Welding Products   Contact Tips

American Weldquip - Binzel - Bernard - Panasonic - Tregaskiss - Tweco

OEM Style Mig Tips in Regular, Zirconium and our own Power Tip

The same high performance, material and manufacturing process as is used for all original equipment contact tips

In Superior Consumable's manufacturing process, during the final drawing through the die, the inside surface of the wall is formed against a mandrel. Since the mandrel determines the size and shape of the bore, exceptionally tight diameter and roundness tolerances as well as a smooth extruded surface finish of the bore can be guaranteed.

Bore accuracy offers several advantages. To the manufacturer of contact tips, it means lower cost as the calibration of the bore is not required. To the welder, it means a smoother running operation and longer tip life.

In some instances C122 DHP or CrZr is an adequate choice. With alloying we can increase several key characteristics creating a Superior Consumable with increased conductivity, even higher softening temperature and improved hardness. This means a reduction in "arc start failures" and increased tip life.

Typical Size Range & Tolerances

Welding Tip Alloy Comparison

• Standard DHP (Regular Copper) – world wide standard excellent general purpose.
• CrZr – (Cr-Chromium Zr-Zirconium) a very hard alloy, has been around for years made for stainless steel and stiff, high column strength or abrasive wires such as Flux cored / Metal cored.
• CuAg (Cu-copper AG-Silver) developed by us with an OEM manufacturer in Japan 1999 specifically for a "sure start" on Robotic or Automated welding of smooth soft wires like mild steel, aluminum and some cored wires

There are 2 main reasons a welding tip wears

1. Common physical wear or abrasion, if you were to place a tip on the wire before the feeder with NO electrical contact, that tip would eventually wear completely through.

2. Electrical erosion is similar to the brushes on an electrical motor or the spark jumping across the gap on a spark plug. As the wire is traveling through the Contact tip at say 300 IPM the electricity has to jump across from the copper tip to the Mig wire. (Hence the name “Contact Tip”) The inside bore of the tip / wire is in constant electrical arcing as this process is happening. Electrical erosion is melting of the welding tip ID.

If you are attempting to get a “sure start” you need to choose the best alloy whether for electrical or physical wear. The next reason a tip wears is to do with heat. As the tip heats from the welding process the properties of the alloys start to break down.

The ability of the tip to dissipate the heat (thermal conductivity) will aid in keeping the tip cooler. The (electrical resistance) of the alloy is also in direct inverse proportion to the electrical conductivity.

As we need a “sure start” and are attempting to jump the gap from the contact tip to wire these two factors play a critical role, if the tip has higher conductivity of electricity it will transfer the current easier (or with less resistance) which will also cause the tip to run cooler.

Resistance equals heat. The additional benefit to higher conductivity is that the arc transfer from the tip to the wire is easier.

Easier arc transfer means a superior “sure start” and less arc failure or wire BURN BACK, sputtering and spatter.

Binzel®
Style  Tips

Tregaskiss®
Style Tips

Tweco® Style
Tips

OTC® Style Tips

Panasonic® /Tokin® Style

Better welding tips make better welds

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