​April is National Welding Month, created by the American Welding Society (AWS) in 1996.
AWS was established by 20 members of the Wartime Welding Committee, as a non-profit organization after World War I, to globally advance the welding industry. To this day, AWS continues to move the industry forward.
​
Being the year 2020, we are in the middle of history. Let us not forget the importance and crucial role that the welding industry plays in our lives locally and globally. Without welding, our world would crumble. There are many key people who discovered, invented, and patented welding technology as it evolved throughout welding history. Some are mentioned below!

​Almost everything you touch and see has been welded. It’s almost like our world wouldn’t even exist if it wasn’t discovered in the Bronze Age more than 5,000 years ago. Welding originated from heating Bronze until melted and then banging it with a hammer to form Gold boxes, as shown to the left.

In the 1800’s, Edmund Davy and Sir Humphrey Davy (cousins) discovered key elements for Arc Welding. Edmund Davy discovered Acetylene in 1836. Sir Humphrey Davy produced the arc between two carbon electrodes using a battery.
 
Although Edmund and Sir Humphrey Davy did not invent welding, they laid the path to the processes we use and see today.

​Auguste De Meritens was a French Electrical Engineer who used an electric arc to weld in 1880. This welding process achieved low temperatures and was not able to penetrate steel. He used a carbon electrode to weld lead plates to manufacture storage batteries.
​De Meritens was known for his magneto-electric generators used in lighthouses and arc lighting. In 1881 he achieved a French Patent for Electric Arc Welding.

No wonder he easily discovered the electric arc, right?

Charles L. Coffin achieved a French patent in 1890 for Arc Welding using a metal electrode. This was the first time that metal melted from the electrode across the arc to deposit filler metal into the joint to make a weld.

In the 1900s, Oscar Kjellberg of Sweden invented the coated electrodes from 1907-1914 by dipping bare iron into thick mixtures of carbonates and silicates, then allowing the coating to dry. Kjellberg was able to achieve a Swedish Patent in 1907.

Fun Fact:
Do you know where the name ESAB came from? Elektriska Svetsnings-Aktiebolaget, which is Swedish for: “Electric Welding Company”
​

The 1900’s was the era that included the development of spot welding, seam welding, projection welding, and flash butt welding.

Pictured are models of how the welding processes were used. Some may be familiar to you today.
​
During WWI, there was a large demand for weapons and armament. Welders became highly prized tradesmen among the armed forces. During this time, welders were challenged with a gas shortage and used electric arc welding to make bombs, mines, and torpedoes! Welders were also able to accomplish an all-welded hull vessel, called the HMS Fullagar of Great Britain.

​Welding is used high and low, under and above (and beyond). For example, you can weld under water and even in space! The possibilities are endless with welding; and our future is only getting brighter as each arc ignites. To everyone who is reading… Stay well, stay safe, and don’t forget to thank the welder in your life!

Let this article inspire you during this difficult time, to show you that no matter how hard things get, welding will always be in our world to produce, protect, and stimulate our economy.

Earlbeck Gases & Technologies has been around since 1919, leading the way in training tradespeople on emerging welding technologies. We help individuals get ahead in their career without the debt of a traditional 4-year education by introducing them to a critical piece of our economy; welding. 

Welders are needed and AWS projects a shortage of 400,000 welders by 2024. So, let’s get welding- we don’t have time to lose! Show us what you’ve been working on or have already accomplished as a welder. Whether you are just starting out or have been in the industry for decades, we want to see what you’ve been up to!
​
Use the hashtag #letsgetwelding #earlbeckwelding #arcflex to show off your work!

The College of Southern Maryland (CSM) and Earlbeck Gases and Technologies (Earlbeck) have formalized their longtime training partnership with a memorandum of understanding today to provide students with the training and certification credentials needed to meet the expanding welder workforce opportunities.

"Through this partnership, CSM and Earlbeck will provide education, training, certification and business solutions in welding to the Southern Maryland region. “This type of public-private partnership is valuable for our local employers to ensure we are preparing a skilled workforce that is trained and work-ready to meet the needs of businesses today. This will make our students more employable and ready to work from day one,” said CSM President Dr. Maureen Murphy.

Advancements in materials, processes and equipment make modern welding an increasingly high-tech skill. With an anticipated shortage of about 400,000 welders by 2024 as reported by the American Welding Society, job prospects are good for welders trained in the latest technologies. According to the U.S. Bureau of Labor Statistics, “many employers prefer to hire workers who have been through training or credentialing programs.”

