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Welding Products   Contact Tips

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

Silver Alloy TipOEM 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.

Power Tip welding tipsIn 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

Outside Diameter 6 - 10mm
Bore Diameter 0.7 - 3mm
Tolerance for OD and bore +/-0.05mm

 

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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.

Bernard® Style   contact tips
Bernard® Style Tips

Binzel®  style contact tips
Binzel®
Style  Tips

Tregaskiss® Style   contact tips
Tregaskiss®
Style Tips

Tweco® Style   contact tips
Tweco® Style
Tips

OTC® Style contact tips
OTC® Style Tips

Panasonic® Style   Mig Tips
Panasonic®
/Tokin® Style

See the Proof in Actual Trials

Power Tips are backed by documented proof that they will reduce consumption and save  you money. See details of the studies here:

Tip Trials 1 & 2

Tip Trials 3 & 4
Tip Trials 5 & 6

Wire Liner Trial

Diffuser Trial  
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Many self proclaimed ORIGINAL manufacturers contract out a large percentage of their consumable manufacturing needs and just charge a higher price for their logo and packaging.  Some even go as far to make statements that the warranty is not valid if their Original brand consumables are not used. The WISE purchaser knows that these statements are false and misleading and are contravening to the MAGNUSON MOSS act in the USA and against the COMPETITION ACT in Canada.
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We
Manufacture:

All of our welding tips are made from the highest quality ISO Extruded Tubing.

Schedule Your
FREE Trial

in North America

Superior Consumables product is backed by proven, documented test results.

Alloy  Choice Guide
Which Alloy is right for your welding application?
Click here

 

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MSDS Sheets

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Copper Alloy
Designation
Composition% Softening
Temperature
Electrical Conductivity
%IACS
Hardness
HV
Thermal Conductivity Electrical Resistance USA
UNS
Chromium Zirconium Cu min 99+
Cr.65 Zr.08
500°C

75

170 335 23 CrZr
Phosphorous Deoxidized Cu min 99.9
P 0.015-.040
300°C

85

115 335 20 DHP C12200
Silver Alloy Cu 99
Ag 0.8-1.2
400°C 98 125 395 17

CuAg

 
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Bernard®, Binzel®, Tokin ®, OTC®, Panasonic®, Tregaskiss®, Tough Lock®, Tweco® and Uhrhan & Schwill® are all Registered Trademarks of their respective holders. All reference to these trademarks or relevant product numbers is for reference only. Superior Consumables is in no way associated with any of these welding products companies.