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Home / How to Increase Productivity in High Arc-On Time, High Duty Cycle Jobs

How to Increase Productivity in High Arc-On Time, High Duty Cycle Jobs

The Tweco Fusion Pro 450 water-cooled MIG gun and VELOCITY2 series of MIG consumables from ESAB improve welding productivity in medium- to heavy-duty applications.

For high arc-on time in high duty cycle spray transfer, pulsed MIG and Flux-Cored welding with .035 in to 1/16 in diameter wires in medium- to heavy-duty industrial fabrication, maintenance and repair applications, the Tweco Fusion Pro 450 water-cooled MIG gun from ESAB has an ergonomic handle, soft-grip areas and a ball-and-socket connection between the handle and cable to reduce strain and make it easier to manipulate the gun.
For Spray Master and Tweco Classic Number Series MIG guns, the heavy-duty nozzle in Tweco VELOCITY2 MIG consumables from ESAB has a nozzle insert “keyed” into place and over-molded with a high-temperature silicone compound. A copper shell crimped over the insert creates the final nozzle. The conductor tube is produced from a single piece of copper with machined threads to securely hold the contact tip and nozzle in place. An O-ring prevents gas leakage if downstream obstruction occurs. A silicone sleeve over the copper tube minimizes radiant heat and improves impact resistance.
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The Tweco® Fusion Pro 450 from ESAB Welding & Cutting Products (Denton, TX) is a water-cooled MIG gun designed for running wires from .035 in to 1/16 in diameter in medium- to heavy-duty industrial fabrication, maintenance and repair applications. Using mixed gas, the Fusion Pro 450 is rated at 450 amps at 100 percent duty cycle; with CO2 shielding gas, it is rated at 500 amps at 100 percent duty cycle. “This robust gun offers an ergonomic and well-balanced handle with rubber soft areas and a ball-and-socket connection with spring support between the handle and the cable to reduce strain and make it easier for the operator to manipulate the gun,” said Jeff Henderson, the global business manager for torches at ESAB. “Both features are new to the Tweco line. Coupled with its high heat dissipation capabilities, the Fusion Pro 450 enhances operator comfort in high arc-on time, high duty cycle applications, such as spray transfer, pulsed MIG and Flux-Cored welding with larger wires.”

The Fusion Pro 450 uses easy-to-service front-end consumables, similar to those found on the Supra 450 water-cooled MIG gun, but it also features an insulated torch neck and slip-on nozzle that makes the torch more comfortable to handle. Guns come with 10 ft or 15 ft cables and are available with standard Tweco back-end connections, Euro-style connections or connects for other leading wire feeder brands. For higher amperage needs or running 3/32 in diameter wires, a Standard 600 amp water-cooled MIG gun is available that has a 100 percent duty cycle at 600 amps with CO2 shielding gas.

ESAB also offer the Tweco VELOCITY2™ series of MIG consumables for the Spray Master™ and Tweco Classic Number Series MIG guns. The heavy-duty nozzle uses a nozzle insert that is “keyed” into place and over-molded with a high-temperature silicone compound, essentially producing a single part from two pieces; a copper shell crimped over the insert creates the final nozzle. The conductor tube has three enhancements, starting with producing it from a single piece of copper with machined threads to securely hold the contact tip and nozzle in place. An O-ring prevents gas leakage in the event of a downstream obstruction, while adding a silicone sleeve over the copper tube minimizes radiant heat and improves impact resistance. “These enhancements deliver unmatched performance through a more robust design, providing less downtime and more weld time,” noted Henderson. “These consumables directly address heat-related issues by reducing consumable count, improving thermal conductivity and lowering operating temperature. As a result, they stay cooler, last longer, produce a more stable weld puddle and improve overall productivity.”

VELOCITY2 consumables feature threadless, “drop-in” style contact tips and integrate the contact tip seating area directly into the conductor tube. With medium- and heavy-duty consumables, the shielding gas flows from the conductor tube through four ports machined into the base of the contact tip. This simplified design eliminates the gas diffuser and enables the shielding gas to keep the tip up to 40 percent cooler. By running cooler, these consumables improve parts life by up to 500 percent or more in gas shielded Flux-Cored, spray transfer and pulsed spray transfer applications. In short circuit MIG applications, they typically last 2X to 3X longer than conventional consumables. A cooler tip also reduces the ability for spatter to stick. The tip needs less cleaning, and any spatter that adheres is easier to remove. Further, spatter generally collects on one part, the nozzle, as opposed to three parts on conventional MIG front ends. “The drop-in style tip also eliminates the hassle associated with burn backs. There’s no need to use vice-grips or welpers when the electrode fuses inside the tip,” added Henderson.

ESAB Welding & Cutting Products, 2800 Airport Road, Denton, TX 76207, 800-372-2123, www.esabna.com.

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