“For several decades, Maryland based welding and manufacturing companies have relied on Earlbeck to provide quality welder training, welder certification and technical expertise.” said Earlbeck’s Vice President of Engineering Andrew Hess. “This training will not only provide job-ready training for new students but also upskill those currently employed, and supporting local businesses with their expanding workforce needs.”

“We are particularly excited as this initiative provides a seamless pathway with highly regarded industry recognition for our students, and this coupled with highly effective industry connections will support students in obtaining jobs,” said Interim Vice President of Continuing Education and Workforce Development Ellen Flowers-Fields.

Another benefit to the Center for Trades and Energy Training Welding Program powered by the Earlbeck Technical Center is that this partnership establishes an AWS Accredited Test Facility (ATF) within CSM’s existing welding space. This program enables a welder who receives an ATF certification to take their credentials to any employer without having to recertify, as well as list them in the AWS National Registry of Certified Welders.

According to CSM’s Executive Director of Workforce Development Kelly Winters, the welding programs offered at the college’s Center for Trades and Energy at the Regional Hughesville Campus were developed several years ago using Earlbeck guidelines.

“Earlbeck is considered a respected industry leader, and even before we formalized this partnership with Earlbeck today we had worked with them over the years to provide curriculum that meets the changing industry needs,” Winters said. The agreement ensures continuous curriculum updating to support students and instructor training and credentialing of CSM faculty.

Hess told those gathered at the signing about the partnership and “magic” that happens between business and education that produces valuable employees.

“Our philosophy is we teach students how to weld, you (the business) teach them your craft whether it is sheet metal, aerospace welding or structural steel. We can provide them with those certifications they need to work at your facility,” Hess said. “That allows us to put together a quick turn-around program that produces quality employees.”

The signing was followed by a tour of the Center for Trades and Energy and CSM’s welding lab. Photos of the event are posted at https://csmphoto.zenfolio.com/earlbeckmou.

About Earlbeck
Recipient of the 2017 American Welding Society and WEMCO “Excellence in Welding Award” in the educational facility category, Earlbeck provides world-class programs, so that their students are job ready at the end of their training. For information about Earlbeck, visit www.earlbeck.com.
​
About College of Southern Maryland
The College of Southern Maryland’s Center for Energy and Training provides direct access to specialized training in career fields that have substantial growth potential, including HVAC, electrical, plumbing and construction. CSM offers three tracks to become a certified welder. Located at the Regional Hughesville Campus, the welding lab is fitted with 20 welding booths.
For information about the center, visit https://www.csmd.edu/about/locations/regional-campus/center-for-trades-and-energy-training/. Course registration begins in January. Visit https://www.csmd.edu/programs-courses/non-credit/career-development/construction-and-skilled-trades/Welding for information.

Transcript: Hey everybody, this is AJ with Earlbeck Gases & Technologies coming to ya from York, Pennsylvania at our welder training and certification center!

Today we are going over the Fronius Accupocket 150; it is a battery-operated STICK/TIG welder.  
This welder is 150 amps and RUNS OFF OF BATTERY POWER!

STICK System includes: Electrode holder, ground clamp, charger and case!
This welder will get about 19-20 3/32 rods on a single charge and about 132” of TIG welding.
The system that we have set up today is just the STICK set up.

***They do make one for TIG welding***
TIG setup includes gas solenoid in the back, welder, flow meter, stick and ground clamp as well.

This machine produces true DC current! From a welder’s standpoint, it’s not like welding with anything else - plug it in and go! You can definitely tell a difference in the way that the rod flows as you are welding.
It is lightweight and only 25 lbs and easy to take on/off the job.
Great for mechanical contractors, steel erectors, handrail and farm repairs.
It is durable and only takes 30 mins to charge – kill the battery, plug it in and after 30 mins you are ready to weld!

It sure does beat pulling 100 ft weld lead and ground cable just to do a 15-minute job.

If you have any questions or would like a demo, feel free to give us a call at any of our locations below:

Baltimore, MD (410) 687-8400
York, PA (717) 916-6611
Belstville, MD (301) 937-8884
Moosic, PA (570) 457-8954

Here are important tips on keeping employees, as well as equipment, safe in the workplace.
Think safety, leave safely!
 
