Mig welding relies on the heat of an electric arc to fuse metal. But, that heat has to go somewhere. It isn’t just contained to the weld pool, the Mig torch itself is impacted by radiant heat from the arc, as well as the resistive heating from the electrical current within it. If a welding torch is not cooled effectively, it will be difficult (or impossible) to reach the stated amperage rating without overheating, so it is clear that cooling plays a key role in the performance and efficiency of your torch. Plus, it also has a massive impact upon the comfort of the welder – even when using high-quality PPE, a hot welding torch can be decidedly uncomfortable.
Why does Cooling Matter so Much?
Damage to Torch and Consumables
High temperatures can damage the torch body, insulation and shorten the lifespan of consumables.
Weld Quality Issues
Excessive heat can negatively impact arc stability, leading to inconsistent and low quality welds.
Safety
An overheated torch is at best uncomfortable for the welder, and at worst could cause burns.
Downtime
Replacing damaged components and dealing with issues caused by overheating waste time and reduce productivity.
Air-Cooling – A Simple Solution
For lighter-duty applications or occasional use, Air-Cooled Mig torches offer a simple and cost-effective solution. Air-Cooled Mig torches rely on the heat transfer properties of the torch to dissipate the heat away from critical components. Various factors can affect how much heat the torch can handle.
Liquid-Cooling for Heavy Duty Welding
For continuous high-amperage welding applications, Liquid-Cooled Mig torches are the ideal choice. Coolant circulates around the torch head and cable, absorbing heat and preventing the torch from overheating.
This offers significant advantages – the torch can handle extended welding periods at higher amperages, and consistent cooling helps maintain a stable arc and therefore better weld quality.
Cooler operating temperatures reduce wear and tear on consumables leading to longer lifespans.
Designs to Manage Heat
Materials used in manufacture can vary in their ability to conduct heat. Components such as the torch head and cables play a key role in heat dissipation. Arc Torchology manufacture these components utilising high conductivity copper or copper alloys, which readily absorb heat, transferring it away from critical areas like the contact tip and liner, helping to maintain optimum conditions. Tip adaptors are another key heat sink, and are manufactured from the same high conductivity copper or copper alloys to effectively transfer heat away.
Arc Torchology also incorporate a number of innovative features to further manage heat:
Swan necks have over moulded body armour for improved insulation, minimising conducted heat as well as protecting the torch from impact.
Handles employ our Air Gap Technology, which isolates conducted heat as well as utilising air pockets to isolate radiated heat, resulting in cooler running handles for improved operator comfort.
Keeping it Cool: Best Practices
Regardless of the cooling method, proper maintenance is crucial:
Air-Cooled
Regularly clean the torch exterior to remove any build up and ensure this does not interfere with proper heat dissipation.
Liquid-Cooled
Maintain proper coolant levels and monitor for leaks. Use the correct coolant mix and replace it periodically as recommended.
By understanding the importance of cooling and choosing the right method for your application, you can ensure your Mig torch operates efficiently, delivers high-quality welds, and lasts for years to come.
