5 Common Welding Gun Issues and How You Can Solve Them

Date Posted:6 February 2023

Welding guns are used to join two or more pieces of metal together. When a welding gun fails, the connection between the metals being joined can be compromised, leading to poor welds, or even complete failure. Understanding the common causes of welding gun failure can help metalworkers prevent and manage such issues.

Welding gun failure can occur due to a variety of factors. Here are some common issues with welding guns.

1) Improper Set Up

To ensure that your welding gun is set up properly, it is important to read the owner's manual and follow the instructions.

It is also important to make sure that the gun is positioned correctly and that the right voltage and amperage settings are used. Doing so will help ensure that your welds are consistent and reliable.
This occurs when the connection between the gun and the power supply is not securely tightened. This can cause the welding arc to be unstable and lead to poor welds.

2) Loosely Secured Connections

To solve this issue, make sure that all the connections between the welding gun and the power supply are tightened securely. Additionally, be sure to check the connections regularly to make sure that they remain secure.

3) Broken or Damaged Power Cable

A broken or damaged power cable is one of the most common welding gun issues. If the power cable is damaged, it is not able to transfer electricity from the power source to the welding gun, which can cause the welding gun to not work.

Make sure the power cable should be replaced with a new one, as any damage to the power cable can be dangerous. Additionally, it is important to ensure that the power cable is not exposed to extreme heat or any other hazardous environment to prevent future damage.

4) Poor Manufacturing Environment

The poor manufacturing environment is a more common welding gun issue than you think. It can be caused by inadequate ventilation, inadequate lighting, and contaminated air.

A poor manufacturing environment can result in welding guns that are not properly maintained and can lead to a decrease in the quality of the welds.

Keep the manufacturing environment adequately ventilated, lit, and free from dust, debris, and other contaminants. Additionally, regular maintenance and inspections of the welding guns should be conducted to ensure that they are in good working condition.

5) Exceeded Gun Rating

Exceeded gun rating is a common issue among welding guns. This issue occurs when a welding gun is used beyond its rated capacity. This can lead to a variety of problems such as wire sticking, welding arc instability, and even wire melting.

Select the correct gun rating for the job, and use the gun within its rated capacity. By doing this, you can help ensure that your welding gun is functioning correctly and safely.

Conclusion

Exceeded gun rating is an issue that should be taken seriously by welders. To prevent this from happening, it is important to select the correct gun rating for the job and to use the gun within its rated capacity. Doing this can help ensure that your welding gun is functioning correctly and safely.

For sturdy and reliable welding guns, National Welding and Industrial Supplies has everything you need. We provide welding parts and equipment for any project. Take a look at our extensive catalogue to try it for yourself

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