Potential Compressed Gas Cylinder Hazards
Compressed gas cylinders can be dangerous, and you need to be aware of the potential hazards and how to stay safe when handling, transporting, and using them.
​
The contents within the cylinder can be toxic, flammable, oxidizing, corrosive, or inert; and can cause physical harm, if not handled and stored properly. According to the Occupational Safety and Health Administration (OSHA), A compressed gas is a gas or mixture within a container. Pressure requirements have an absolute pressure of 40 psi at 70 degrees Fahrenheit or an absolute pressure of exceeding 104 psi at 130 degrees Fahrenheit, or a liquid having a vapor pressure exceeding 40 psi at 100 degrees Fahrenheit.

Here are some things to keep in mind when handling cylinders:
The cylinder can become something very similar to a missile. The valve controls the flow of gas; and if broken, you have lost the ability to manage a safe working environment. If this is not corrected, the potential mishap could be detrimental to employees and your business.
​Have you seen that MythBusters episode? (…It’s fact)  
Click here to check out their experiment.

Compressed gas cylinders can cause explosions, fires, or even deplete a working area of oxygen, if you have a faulty valve or not handling the vessel properly. Always contact your supplier whenever you have concerns about your gas cylinder!

Don’t worry, you do have control over this situation at your facility!
​
Always store cylinders upright with a chain or strap to prevent them from falling. Never store cylinders in a cabinet or closed-in area with little ventilation, this promotes a dangerous gas build up if a leak occurs.
If you store cylinders outside, you want to protect them from any extreme heat elements. When storing your cylinders inside, keep Oxygen and Nitrous Oxide at least 20 feet away from flammable gases. If you are tight on space, a high-pressure storage cabinet, with firewall, may be a good option for your company. These types of storage cabinets are engineered to be OSHA and NFPA compliant; and allow you to store oxygen and flammable gases together. Also, use the proper signage over the area where the cylinders are being stored, i.e. Flammable over the acetylene cylinders. Finally, all cylinders that are empty should be tagged and kept separate from ones that are full.

Keep the valves closed when not in use, this is especially important because some gases are inert, such as Helium and Argon (to a welding perspective). If your valve is left open, it will deplete the oxygen within your facility. It can also cause respiratory, eye, and even skin problems without the proper safety gear or plan in place. If you have a leaking valve, you will need to transport the cylinder to a well-ventilated area and call your gas supplier immediately! 

As your gas supplier (or prospective), we have included CGA Cylinder Safety Poster for download on our Resources page, check it out! 

Most accidents occur while a cylinder is being transported or moved.
Proper safety, when transporting cylinders, includes employees being fitted with safety glasses, gloves, and protective footwear. Safety wear should always be a requirement; and be worn whenever handling a cylinder. Use of a cylinder cart, with a chain or strap, instead of rolling or dragging a cylinder to the desired location, is the safest way to relocate a cylinder.  Also, make sure that the person handling the cylinder is physically capable and knowledgeable in cylinder handling. Always remember to close the valve and put the safety cap on when moving the cylinder, even if it is just a small distance away! These tips can help minimize the risks of physical injury, that can be caused by dropping or mishandling a cylinder.
When you need to transport a cylinder by vehicle, you will always want to keep the cylinders upright and strapped in securely during transport. Never ever lay a cylinder on its side, as it can lead to catastrophic damages to your vehicle and major injuries to the driver.

Safety during the use of the cylinders.
Always open the valve by hand if the cylinder is fitted with a hand wheel. If you are unable to open the valve, using a hand wheel, notify your gas supplier to request a replacement. If a tool is needed, leave it in position so the valve can be cut quickly in case of emergency. When releasing the valve, do so slowly. While in use, always keep the cylinder upright and away from sparks, high heat, fire and electrical circuit, as this will help prevent a disaster. Employees must also keep oil and grease away from oxygen cylinders, if the two mix it has the potential of violent reaction.

Even though compressed gas cylinders look sturdy, they are very dangerous! Good safety practices are vital to keeping you and your employees safe. Safety is our goal, why not take advantage of our Free Gas Application Analysis? You can click the "Learn More" button to the right of your screen and one of our gas experts will be there to assist! 
​
Here's a step-by-step tutorial on how to load your compressed gas cylinder onto a hand cart.
                              Special thanks to Matt Myers in Shipping and Receiving for the demonstration!
​

Let’s flux about it…
 
You’ve decided to make a repair; you have your soldering gun or brazing torch ready to go, but it hits you! “I don’t have any flux!”
Not to worry, we will help you choose what flux is right for you, but first you will know the difference between the applications.
 
