5 Signs It’s Time to Replace Your MIG Welding Contact Tip

Sign #1: Burnback

When the wire starts to melt and burns back, fusing to the contact tip, it’s time to replace the tip. If you don’t, it can cause irregular wire feeding, arc instability, and stoppages during wire feeding.

Sign #2: Wear and tear

If you see evidence of erosion in the contact tip bore, it’s time for a replacement. This is caused by friction from wire feeding and can cause issues, from an erratic arc to irregular welds and even wire placement offset.

Sign #3: Keyholing

When a tip needs to be replaced, it will start to take on an oval shape bore, also known as a “keyhole.” This also causes an erratic arc if you don’t replace the tip.

Sign #4: Debris and spatter

A little bit of spatter is normal, but too much is a clear sign that the tip needs to be replaced. Too much spatter will limit tip life, diminish the quality of your arc and weld, and cause burn backs.

Sign #5: Hitting the 100-pounds of wire mark

If you’re using the same contact tip for more than 100 pounds of wire, it’s time for a change. After surpassing the 100-pound mark, most tips will be worn out, leading to a lower quality weld.