nexAir KnowHow: Providing Welding Professionals with Expert Tips and Best Practices

What follows are practical, field-tested tips built around real challenges and repeat questions from working professionals.

Tip 1: Measure Gas Flow at the Torch

Gas delivery issues often come from a gap between what’s set at the regulator and what actually reaches the weld. Long hose runs, damaged fittings, or internal leaks can cause loss in shielding that shows up as porosity, erratic arc behavior, or inconsistent bead quality.

To confirm your gas is reaching the arc as expected, place an in-line flowmeter or test gauge at the torch. For reactive materials like stainless steel or aluminum, even small drops in coverage can affect integrity. Checking this once can save hours in rework.

Tip 2: Keep Stick-Out Tight for MIG

Many operators run with excessive contact-tip-to-work distance, especially on fillet welds or horizontal passes. The result is reduced current, poor puddle control, and uneven penetration. For solid wire in short-circuit transfer, aim for a stick-out of three-eighths to one-half inch.

This small adjustment improves arc stability and reduces spatter. For pulsed or spray transfer, slightly longer distances are acceptable, but they should still fall within the recommended range for your wire and machine settings.

Tip 3: Clean Nozzles Before Arc Instability Starts

Waiting for arc inconsistency before maintaining your torch is too late. Spatter accumulation in the nozzle disrupts gas coverage and affects every weld that follows. Use a nozzle brush or dedicated cleaning tool to remove buildup at the start of each shift and again mid-day during high-volume work.

Pair this with anti-spatter gel or spray to slow down future buildup. A clean nozzle means fewer porosity issues and more reliable arc starts.

Tip 4: Check Preheat Consistently Across the Joint

Preheating is often treated as a checkbox item, but the way it’s applied affects bead performance and structural reliability. Instead of checking temperature in a single location, scan the full length of the joint and the adjacent base material.

Use an infrared thermometer to verify that the entire weld zone reaches the required temperature before striking the arc. Inconsistent preheat contributes to cracking, uneven fusion, and slow puddle response—especially on thicker material or high-strength steels.

Tip 5: Adjust Voltage and Wire Speed Together

In MIG welding, voltage and wire feed speed must be balanced. Increasing one without the other leads to erratic transfer, excessive spatter, or lack of fusion. As a general rule, increasing voltage by one volt should be matched with an increase in wire feed speed of ten to fifteen inches per minute.

Use test plates to dial in the right combination for each joint type and material thickness. Once dialed in, document your settings and revisit them whenever wire or shielding gas changes.

Forge Forward With Confident Technique

Small habits lead to measurable improvements. Better control over shielding gas, consistent positioning, and smarter setup practices all contribute to fewer defects and stronger, more predictable welds.

This is how we help you Forge Forward. Through expert KnowHow™, hands-on guidance, and practical advice, nexAir supports welders in producing results that hold up under pressure.

Talk to nexAir to access training, equipment guidance, and support designed around the work you do every day.