 “What’s the difference between soldering and brazing?”
The American Welding Society (AWS) defines brazing as a process which involves a filler metal that turns to liquid above 842 degrees Fahrenheit (450 degrees Celsius). Brazing applications are a mechanically strong joint. You would typically see this application being used in the automotive industry, for jet engines and in HVAC. You may not know, but your cookware and utensils are also put together using this application. Did you ever wonder how your cookware was so durable? Probably not, but it’s still good to know!

Soldering also involves a filler metal but turns to liquid below 842 degrees Fahrenheit (450 degrees Celsius). This makes the joint electrically strong and can withstand any electric currents running through. If you are soldering any type of electronics, you will need to keep in mind that the temperature needs to stay below 842 degrees Fahrenheit so that your electronics don’t burn up. Yikes! 
Since soldering has a lower processing temperature, the joint is not as strong, compared to the brazing application. This is sometimes the most desirable application, because it has a lower liquidus state compared to brazing.

Of course, always follow your procedure or spec sheet for the proper application for every job!
 
Now we know the difference between the applications, but we need something else to complete the job. “We need flux!”

“What is flux?”
Flux is a chemical cleaning agent, flowing agent, or purifying agent. Flux is used in extracting and joining metals and is crucial to promote melting of the filler metal.
​
“Do I even need flux?”
Yes. It is imperative to use flux for the following reasons:

1. Removes oxides from metals to be joined (you will still need to clean your metals prior to application).
2. Prevents oxidation after completion.
3. Improves “wetting out” characteristics and heat transfer, which allows the filler metal to flow and not ball up.

“What type of flux do I need?”
There are many options available, but they all have their advantages and disadvantages.  You will have to take many variables into consideration, before you grab the nearest flux on the shelf. Not all flux is created equal!
Here are the things you need to know, in order to find the right flux for the job:

• Application
• Process
• Type of metals to be joined
• Filler metal
• Thickness
• Diameter of filler metal
• Desired appearance/cleanliness
• Any additional information that is relevant for the job

​You will have choices when it comes to the type of flux you will need. Here are some types that are out there:

• Flux coated filler metals
• Rosin core solders
• Powder
• Liquid
• Paste
• Gel
• Flux that is “injected” into the flame from the fuel supply

 
 Solder Fluxes:
No Clean Flux- Residue, if any, is minimal and will “vanish” from the heat produced. If residue needs to be removed, it will require solvent cleaning. It’s very hard to remove and could become an issue because it can interfere with electronics. The residue left behind from the flux is conductive.                  Typical primary ingredient: Isopropanol

Rosin Flux- The reaction between the flux and the metallic oxides on the joint metals make the flux flow easily and provides the cleaning required to “wet” the joint. Rosin flux becomes inert when cooled and solid. If electronics heat up enough to make the residue liquid, the acid can start deteriorating connections. Residue can be removed with alcohol. Typical primary ingredient: Rosin (tree sap)

Water Soluble Flux/Organic- Highly acidic and corrosive. Residue should always be removed when complete. Clean with water, steam, or water-based cleaning product. Typical primary ingredient: Isopropanol
 
Brazing Fluxes: 
General Purpose Powder Flux- Active range 1400-2200 degrees Fahrenheit. Use with low fuming Bronze, Nickel Silver, Copper base alloys, Steel and Cast Iron. This is the same flux that is coated on flux Bronze. Typical primary ingredient: Boric acid, Borax

White Flux- Low temperature (1050-1600 degrees Fahrenheit) silver brazing. This flux is used with most ferrous and non-ferrous metals and not recommended on Aluminum, Magnesium, or Titanium. Typical primary ingredient: Boric acid, potassium fluorohydroborate

Black Flux- High temperature (1050-1800 degrees Fahrenheit) silver brazing. Used on heavy parts where overheating or prolonged heating may occur. This flux is recommended when brazing stainless steels. Residue can be more difficult to remove.
​Typical primary ingredients: Boric acid, potassium fluorohydroborate.

Aluminum Flux- A powdered flux designed for use with aluminum alloys (915-1115 degrees Fahrenheit). You can apply this by sprinkling on dry, mixed with water or alcohol to form a paste. Typical ingredients: potassium chloride, sodium chloride.

Flux Injected in Flame- This flux is introduced into the fuel gas and passed through flame. This increases strength, reduced filler metal consumption, minimal post braze cleaning, quicker braze times, increased penetration, and can cut costs by 40%.
Typical primary ingredient: Trimethyl borate.

