The key component in any welding operation is the welding gun nozzle and having the correct nozzle can help to reduce defects in the weld, reworking and the downtime due to this and also helps to increase consumable life. However, often selecting the proper type of nozzle is overlooked and this can impact the productivity, quality and the total cost of the operation significantly. Handling and storing the nozzles correctly can help to improve the overall performance and here are some useful tips that will give you best results.
Choosing the Correct Nozzle Shape
There are many different shapes of nozzles that are available such as bottleneck, long and short taper and straight nozzles. Straight nozzles have a larger inner diameter and do not offer good joint access and if joint access is a very important factor, then a bottleneck nozzle is a better alternative and is better for automatic welding jobs. Long and short taper nozzles also have good joint access; however, the inner diameter of long taper nozzles is smaller and accumulate spatter more easily and making use of a short taper nozzle can help to prevent this issue.
While selecting the nozzle, ensure to choose the one which provides the best joint access for the job and allows good gas flow to prevent any contaminants. The best option is to use the largest nozzle which allows the best access to the joint as this ensures the best flow of the shielding gas. Also, large-sized nozzles do not accumulate as much spatter as nozzles with smaller inner diameters.
Choosing the Best Material
There are different types of nozzles – standard or heavy-duty and thread-on or slip-on varieties.
Heavy-Duty vs Standard Nozzles
The walls of heavy-duty nozzles are not only thicker, they also have thicker insulators and can be used in jobs ranging between 400-600 amps and since they have a heavier construction, they have a better heat resistance compared to standard nozzles. The walls of standard nozzles are thinner and these nozzles are suitable for 100-300-amp jobs.
Slip-On vs Thread-On Nozzles
Slip-on nozzles can be simply slipped onto the front of the welding gun and these are more commonly used as against thread-on varieties that require to be twisted on for installation and can be changed more easily and quickly. When using slip-on nozzles, you must ensure that the nozzle is seated properly on the head to stop the shielding gas from leaking that can lead to a poor-quality weld.
Typically, welding nozzles that are used are made of copper or brass, although sometimes, you can also use a chrome-plated nozzle. Brass nozzles are suitable for low amperage jobs (100-300 amps) and they also resist spatter better, while for jobs involving high-amperage (above 300 amps), copper nozzles are best or for jobs with longer arc-on times. There are nozzles which circulate the coolant around the torch nozzles which are suitable for high-amperage and water-cooled welding jobs; however, these are more expensive.
Proper Nozzle Handling, Maintenance and Storage
The welding nozzles must be handled, maintained and stored properly so that you get consistent welding results and to avert premature failure of the welding torch. Making use of high-quality nozzles can prolong the consumables life. Select nozzles that have smooth edges and surface finish as they help to prevent spatter build-up. Choose nozzles that are heavier as they are better than thinner or lighter ones when it comes to heat resistance. Look for nozzles that contain a brass insert as this aids the nozzle to maintain the inner diameter and prevents the nozzle from premature wear. A fibreglass insulator enables to extend the nozzle life. And finally, a nozzle with heavy-duty crimping is long-lasting as the crimping helps to hold the various layers together.
Always store the nozzles in their packaging, as storing them in a bin causes dents and scratches that cause the spatter to stick to the nozzle thereby reducing the nozzle life. Also, while replacing the nozzle or handling it, it is a good idea to wear gloves to prevent oil, dirt and other contaminants from sticking to the nozzle.
Inspect the torch nozzle regularly for build-up of spatter and clean any spatter using the tools that are recommended by the producer and also make use of an anti-spatter compound to shield the nozzle from spatter build-up.
The nozzle plays an extremely vital role in producing a high-quality weld and can significantly impact the operating cost and productivity also. It is a good idea to take time and select the correct type of nozzle for the particular application. Selecting and maintaining the nozzles carefully can help to keep your operation running smoothly and minimise downtime.