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.

Welding Application

Optimizing Shielding Gas Performance in MIG Welding 

Using the wrong shielding gas for MIG welding applications — or having improper gas flow — can significantly impact weld quality, costs and productivity. Shielding gas protects the molten weld pool from outside contamination, so it’s critical to choose the right gas for the job. Read more. 

Welding Application

MIG Welding Basics: Techniques and Tips for Success

From employing safe ergonomics to using the proper MIG gun angle and welding travel speeds and more, good MIG welding techniques provide good results. Read more

Welding Application

MIG Welding FAQs Answered

MIG welding, like any other process, takes practice to refine your skills. Consider these frequently asked questions, along with their answers, as welding tips to guide you.  Read more

Welding Application

7 MIG Welding Mistakes and How to Avoid Them

MIG welding offers numerous benefits for productivity without sacrificing quality of the finished weld, but there are many factors that can interfere with successful MIG welding performance. Consider these common causes of poor performance in MIG welding and learn how to prevent them. Read more

Welding application

Proper Ergonomics Improve Welding Productivity, Protect Welders 

Ergonomics not only protects welding operators from injuries, but it can also improve the productivity and profitability of a welding operation. Stressful postures and motions tend to be inefficient. Read more.

Welding application

Signs Your MIG Gun Is Overheating — and How to Prevent It

An overheated MIG gun can result in downtime, wasted consumables and lower productivity — costing a company more time and money than necessary. Read more.


Reduce Costly Downtime By Preventing Poor Wire Feeding

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.

MIG Welding

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.

 Welding Application

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.

Novice Welding

Teaching New Welders to Improve Quality and Productivity

For companies faced with training new welders, it is important to instill good habits early in the process. Doing so helps ensure the welders are well prepared not only to create quality welds, but also to contribute positively to the operation’s productivity. Read more.

CoolBelt Application

Stay Cool When Welding In The 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.

Welding Application

10 Mistakes in Running a Welding Operation and How to Fix 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.

Welding Application

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.

Shielding gas coverage

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.

Welding Application

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.

Gun breakdown

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.

Welding Application

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.

Welding Application

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.


Welding Application

Configuring a MIG Welding Gun for Your Application

Have you struggled to gain proper joint access when welding? Or found yourself fatigued at the end of the day because of repeatedly welding in awkward positions? Configuring a MIG welding gun can help. Read more. 

Welding Application

How to Choose MIG Welding Gun Parts

In addition to the amperage of MIG welding gun you choose, the MIG gun parts — cable, neck and handle — affect how comfortably and efficiently you can weld. Configure your gun accordingly. Read more

Welding Application

Taylor Forklift Operation Reduces Downtime, Costs with Bernard

Taylor employs some of the best welders in the business to meet those customer demands, but even great welders can’t overcome their tools’ limitations. When Taylor decided to try Bernard™ Semi-Automatic MIG Guns and Centerfire™ Consumables, they discovered their talented team could take productivity up a few notches —and still gain the best quality. Read more. 

Welding Application

Fume Extraction Guns: Features and Techniques to Improve Performance

A fume extraction gun is a viable alternative in certain welding applications, including when the welder is in a tight or confined space or must move often to complete welds on a large part. Welding guns with built-in fume extraction are commonly used in heavy industrial welding, such as truck and trailer, rail car and heavy equipment manufacturing. Read more

Welding Application

Managing MIG Guns and Consumables for Multiple Applications

The fabrication and manufacturing industries continue to experience demands for greater productivity, increased efficiencies and higher cost savings — often times with less labor to support the efforts. Read more

Welding Application

How Can Customizing a MIG Gun Benefit the Welding Operation? 

Customizing a MIG gun for the specific needs of the application, in addition to choosing the proper consumables, can pay off in greater productivity, better comfort and improved quality in the completed welds. Read more

Welding Application

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.

 Welding Application

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.

MIG Guns

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.

Welding Application

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.

Welding Application

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.

Bernard Fume Gun

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.

Conventional Liners

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.

BTB Platform MIG Guns

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.

BTB Straight and Curved guns

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.

Welding Application

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.

Welding application

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.

Welding Application

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.

Welding Application

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.

CW Boat

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.

Welding Application

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.

Welding Application

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.

Bernard Q Gun

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.

Bernard Filtair

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.

Bernard Welding Guns

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 productivity. Read more.

Liner Handle

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.

Welding Application

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.

MIG Q Gun 300 Amp

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.

Welding Application

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.

Welding Application

Avoid These 5 MIG Gun Myths to Optimize Performance

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.

Welding Application

Air- vs. Water-Cooled MIG Gun: 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.

San Diego School Welding Application

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.

Welding Application

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.

Welding Application

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.

Semi Auto Guns

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.

Welding Application

Self-Shielded Flux-Cored Welding: Choosing Your Gun

There are some key factors to keep in mind to help choose the right self-shielded flux-cored welding gun for the job — and to use and maintain it properly. Gun options such as heat shields, configurable necks and adjustable cable lengths can help improve weld quality, efficiency and operator comfort in self-shielded flux-cored applications. Read more

Welding Application

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.


Welding Application

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.

Welding Application

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.

Welding Application

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 Team

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.

Hot Az Hell Welding Group

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.

Welding Application

Selecting the Right MIG Welding Consumables

MIG welding gun configurators, like the Bernard® BTB Semi-Automatic Air-Cooled Configurator, allow you to choose specific styles or types of consumables to match the demands (amperages and waveforms) of your application. Read more

Welding Application

Common Problems with MIG Welding Consumables and How to Fix Them

MIG welding consumables are a critical but often overlooked part of the welding operation. Unfortunately, without a clear understanding of the problems that can arise with consumables — and the best way to fix them — companies stand to lose productivity, jeopardize quality and increase costs. Read more

Welding Application

MIG Welding Consumables Reduce Wire Feeding Issues and Downtime

When MIG welding consumables aren’t properly installed or maintained, it can result in wire- feeding issues and weld quality problems. Troubleshooting and correcting these challenges can cost hundreds of dollars — and hours per day — in a manufacturing operation. Read more.

Welding Application

What MIG Gun Neck is Right for You?

Optimizing MIG welding gun performance in specific applications can be a matter of choosing different components for the gun. Selecting the right MIG gun neck improves access to the weld joint, increases operator comfort and can reduce costs in the operation. Read more

Contact Tips

Correct Contact Tip Recess Can Improve Welding Efficiency

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.

Welding Application

Tips for Choosing 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.

Welding Application

Understanding and Extending Contact Tip Life

Premature contact tip failure is a common problem that can lead to unexpected downtime — and added costs — in a welding operation. This issue not only hinders productivity, it can also negatively affect weld quality and create rework. Read more.

Quick Load Liners

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.

Welding Application

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.

Spatter tips

MIG Gun Consumables: Tips to Extend Life

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.

Bernard Group

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.

Bernard Q Gun

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.

Welding Application

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.

Universal Conventional Liners

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.

Welding Aplication

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.

MIG Consumable

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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