Hybrid Fluxes- Some manufacturers have hybrid fluxes available for difficult applications. Brown fluxes have been tested to work like black flux, but easier to remove residue.
 
Although there is no “silver bullet” when choosing the appropriate flux, you may find that multiple types of flux are needed but testing and evaluating may be required for best results. Please contact an Earlbeck Gases & Technologies Representative to help determine the best flux for your job!

We're 100 years old! Yes- we do look good for our age, right?

​Earlbeck Gases & Technologies is so proud to announce that we are celebrating our 100 year anniversary. We would like to sincerely thank everyone who has helped us reach this milestone.

Earlbeck Gases & Technologies dates back to 1919, when it when it was formed as the T.A. Canty Company, a wholesale welding products distributorship. It has been owned and operated by the Earlbeck family since 1952. 

Though time has changed many aspects of our business, and expanded our offerings, the core of our business remains the same. Al Earlbeck's creed has been the foundation for our continued success and it still holds true today. 

This philosophy will continue to guide our service for years to come, as we transition to our next generation of leadership. We are committed to remaining an independent family owned business so that we can best serve our customers and employees.

​To our customers: We are grateful for the opportunity you've given us to serve you. As our 1956 mailer best said, "Our customer is not the interruption of our work, they are the purpose of it. We are not doing them a favor by serving them, they are doing us a favor by giving us the opportunity to do so." Thank you for your business.

To our employees: Thank you for being part of our history. Congratulations on achieving this anniversary with us and your commitment to this company that will continue to bring us new milestones. The hours and effort you put into helping this company grow and keeping our customers satisfied does not go unnoticed.

Happy 100 years, Earlbeck Gases & Technologies! May the next 100 be as fun and exciting as the first. 

When it comes to TIG welding, the most commonly asked question is “What tungsten do I use?” As we know, welding equipment is constantly evolving. At one point in history, the most commonly used power source was known as a rectifier machine. Today, equipment is more commonly inverter based, which gives the welder more control of the arc.

There are a few things you must determine before selecting a tungsten electrode such as:

• Type of material being welded
• Type of weld
• Welding output (AC or DC)
• Material thickness
• Amperage range
• Type of welding power source, transformer/rectifier or inverter

Metals such as carbon steel, stainless steel, titanium, chromoly, brass, and copper will be welded using Direct Current with the electrode negative.  Generally, aluminum alloys are welded using Alternating Current (AC).

Pure tungsten (green stripe), for years was the best choice for AC welding, but with the industry shift to invert based machines, with advanced squarewave technology, rare earth tungsten such as Ceriated (gray stripe) and Zirconiated (brown stripe) are an option.

The most commonly used electrodes today are 2% Thoriated (red stripe).  Thorium has great arc start characteristics and allows for higher current carrying capacity. Although, if thoriated tungsten is used in the AC mode, the tungsten tends to split and get nodules around the electrode instead of a nice round ball. In return, this gives you an unstable arc and inconsistent heat input. It can also cause tungsten spitting giving you impurities in your weld. 

Also, choosing the proper grind angle, constant current range or pulsed current range will affect the electrode current range. Example .040 has range from 2 to 60 amps, .093 has range from 12 to 250 amps and .125 has range from 20 to 350 amps.

Type of Tungsten
Pure

Ceriated


Thoriated 1.7 to 2.2%


Lanthanated 1.3 to 1.7%
​

​Zirconiated  .15 to .40%   

Color Code
Green

Gray


Red, Yellow


Gold, Black, Blue
​

​Brown

Remarks
Good arc stability for AC.  Least expensive.

Easy arc starts, and long life.  Replacement for thoriated.

​Higher current capacity, greater arc stability, difficult to maintain balled end on AC.  

Easy arc starts, high current carrying capacity, similar to thoriated.
​
Excellent for AC, good arc starting, limited contamination of weld.

On July 17, 2018, the Earlbeck Technical Center was evaluated by an American Welding Society representative in order to have our Accredited Test Facility status renewed. Each ATF undergoes an audit every 3 years to determine that the quality system is effectively implemented and maintained. Here's what the AWS auditors had to say...

Congrats to the Earlbeck Technical Center staff! To learn more about Welder Certification or to schedule an ATF test, please visit our Weld Testing page.

Let’s begin by understanding duty cycle. We all know what it is, but just for a quick refresh:  Duty cycle is a rating measurement of 10 minute increments using CO2 gas.  So, if we take a 350 amp gun as an example – that means at it’s maximum it can weld 10 minutes at 350 amps with a constant current using CO2 gas. 

