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Once a welding machine has reached the end of its life cycle, or a company expands its operations, it&#;s time to find a new best friend for the welder. There is a wide range of welding machines on the market, and in many cases, comparing different brands and models is challenging. What kind of things should be considered when purchasing a welding machine?

A good welding machine is a long-lasting purchase and often also a significant investment. It is smart to spend some time comparing machine characteristics with your needs and demands. At best, your company&#;s productivity &#; and the job satisfaction of your welders &#; will reach new levels with the right equipment.

Here are some essential points to consider when making the purchase decision.

What are you welding?

The first things to go through are very basic: what are the applications that the welding machine will be used for, and why a new machine is purchased. The welding process (MMA, TIG, MIG/MAG) already guides us a good step further and often narrows down model options. Purchasing new welding equipment is also a good time to check whether existing welding processes could be replaced, or further enhanced by introducing special processes.

Base materials play a key role when considering the specifications of the welding machine. In MIG/MAG welding, it is good to take plate thickness and the length of the welds into account. The thicker the plates and longer the welds are, the higher are also the required power and duty cycle of the power source. In MIG welding, if the main base material is aluminum, a pulse welding machine is the only right option. TIG welding, on the other hand, always requires an AC/DC welding machine. These criteria, in turn, affect the price of the new machine, and the available models.

It is also worth considering whether a machine specializing in a particular welding process would suit your needs best, or could one multi-process welding machine do the same thing? This particularly depends on the role of welding and its criticality in the operations.

What is the role of welding?

The role of welding in the company and different applications define the characteristics of the new welding machine. When welding is secondary auxiliary work, even an affordable welding machine may meet the needs. However, cheap is seldom a synonym for good &#; the better the welding machine, the better its arc characteristics. A high-quality, spatter-free arc ensures that there is no need to waste time in after-treatment. The functionality and reliability of the welding machine are, of course, always important features &#; then time and money will not be spent on additional maintenance and ordering spare parts.

Does welding take place only on the factory floor, or for example in a small, enclosed space? The size, mobility, and location of the machine play a significant role when welding needs are exceptional. Different accessories (boom hangers, long interconnection cables, etc.) ease the welder&#;s daily work. In some tasks, the availability of certain accessories is critical enough to affect the purchase decision. It is a good idea to go through the available accessories with the salesperson even before making the purchase decision and to buy the needed accessories at the same time as the welding machine itself.

Is the welding machine in personal or shared use?

A welding machine is a production tool for the company, but also a partner for the welder. The end user&#;s opinion is often the decisive factor in the purchase decision, tilting the scales in a certain direction.

When the welding machine serves only one user, the brand loyalty of a satisfied user comes into play. When there are several users, ease of use, language options, and a fast-to-adopt user interface are of high value.

Particularly in an industrial environment, the welding machines are purchased based on demonstrations and experimentation. When the welders, after the demo, are free to familiarize themselves with the machine&#;s characteristics and like what they see, it is easier to justify the choice. Make sure that the salesperson guides you through the machine&#;s features, and that the trial period is sufficient for your business needs. Listen to your network as well &#; companies in the same industry may already have experience with the welding machine that interests you.

Are maintenance and spare parts easily available?

No matter how brilliant your welding machine is, there will be a moment when it requires maintenance or spare parts. Even before buying the machine, find out where the nearest service point is, and what is their response time. Likewise, make sure that consumables and spare parts are available. When the consumables are of high quality, their life cycle is longer, providing significant cost savings in the long term. The manufacturer&#;s original consumables are the most cost-effective and safest choice.

Business happens between people. A dedicated salesperson looking for solutions to your key welding issues inspires more confidence than a faceless online store. A professional retailer or manufacturer will answer your questions without delay, even after the deal is done. When promises are kept and the product meets the expectations, it is only natural to turn to the same seller with your future welding needs.

Depending on the market and need, it may be a good idea to make sure in advance that the documentation for your new welding machine is in order, and that it meets the standards and industry requirements. Again, a well-known manufacturer with a long-standing market presence is a good and safe choice.

Don&#;t forget to check the warranty policy of the product before making the purchase decision.

Does price matter?

The price of a welding machine, like with any other product, is not measured only in money. In the end, the product&#;s price stands for reliability, quality, life cycle, and service life as well as the available spare parts and serviceability. Money is not only needed for buying a welding machine but also for buying a reliable production tool.

There often is a price that you can&#;t or don&#;t want to exceed, but it is worth remembering that cheap rarely stands for good quality. A high-quality and long-lasting welding machine will pay for itself during its life cycle.

