US 2026/0241479 A1Published application

Multi-piece contact for an end assembly of a welding device

OwnerEdward L. Cooper, Steven J. Hayesinventors

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Abstract

A contact tip for an end assembly of an arc welding system includes a body that is a separate piece relative to a cap that is assembled with the body. The body is made of a higher conductive material such as copper, and the cap is made of a higher temperature resistance material such as tungsten copper. The body is configured to conduct the current of the welding system, the with cap resisting the high temperatures of the welding process to increase wear resistance and durability. The body includes a projecting boss that is received in a corresponding bore of the cap. The boss includes external threads and the bore includes corresponding internal threads. The body and cap each include central bores that combine to define an overall bore through assembled multi-piece contact tip.

Claims20

Dependent claims

A contact tip for use with an end assembly for an arc welding device of a type including a gooseneck having an internal passageway for conducting a shielding gas, a diffusor coupled to the gooseneck, a nozzle extending from the gooseneck, and a wire guide for guiding a consumable wire electrode, the contact tip comprising:

a body made of a first material and defining a first end of the contact tip configured to mate with an end assembly of a welding system;
a first set of external threads formed on the body and located adjacent the first end, wherein the external threads are configured to engage corresponding threads of the end assembly;
a cap made of a second material different from the first material and defining a second end of the contact tip configured for feeding a weld wire therefrom to a weld site, the cap sized and shaped to mate with the body, wherein the cap is a separate piece that is assembled with the body to define the contact tip;
an overall central bore defined by the body and the cap and extending fully through the contact tip, the overall central bore configured to feed a weld wire therethrough;
wherein the first material of the body has higher conductivity than the second material of the cap;
and
wherein the second material of the cap has a higher temperature resistance than the first material of the body.

4 more elements

A method of assembling a contact tip for use in an end assembly for an arc welding device of a type including a gooseneck having an internal passageway for conducting a shielding gas, a diffusor coupled to the gooseneck, a nozzle extending from the gooseneck, and a wire guide for guiding a consumable wire electrode, the method comprising:

providing a body made of a first material and defining a first end of a contact tip configured to mate with an end assembly of a welding system;
providing a cap made of a second material different from the first material and defining a second end of the contact tip and configured for feeding a weld wire therefrom to a weld site, the cap sized and shaped to mate with the body, wherein the cap is a separate piece that is assembled with the body to define the contact tip;
inserting a projecting boss of the body into a corresponding bore of the cap;
fixing the cap to the body and defining the contact tip in an assembled state;
defining an overall central bore defined by the body and the cap and extending fully through the contact tip in the assembled state, the overall central bore configured to feed a weld wire therethrough;
wherein the first material of the body has higher conductivity than the second material of the cap;
and
wherein the second material of the cap has a higher temperature resistance than the first material of the body.

5 more elements

Dependencies are inferred from the claim text.