Bernard Article Library


Find out how to make the best MIG gun and consumable selection, important troubleshooting and maintenance techniques, and more from our informative articles.

 

General Welding Tips and Advice Articles

From troubleshooting weld defects to avoiding mistakes in the welding operation, learn best practices from our experts.
 


Preventing Common Causes of Poor Wire Feeding...And Their Impact on the Welding Operation

In welding, poor wire feeding is a common challenge — one that can be extremely costly for an operation and take a toll on productivity. From the downtime for troubleshooting to faster wear and replacement of consumables, wire feeding issues such as bird-nesting, burnback and liner clogging can have a significant impact on the bottom line. Read more.


7 Tips for Improving MIG Welding

Want to improve your MIG welding? By following these seven tips, you can take your MIG welding operation to the next level and ensure you are as safe, efficient and professional as any other shop. Read more.


 

What You Should Know About Shielding Gas

Consistent productivity, high quality and low costs are all key components in a successful welding operation. Gaining these advantages depends on everything from the equipment and filler metals to the skill of the welding operators and the techniques being used in the process. Read more.


Top 10 Things to Teach Novice Welders

Learning to weld is no easy task. It takes patience, practice and a solid foundation of knowledge. For companies who find themselves faced with the challenges of training novice welders, it is important to instill good habits early on in the training process. Read more.


Ways To Stay Cool When Welding In The Hot Summer Heat

It's tough enough to stay cool in the hot summer months, let alone when you are "under the hood" welding. Unfortunately, that heat can take a toll on your body, mind and performance. Read more.


Top 10 Mistakes in Running a Welding Operation ... and Simple Ways to Solve Them

With so many factors to monitor — equipment, weld procedures, filler metals and consumables — it's inevitable that mistakes will occur in most welding operations on any given day. Human error dictates that a welding operator can easily set a power source and wire feeder to the wrong parameters or trim and install a MIG gun liner improperly. Read more.


The Cause of GMAW Flaws ... and the Cures to Help Welding Operators Get Back to Work Faster

Weld flaws come in all shapes, sizes and degrees of severity. Yet one thing holds true regardless of the application or material on which they occur: They are a common, and costly, cause of downtime and lost productivity. Read more.


MIG Welding Shielding Gas Basics

MIG (GMAW) welding with shielding gas and a solid wire electrode produces a clean, slag-free weld without the need to continually stop welding to replace the electrode, as in Stick welding. Increased productivity and reduced clean up are just two of the benefits possible with this process. Read more.


The Basics: MIG Troubleshooting

Like any welding process, MIG welding has its complications. Even so, there is no reason to let common problems slow you down. With a bit of knowledge and some troubleshooting skills, you can easily find the right solution to get you back to welding — sooner than later. Read more.


Is Poor Conductivity Impeding Your Welding Performance?

Most people understand that the electrical circuit is at the heart of the welding operation. What you might not be aware of, however, is how easy it is for disruptions in this circuit to interfere with productivity, weld quality and equipment service life. Read more.


Good GMAW Welds Start with Good, Well-Maintained Equipment

It might at times seem like alchemy, but in fact there is nothing mysterious or magical about making a good GMAW weld. A good weld is the result of properly functioning equipment, good technique and the correct equipment settings for the application at hand. Read more.


A Guide to Troubleshooting Common GMAW Gun and Consumable Problems

Making a high-quality MIG weld is no easy task. But making a high-quality MIG weld when your gun and consumables aren't functioning properly is just about impossible. Read more.


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MIG Gun Articles

Having the right MIG gun can help increase productivity, reduce costs and improve quality. Learn tips for selecting and maintaining your MIG gun and other helpful advice.
 


Tips for Maximizing Welding Operator Comfort and Productivity

Being as comfortable as possible contributes to welding operator safety and productivity — and it's a factor that can impact the quality of the finished weld. There are numerous issues that play a role in welding operator comfort, including the heat generated by the welding process, the repetitive motions and, at times, cumbersome equipment. Read more.


 

Understanding Gun Ratings: What You Need to Know to Select Your MIG Gun

When it comes to welding, too much of a good thing can often add up to unnecessary costs, potential downtime and lost productivity — expecially if you have too large of a MIG gun for your application. Unfortunately, many people believe a common misconception: that you need a MIG gun rated to the highest amperage you expect to weld. Read more.