Whatever your welding needs or situation, at Kemppi we work for you. Our job is to create a perfect match between the welding machine, its user, and the task.

How can we help you today?

Criteria for Selecting a MIG Gun

To maximize the benefits of MIG welding, it is imperative to select the right MIG gun for the job. This equipment&#;s specifications can significantly impact productivity, downtime, weld quality and operating costs &#; as well as welding operators&#; comfort.

MIG welding is considered among the easiest welding processes to learn and is useful for a variety of applications and industries. Since the welding wire constantly feeds through the MIG gun during the process, it doesn&#;t require frequent stopping, as with stick welding. The result is faster travel speeds and greater productivity. 

The versatility and speed of MIG welding also make it a good option for all-position welding on various metals, including mild and stainless steels, in a range of thicknesses. In addition, it produces a cleaner weld that requires less cleanup than stick or flux-cored welding.

To maximize the benefits this process offers, however, it is imperative to select the right MIG gun for the job. In fact, this equipment&#;s specifications can significantly impact productivity, downtime, weld quality and operating costs &#; as well as welding operators&#; comfort. Here is a look at different types of MIG guns and some key factors to consider when making the selection. 

Want more information on Welding Gun Exporters? Feel free to contact us.

What&#;s the right amperage? 

It is important to select a MIG gun that offers adequate amperage and duty cycle for the job in order to prevent overheating. Duty cycle refers to the number of minutes in a 10-minute period that a gun can be operated at its full capacity without overheating. For example, a 60 percent duty cycle means six minutes of arc-on time in a 10-minute span. Because most welding operators don&#;t weld 100 percent of the time, it is often possible to use a lower amperage gun for a welding procedure that calls for a higher-amperage one; lower-amperage guns tend to be smaller and easier to maneuver, so they are more comfortable for the welding operator. 

When evaluating a gun&#;s amperage, it is important to consider the shielding gas that will be used. Most guns in the industry are tested and rated for duty cycle according to their performance with 100 percent CO2; this shielding gas tends to keep the gun cooler during operation. Conversely, a mixed-gas combination, such as 75 percent argon and 25 percent CO2, makes the arc hotter and therefore causes the gun to run hotter, which ultimately reduces duty cycle. For example, if a gun is rated at 100 percent duty cycle (based on the industry-standard testing with 100 percent CO2), its rating with mixed gases will be lower. It is important to pay attention to the duty cycle and shielding gas combination &#; if a gun is rated at only 60 percent duty cycle with CO2, the use of mixed gases will cause the gun to operate hotter and become less durable.

Water- versus air-cooled

Choosing a MIG gun that offers the best comfort and operates at the coolest temperature allowed by the application can help improve arc-on time and productivity &#; and, ultimately, increase the profitability of the welding operation.

Deciding between a water- or air-cooled MIG gun depends largely on the application and amperage requirements, welding operator&#;s preference and cost considerations. 

Applications that involve welding sheet metal for only a few minutes every hour have little need for the benefits of a water-cooled system. On the other hand, shops with stationary equipment that repeatedly weld at 600 amps will likely need a water-cooled MIG gun to handle the heat the applications generate. 

A water-cooled MIG welding system pumps cooling solution from a radiator unit, usually integrated inside or near the power source, through hoses inside the cable bundle, and into the gun handle and neck. The coolant then returns to the radiator, where a baffling system releases the heat absorbed by the coolant. The ambient air and shielding gas further disperse the heat from the welding arc. 

Conversely, an air-cooled system relies solely on the ambient air and shielding gas to dissipate the heat that builds up along the length of the welding circuit. These systems, which range from 150 to 600 amps, use much thicker copper cabling than water-cooled systems. By comparison, water-cooled guns range from 300 to 600 amps.

Each system has its advantages and disadvantages. Water-cooled guns are more expensive upfront, and can require more maintenance and operational costs. However, water-cooled guns can be much lighter and more flexible than air-cooled guns, so they can provide productivity advantages by reducing operator fatigue. But because water-cooled guns require more equipment, they can also be impractical for applications that require portability. 

Heavy- versus light-duty

While a lower-amperage gun can be appropriate for some applications, be sure it offers the necessary welding capacity for the job. A light-duty MIG gun is often the best choice for applications that require short arc-on times, such as tacking parts or welding sheet metal. Light-duty guns typically provide 100 to 300 amps of capacity, and they tend to be smaller and weigh less than heavier-duty guns. Most light-duty MIG guns have small, compact handles as well, making them more comfortable for the welding operator.

