A Guide To Maintaining And Replacing Welding Torch Consumables

Is your welding torch misfiring, difficult to start or has the cutting quality dropped off? The torch consumables could be the culprit for the torch not working correctly. This guide is broken down into hand and machine torches, GYS plasma and Jasic plasma torches. Our welding experts will help you identify wear and tear, tell you what to consider when replacing your torch consumables, plus there are some handy links so you can purchase the spare parts you need.

Hand torches and machine torches

To achieve a flush cut, gouging and a fine feature cut, it might be time to replace the parts in your torch. When to replace the parts is down to how you use your torch and for how long.

It's a good idea to inspect your torch for wear and tear on a regular basis. Keep an eye on its performance, if parts needs replacing the performance can look like:

- Cutting quality is poor
- Not being able to cut
- Discoloration of the arc or fumes
- The arc is misfiring
- The torch is difficult to start
- If you need to slow down considerably

When to change electrodes and nozzles

As mentioned above, there is no exact time-frame in which to change your electrode. However, it is important to look for signs that it may need replacing. On the electrode, look out for dips in the tip - the deeper the dip, the more wear it has been through.

The nozzle is the most frequently replaced consumable. On the weld inspect for dross appearing on your cuts. On the nozzle itself, look out for signs of a distorted shaped hole which indicates excessive wear.

It's good practice to replace both the nozzle and electrode at the same time to take the guesswork out of replacing.

Spotting a broken swirl ring

The swirl ring is often forgotten, but it also needs to be changed if you are noticing your welds are out of shape. Look out for cracks or clogged holes. Through regular use of a torch, a swirl ring can last for up to 15 electrode changes. This can differ with excessive use.

Signs you need to change your shield

The drag shield and mechanised shield are really important parts of the torch that need to be looked at. It helps if you hold the shield up to the light to see if any of the holes are clogged. These holes are the outlet for gas, if they are clogged it can misshape the arc. Also keep an eye out for the shield shape being distorted, if it looks worn out, or there are signs of excessive dross.

Replacing the retaining cap

The most durable of the consumables, and the consumable that needs to be changed the least, is the retaining cap. Look for physical signs appearing such as cracking, clogging or corrosion due to heat exposure.

In need of new hand torch consumables? Shop our wide range, PowerMax 30 Air consumables, 30 XP consumables and 45 XP consumables.

Looking for machine torch consumables? Duramax 180 consumables, Duramax mini machine consumables, Hypertherm Hyamp consumables.

GYS plasma and Jasic plasma torches

Plasma torches have a lot of the same parts as the hand and machine torches, so replacing the consumables still applies as mentioned above. However, there are some parts that are specific to this tool.

When to change the air diffuser

This plays a vital role in air regulation. Look out for any chips, melting or burnt parts on the air diffuser. Any damage to the air diffuser can cut vital air flow down. It can also cause other parts of the torch to wear out prematurely if this part is not replaced.

Replacing the cutting tip

This is one of the fastest parts to wear out. You may notice the hole in the centre becoming larger. This allows the arc to wander, making you lose precision, in turn making your cuts less clean. You may also notice more slag if the cutting tip needs to be replaced.

So there you have it, a guide of when to replace your welding torch consumables. After making these adjustments you will notice your torch working at a much higher standard, leaving you with a better quality finish. If you're in need of any more expert advice on welding or replacing your torch consumables, contact us today.

Looking for GYS plasma consumables and Jasic plasma consumables including, Pro Air Cut 45, Pro Air Cut 60 & 80 and Pro Air Cut 100 & 160? Shop our wide range including, cooling tubes, double pointed spacers and cutting diffusers.