Customizing Your GMAW Gun for the Job

The heat and repetitive motions that accompany gas metal arc welding (GMAW) can take their toll. Customizing your GMAW gun to match your application, however, can make a big difference in improving your comfort, and gaining the best welding performance. Read more.


Common Causes and Solutions to GMAW Gun Overheating

When choosing a gas metal arc welding (GMAW) gun, there are several factors to consider. After all, welding is simply the result of one large electrical circuit — and the gun reflects that. Read more.


Preventive Maintenance Helps Optimize MIG Gun Performance

Planned downtime for preventive maintenance in the welding operation is not time wasted. Rather, it is a crucial part of keeping production flowing smoothly and avoiding unplanned downtime. Read more.


Criteria for Selecting a MIG Gun

MIG welding is considered among the easiest welding processes to learn and is useful for a variety of applications and industries. Since the welding wire constantly feeds through the MIG gun during the process, it doesn't require frequent stopping, as with stick welding. Read more.


Proper Storage of MIG Guns and Consumables

As with any piece of equipment in the shop or on the jobsite, proper storage and care of MIG guns and welding consumables are important. These may seem like rather insignificant components at first, but they can have a big impact on productivity, costs, weld quality and even safety. Read more.


What's Changing? Trends in Semi-Automatic MIG Guns

There are many considerations that factor into a company's ability to achieve the best quality and highest productivity in the welding operation. Everything from selecting the right power source and welding process to the organization of the weld cell and workflow play a role in that success. Read more.


Which is the Right MIG Gun? Tips for Making the Selection

When it comes to welding, no two applications are alike. Just as it's important to select a power source that is right for the job, it is also essential to select a MIG gun that will deliver the appropriate amperage and cooling capabilities. Read more.


Money-Saving Tips for MIG Guns

Equipment repairs are a fact of life on most jobsites, so finding ways to reduce costs and downtime while making them is important for overall efficiency and productivity — and the bottom line. Read more.


Tips for Making a MIG Gun Last on the Jobsite

Outdoor jobsites — and even some shops — can be harsh environments for welding equipment, including guns and consumables. When it comes to MIG or flux-cored (FCAW) welding on the jobsite, selecting the right gun for the application, and following some basic maintenance and preparation tips can help make guns and consumables last longer. Read more.


Selecting the Right Gun for MIG Welding Is Key to Achieving the Best Results

The MIG welding process offers many benefits for various applications and industries, including fabrication, manufacturing and general maintenance. It's one of the easiest welding processes to learn and offers good control on thin metals. Read more.


Gain Comfort, Productivity with the Right Welding Equipment

Taking into account the heat, the repetitive motions and the sometimes cumbersome equipment, gas metal arc welding (GMAW) can sometimes take a toll on welding operators in the form of aches, fatigue, and physical and mental stress. But there are tools and accessories that promote a more comfortable environment and minimize downtime. Read more.


Premier Boat Fabricator Improves Productivity 25 Percent with New MIG Guns and Consumables

When 90 percent of your business focuses on boat fabrication and repairs that require you to meet specific deadlines and codes, having the right welding equipment to manage the job isn't just ideal, it's essential. Read more.


Attacking Weld Fume at the Source: Ways to Get the Most from a Fume Extraction Gun

Providing welding operators with proper ventilation during the welding process is an important step companies can take to help meet health and safety standards — and to help provide a safe and comfortable work environment. Read more.


Emergency Vehicle Service Provider Gains Versatility, Comfort and More from New Welding MIG Guns

When your company is responsible for rebuilding, repairing and up-fitting vehicles that deploy to firefighting and rescue stations day in and day out, quality is non-negotiable. Every component must be precisely tooled, every weld precisely placed. Read more.


10 Money Saving Tips for Your Semi-Automatic MIG Gun

Your welding operation, just like any other portion of your business, offers opportunities to conserve resources. Consider these 10 money-saving tips for MIG gun care and maintenance as a good first step. Read more.


Fume Extraction Guns: Understanding the Basics

New industry standards, and an increased desire to maintain optimal welding operator safety and to attract new skilled welding operators to the field is also a consideration, has led many companies to invest in fume extraction equipment. Read more.


The Value of Comfort: Gaining Productivity with the Right MIG Gun

The term "ergonomics" has become increasingly common in the workplace as companies strive to improve safety and efficiency among employees — whether in the office or on the plant floor. At its most basic level, ergonomics refers to the discipline or science of designing equipment and arranging the work environment for optimal worker comfort and prodcutivity. Read more.