Light-duty MIG guns offer standard features at a lower price. They use light- or standard-duty consumables (nozzles, contact tips and retaining heads), which have less mass and are less expensive than their heavy-duty counterparts.

The strain relief on light-duty guns is usually composed of a flexible rubber component and, in some cases, may be absent. As a result, care should be taken to prevent kinking that may impair wire feeding and gas flow. Also note, overworking a light-duty MIG gun can lead to premature failure, so this type of gun may not be appropriate for a facility that has multiple applications with various amperage needs. 

At the other end of the spectrum, heavy-duty MIG guns are the best choice for jobs that require long arc-on times or multiple passes on thick sections of material, including many applications found in heavy equipment manufacturing and other demanding welding jobs. These guns generally range from 400 to 600 amps and are available in air- and water-cooled models. They often have larger handles to accommodate the larger cables that are required to deliver these higher amperages. The guns frequently use heavy-duty front-end consumables that are capable of withstanding high amperages and longer arc-on times. The necks are often longer as well, to put more distance between the welding operator and the high heat output from the arc. 

Fume extraction guns

For some applications and welding operations, a fume extraction gun may be the best option. Industry standards from the Occupational Safety and Health Administration(OSHA) and other safety regulatory bodies that dictate allowable exposure limits of welding fumes and other particulates (including hexavalent chromium) have led many companies to make the investment. Similarly, companies that seek to optimize welding operator safety and attract new skilled welding operators to the field may want to consider these guns, as they can help create a more appealing work environment. Fume extraction guns are available in amperages typically ranging from 300 to 600 amps, as well as various cable styles and handle designs. As with all welding equipment, they have their advantages and limitations, best applications, maintenance requirements and more. One distinct advantage to fume extraction guns is that they remove the fumes at the source, minimizing the amount that enters the welding operator&#;s immediate breathing zone.

One distinct advantage to fume extraction guns is that they remove the fumes at the source, minimizing the amount that enters the welding operator&#;s immediate breathing zone.

Fume extraction guns can, in combination with many other variables in the welding operation &#; welding wire selection, specific transfer methods and welding processes, welding operator behavior and base material selection &#; help companies maintain compliance with safety regulations and create a cleaner, more comfortable welding environment.

These guns operate by capturing the fumes generated by the welding process right at the source, over and around the weld pool. Various manufacturers have proprietary means of constructing guns to conduct this action but, at a basic level, they all operate similarly: by mass flow or the movement of material. This movement occurs by way of a vacuum chamber that suctions the fumes through the handle of the gun and into the gun&#;s hose through to a port on the filtration system (sometimes informally referred to as a vacuum box).

Fume extraction guns are well-suited for applications that use solid, flux-cored or metal cored welding wire as well as those conducted in confined spaces. These include, but are not limited to, applications in the shipbuilding and heavy equipment manufacturing industries, as well as general manufacturing and fabrication. They are also ideal for welding on mild and carbon steel applications, and on stainless steel applications, as this material generates greater levels of hexavalent chromium. In addition, the guns work well on high amperage and high deposition rate applications.

Other considerations: Cables and handles

When it comes to cable selection, choosing the smallest, shortest and lightest cable capable of handling the amperage can offer greater flexibility, making it easier to maneuver the MIG gun and minimize clutter in the workspace. Manufacturers offer industrial cables ranging from 8 to 25 feet long. The longer the cable, the more chance it can get coiled around things in the weld cell or looped on the floor and possibly disrupt wire feeding. 

However, sometimes a longer cable is necessary if the part being welded is very large or if welding operators must move around corners or over fixtures to finish the task at hand. In these cases, where operators are moving back and forth between long and short distances, a steel mono coil cable might be the better choice. This type of cable doesn&#;t kink as easily as standard industrial cables and can provide smoother wire feeding. 

A MIG gun&#;s handle and neck design can impact how long an operator can weld without experiencing fatigue. Handle options include straight or curved, both of which come in vented styles; the choice often boils down to welding operator preference. 

A straight handle is the best choice for operators who prefer a trigger on top, since curved handles for the most part do not offer this option. With a straight handle, the operator can rotate the neck to place the trigger on top or on bottom. 

Conclusion

In the end, minimizing fatigue, reducing repetitive motion and decreasing overall physical stress are key factors that contribute to a safer, more comfortable and more productive environment. Choosing a MIG gun that offers the best comfort and operates at the coolest temperature allowed by the application can help improve arc-on time and productivity &#; and, ultimately, increase the profitability of the welding operation.

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