with reliable welding performance. If you have lower heat applications, brief arc-on times for short welds or tacks, or if you are using mixed shielding gases and small diameter wires, standard-duty contact tips should work just fine, and they cost less, too. You can also use these types of contact tips if you have applications with restricted access, as the smaller outside diameter can help to increase gas coverage and to reduce the nozzle's bore size, making it easier to reach tough joints.

Tip #7: Double the life

Look for contact tips that have a dual-thread design that can be rotated 180° and re-installed to create a new wear surface. This design helps extend the life of your contact tip even if one side of it keyholes. Keyholing occurs when the bore of the contact tip erodes due to the constant pressure of the welding wire feeding through it.

Also, look for a contact tip system that stays tight and/or has locking features to ensure good electrical conductivity, and to prevent overheating (caused by electrical resistance).

These features can lengthen the life of your contact tips and will improve your weld quality.

Tip #8: Keep it smooth and clean

As an additional defense against spatter accumulation, purchase nozzles that have a smooth, non-porous surface. Be sure that the nozzles are free of any sharp edges or flat spots that would further allow spatter to adhere. As when handling the liner, be sure you have clean hands or gloves when you are handling or installing your nozzle. Dirt, oil, grease or other debris can easily adhere to nozzles and later enter the weld puddle, causing weld defects. These contaminants can also cause premature failure of the component.

Tip #9: Size it right

Use the shortest MIG gun cable available for your welding application, as this helps prevent kinking and premature wear of both the cable and the MIG gun liner. It also helps to prevent wire-feeding problems that could lead to an erratic arc, poor weld quality and unnecessary downtime for rework or consumable replacement.

Also, remember to choose the correct diameter liner and contact tip for your welding wire, as this prevents similar problems and helps extend the life of these consumables.

Tip #10: Think long term

Whenever possible, purchase MIG guns and consumables that are backed by a reliable manufacturer's warranty — most protect against defects for a year or two and some will replace certain parts for a lifetime. Use all guns and consumables as intended so as not to void the terms and conditions of your particular warranty. For example, using your MIG gun as a chipping hammer (a common occurrence, believe it or not!) will definitely void a warranty.

Also, consider the upfront cost versus the long-term savings of purchasing sturdier and more expensive consumables. It's likely they will last longer, reducing downtime associated with changeover and the cost of the consumables themselves.

Keep these tips in mind and you can get back to welding faster … and keep conserving your resources.

David Bellamy is the product manager for the Tregaskiss semi-automatic/consumables group. Visit www.tregaskiss.com