GMAW Guns, Consumables and More: Common Questions Answered

Gas metal arc welding (GMAW) involves more than just arc-on time. Welding operators also need to be mindful of other activities that contribute to the overall productivity and quality in the welding operation, including proper joint preparation, following correct weld parameters and ensuring good part fit-up. Read more.


Three Ways Welding Guns and Consumables Can Improve Productivity

From the power source to the welding wire, each of the components in an arc welding operation can have a significant impact on productivity. The welding gun and consumables — nozzles, contact tips and diffusers — in particular, are often an overlooked aspect of the whole process, but these components directly affect quality, welder comfort, rework, downtime and more. Read more.


Maintaining Your MIG Gun ... and Your Welding Costs

Selecting the right MIG gun for your welding application, and maintaining it properly, is just as important to your overall productivity as any other part of the welding operation. Read more.


Finding a MIG Gun That Fits: Stay Cool and Comfortable While Welding

A welding operator typically spends much less than 50 percent of an eight-hour day engaged specifically in the act of welding, with the remaining portion allocated to joint preparation, part fit-up and movement, and other activities that contribute to the throughput of the welding operation. Read more.


MIG Gun Mythbusting: Separating Fact from Fiction

Much of the reason MIG guns and consumables do not receive their fair share of attention within the equipment selection process arises from common misconceptions about their importance in the welding operation. Read more.


Air vs. Water- Which is Right for You?

For some companies, choosing between and air-cooled or a water-cooled MIG welding system is pretty cut and dry. Mobile fabrication and repair companies that weld sheet metal for only a few minutes every hour will have little need for the benefits provided by a water-cooled system. Read more.


Strong Bond and Strong Community at San Diego Continuing Education

Now in its 35th year, San Diego Continuing Education's welding program focuses on adult eduction for unemployed and underemployed San Diego-area residents. Its curriculum is narrowly tailored to the needs of local industries — specifically shipbuilding, construction and manufacturing. Read more.


Maintain Your MIG Gun

Time spent maintaining a MIG gun can be considered downtime, but that doesn't mean it is time wasted. Proper gun maintenance can substantially extend the service life of the equipment and reduce the even greater cost of weld rework. Read more.


Miller Welding and Machine Turns to Bernard for MIG Guns and Consumables

Rapid growth is a probelm many companies would love to have. Those that experience it, however, must properly manage that growth in order to maintain profitability and avoid the potential pitfalls of taking on more work than they are equipped to handle. Read more.


Which Semi-Automatic MIG Gun is Right for the Job?

When it comes to choosing welding equipment, welding operators may find themselves first and foremost contemplating which power source they use. And rightly so. But having the right semi-automatic MIG gun for the job is equally important. Read more.


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Flux-Cored Welding Articles

Flux-cored welding is a good alternative to MIG welding for many applications. Find out if the process is right for you and ways to optimize it.
 


Best Practices for Success in Self-Shielded Flux-Cored Welding

Self-shielded flux-cored welding (FCAW-S) offers numerous benefits, including good weldability, high deposition rates, and excellent checmical and mechanical properties. These make the process a common choice for many applications, such as structural steel erection, bridge construction and heavy equipment repair. Read more.

 


Heavy Structural Welding Simplified with Low-Speed Diesel Welder/Generators, Low-Hydrogen Flux-Cored Wire, Flux-Cored Guns and New Wire Feeding Technology

The primary benefit of a flux-cored wire over a stick electrode is that it is continuously fed, whereas a stick electrode requires the worker to continuously start and stop to replace electrodes. This improves productivity and minimizes the possibility of defects caused by more frequent starts and stops. Read more.


Your FAQs About FCAW-SS Problems Answered

For structural steel applications, bridge construction and heavy equipment repair, self-shielded flux-cored welding (FCAW-SS) has become a standard and reliable process due to its ability to provide high-deposition rates with good weld quality. Read more.


Tips For Avoiding Common Flux-Cored Problems & Improving Your FCAW Welds

Self-shielded Flux-Cored Arc Welding (FCAW) offers high deposition rates, excellent chemical and mechanical properties, and the weldability required for structural steel erection, heavy equipment repair, bridge construction and other similar applications. Still, it doesn't mean that the process is without its challenges. Read more.


