Mig Welder Maintenance – A Practical Welding Maintenance Guide 2017

Introduction for Mig Welder Maintenance:

Proper MIG welder maintenance can substantially extend the service life of the equipment and go a long way to reducing the cost of rework or replacement. On this note, proper maintenance of welding equipment is essential to its efficiency and lifespan.

Below are some recommended tips for most brands of MIG welding machines. However, you must ensure that you adhere to the manufacturer’s safety precautions at all times, as this is the first step towards proper maintenance.

User Level maintenance of Mig welder:

  • Keep Covered: One of the most important steps for maintaining an MIG welder is to keep it covered when not in use. One good way to ensure its safety is to use protective shield such as canvas cover to store the machine. Also, you should ensure that the shielding gas is covered properly.
Mig welder maintenance
  • Equipment Cleaning: The equipment should also be cleaned periodically for best results. Ensure that you remove all dust, dirt or debris from the machine or its accessories. Dust and dirt may cause the machine to malfunction and may also lead to weld bead problems. Poor maintenance can also lead to wear of equipment parts, which may lead to repair or replacement. On this note, it is vital that you clean all machine parts regularly.
  • Electrical Components: The electrical components of the MIG welding machine must be in check. Ensure that you are using the appropriate fuse and the voltage has been set accordingly, as recommended by the manufacturer. You should also check that the amperage is set correctly too. Also, ensure that there are no circuit problems for the machine to work properly.
  • Drive rolls should be clean & settled properly: The drive rolls on the welding machine should be cleaned properly to avoid troubleshooting or damaged liners and faulty wire delivery. Ensure that the drive roll tension is adjusted such that it is neither too tight nor too loose, as these situations may pose serious problems for the weld. When the drive rolls have worn-out, they should be replaced.

Follow More Things:

  • Drive roll pressure too high: When the drive roll pressure is too high, it can crush the wire. To avoid this problem, before feeding the wire through the hose assembly, blow out the liner using an air nozzle from the torch end and feeder end. This will help clear out debris in the liner.
  • Gun nozzle should be cleaned: The gun nozzle should also be cleaned regularly. The tip is the most replaced part of the machine because it receives more pressure from the heat and spatters. The gun nozzle often becomes filled with spatter during the weld. Ensure that you keep the nozzle clean in order to avoid inhibiting the gas flow or preventing the ability to weld.
  • Be care about Gas Lines: The gas lines should also be checked and any form of obstruction should be cleared out. Inadequate gas flow may lead to porosity issues in the weld. Another maintenance tip is to make sure that the gas nozzle is plugged in correctly to avoid leakage.
welding maintenance
  • Feeder Connection: The feeder connection should be checked and a defect in the feeder connection may occur when the drive rolls are worn out. In such cases, the drive rolls should be replaced immediately. Also, a loose or dirty wire connection may cause electrical resistance and build-up of heat which may lead to premature equipment failure. Ensure that you check the connection on a regular basis to avoid these problems.

Keep These Steps in Mind:

  • Don’t Be Undercut: undercutting may be as a result of excessive and poor welding conditions. It can be avoided or rectified by reducing the welding current and voltage and also, improving the welding technique.
  • Handle and Trigger: The handle and trigger on the welding machine should be maintained periodically. Just like other, parts, they should not be neglected, but instead cleaned and freed from dust and debris. A damaged handle may cause electrical shock if there is any exposed cable. Also, a defective trigger can cause several welding problems and as such should be avoided.
  • Neck: The neck is responsible for transferring electrical current from the cable to the consumables. If there is a loose connection on either end, it may lead to poor electrical conductivity and give rise to welding defects. On this note, the neck connections should be tightened on a daily basis.
  • Keep Track of the Heat: Loose connections or inappropriate duty cycles can lead to the electrode holder heating up. It is crucial that you keep track of heat during the welding process. Also, if the cable heats up really fast, it could be an error in the cable size and hence, should be corrected immediately. Excess or inadequate heat will lead to weld problems.
  • All about Wire: The wire or cable may get worn out especially after prolonged use. Ensure that you replace then when it is due. Damaged cables may lead to severe welding problems and may also affect the quality of your work.

A Few Last Steps:

  • Worn spring liner: If the spring liner is worn out, they should be replaced immediately. Also, you should occasionally remove and inspect the liner. If there is any kink, it may cause feeding problems. You should blow out the liner guide and reinstall it. This process will extend the service life before you eventually replace it.
  • Cleaning of Diffuser screw: The diffuser screw should be cleaned on a regular basis. A build-up of debris or rust may lead to weld problems. This can be avoided by periodically cleaning the diffuser screw.
  • The Tip should be kept out of problems: The tip is the most commonly replaced part of the machine. This is because it is at the end of the torch and receives excess heat and spatter. If the tip is worn out, it should be replaced immediately.
  • Check your "earth in" proper or not: Finally, check your ground. A bad ground can cause the wire to malfunction as though it needs speed or voltage adjustments. A bad ground can also destroy your tip with spatter. On this note, you should periodically check the ground at the power source, work clamp, and wire feeder.

Final Thoughts: 

Every operator should strictly follow the above mentioned points. So that his valuable Mig welder will be in good condition to work smoothly. Take a look again to the Mig welder maintenance procedure and make your welding job easier. Happy welding.

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