Now take into consideration factors that affect duty cycle.  Argon base gas – which mixes Argon at 75% and CO2 at 25% won't cool a gun like 100% CO2. Many other gas mixes are used in welding beyondf those two mixes, such as Argon 90/10 and Argon 95/5. Pulse is yet another factor that lowers your duty cycle.

There’s also the consideration of constant voltage. Constant Voltage, or Current,  is used in MIG welding.  Polarity – the direction the current flow goes can be either Straight or Reverse in nature. In MIG welding, you use Reverse Polarity Constant Voltage. In this process, the heat produced is created on the ground side of the work, while the nozzle and the contact tip are exposed to reflected heat.  In this welding process, CO2 acts as a cooling agent, with smoke acting as the filtering agent – shielding the reflected heat.

Pulse welding is the process of pulsing your weld current  several times per second instead of holding it constant. Pulsing causes the arc to act like its welding hotter than it actually is.  However, the torch will react like the current is at the peak of the pulses rather than the “average” as read on the current meter of the power source. That’s because the arc is starting and stopping constantly, which takes more power.  Also, pulse welding creates less smoke, considerably less, in fact, and doesn’t filter the reflected heat to the nozzle and contact tip.

So, how does that lesson on welding actually affect the torch you may want to use?
Well, it’s all a matter of the heat you’re generating. Air cooled torches depend on thermal transfer to conduct the heat from the contact tip through the handle and into the power cable before radiating into the air.  This is where the duty cycle becomes important – how much heat is generated and how fast it can be conducted and radiated? For example, aluminum power cable guns are a little better at radiating heat than copper, but are also less capable of conducting current.  The nozzle is insulated, electrically and thermally from the gun and radiated heat on its own.

Water cooled guns act differently. With water-cooled (or gas or liquid-cooled…. they all mean the same thing), these depend on water (or liquid) to transfer heat into the power cable, contact tip and the nozzle. Systematically, it is a more efficient system for cooling.  Heat in the water is transferred to a radiator, into a holding tank and circulated back to the welding torch.

Looking back at the break down of gases welding styles, consider that an air cooled torch rating is reduced 40 to 50% using Argon based gases, and another 20 to 30% when pulse welding is used.
Water cooled guns, on the other hand, get a duty cycle reduction of 10% for Argon base gas, and a negligible reduction for pulse welding.
​
There are ample pros and cons to both welding gun types, but let’s break them down here by category, and you can decide whether you’ve fairly considered each:

• Air-cooled Pros: Simple, power cable, handle and neck. “Plug and play” in every sense.  Less ancillary equipment costs or chemical use to keep the gun running.

• Air-cooled Cons: The longer or hotter the weld, the bigger and heavier the torch. Nozzles and tips are always hot, and depending on the delay between welds to cool, wear due to heat overexposure.  Once maximum duty cycle has been reached once, the duty cycle next time is reduced. So you’re always spending less time welding than you could be just because of the design of the gun. 

• Water-cooled Pros: These guns are always cool. The water system will remove heat from your tips and nozzles anywhere from 30 seconds to 2 minutes after you finish welding any length of time to the point of touch. (don’t recommend welding bare handed, though!). Your nozzles and tips will also last longer – sometimes at low amperages, too long, tips may reduce ability to conduct when used too long, to the point it could damage gun. It’s always recommended to change tips on days you weld or amount of wire used. Water-cooled guns are also surprisingly light weight; the liquid and the pressure flowing through the cable makes them somewhat buoyant. A water-cooled gun that’s 500 amp, for instance, is about the same as 350 amp air-cooled gun. 

• Water-cooled Cons: Water cooled gun is more expensive to manufacture and needs the added expense of a cooling system. Connections and fittings on the gun are easier to damage and break – mostly because there is just more opportunity to do so.  Water leaks in the welding area can be messy.  The thermal transfer for the nozzle is a pressed ceramic and can be broken if abused, which will reduce the efficiency of the gun.  Cooling systems that are not maintained or improperly setup can also damage the guns. Lastly, while water-cooled guns can reach amperages air-cooled guns could only dream of, it is difficult to reach that full duty cycle for 500 amp, 600 or 650 amp guns. 

Water cooled guns have received a bad reputation of being maintenance problems, unjustly.  With operator training and the proper set up they’re more comfortable for the operator, increase arc on time and increase productivity.