Jolson Welding Improves Productivity with New MIG, FCAW Equipment

From welding piles and water lines to beams, heavy wall underground pipe and bridges, owner Bob Jolson and his team of contractors tackle some of the toughest jobs on the West Coast. And they do it quickly, thanks to some recent changes to their welding equipment and consumables. Read more.


Handrails in Hell: Hot Az Hell Welding and Fabrication Puts Dura-Flux™ Guns to the Test

Hot Az Hell Welding and Fabrication learned first hand the value of a welding gun when they began upgrading the majority of their equipment from Stick to the flux-cored process. Read more.


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Consumables Articles

From the nozzle to the MIG gun liner, consumables make a difference in your welding performance. Find out ways to make the most of yours.
 


Correct Contact Tip Recess Can Improve Welding Efficiency, Reduce Downtime

In many cases, MIG gun consumables may be an afterthought in the welding process, as concerns with equipment, workflow, part design and more dominate the attention of welding operators, supervisors and others involved in the operation. Yet, these components — particularly contact tips — can have a significant impact on welding performance. Read more.


Selecting the Right Size Contact Tip

While only one part of a much larger system, the contact tip in both robotic and semi-automatic welding MIG guns plays a critical role in providing sound weld quality. Read more.


Tips for Contact Tips

Selecting equipment to provide the highest quality and productivity in a welding operation goes beyond just the power source or welding gun — consumables play an important role, as well. Read more.


Understanding and Extending Contact Tip Life

While only a small part of a larger system, contact tips play a critical part in achieving high quality welding performance. The primary function of this consumable is to transfer the welding current to the welding wire as it passes through the center bore, effectively creating the arc. Read more.


Tips for Proper Liner Installation to Help Optimize MIG Gun Performance

MIG gun consumables are often one of the most overlooked portions of the welding operation. However, choosing the right consumables, and using and maintaining them properly, can make a significant difference in gun performance and weld quality. Read more.


Quality of Consumables Can Play a Role in Welding Productivity, Costs

Consumables — Contact tips, nozzles and gas diffusers (or retaining heads) — play an important role in the welding process and can impact productivity, costs and weld quality. Many factors influence the selection of consumables, including the application at hand, available budget and more. Read more.


Tips for Keeping MIG Gun Consumables Cleaner and Lasting Longer

When it comes to welding, many factors can influence the level of productivity a company achieves, as well as the quality. The power source, filler metals and consumables all factor into the equation and require special attention during the selection process. Read more.


Keeping an Open Mind and Reaping the Benefits: How One Company Reduced its Downtime and Costs Through a Simple Product Trial

When you have a company that fabricates its projects by the tons and measures its man-hours by the thousands, downtime simply isn't an option. Keeping an open mind isn't always easy. But sometimes, taking a chance can yield unexpected benefits. Read more.


Choosing Wisely: Simple Ways to Save Money and Reduce Downtime by Selecting the Right MIG Gun Consumables

Everyone is trying to save money these days. From implementing lean practices to repairing equipment instead of purchasing new, companies are seeking ways to reduce costs without sacrificing quality. Read more.


Don't Let Consumables Consume Your Profits: Choose, Use and Troubleshoot Wisely

It doesn't take much to create a MIG weld. All you really need is a power source, some CO2, a MIG gun, ground cable and a wire electrode. Of course, that doesn't mean you'll end up with a mechanically sound or decent looking weld. Read more.


Understanding MIG Gun Liners

The liner is both one of the simplest and most important components of a MIG gun. Its sole purpose is to guide the welding wire from the wire feeder, through the gun cable and up to the contact tip. If it is not performing this task properly, the gun is virtually worthless. Read more.


Profiting in Lean Times: Bernard Consumables and MIG Guns Help OEM Fabricators Standardize Their Operations

Anyone in a job shop environment knows how much downtime accrues from changing over a welding cell to accommodate different product runs. For Wisconsin-based OEM Fabricators, that downtime added up to $2,000 a day until it adopted the "rule of ones," which standardized their welding processes, and implemented lean manufacturing concepts. Read more.


Making Your MIG Gun Consumables Last

Even though many consider MIG gun consumables to be a commodity — a simple "throw-away" item — these components play a critical role in achieving good welding performance and quality. They can also impact the overall productivity and cost of your welding operation, often in some rather subtle ways. Read more.


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