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A MIG gun may stop feeding wire because of a worn or blocked liner, incorrect drive roll tension, a worn contact tip, excessive spool tension or damaged welding wire. Check the complete wire-feeding path from the spool and drive rolls to the liner and contact tip. Replacing worn consumables and adjusting the drive system according to the welding machine manufacturer's recommendations can often restore smooth wire feeding.
MIG contact tip burnback can be caused by incorrect welding parameters, excessive wire stickout, poor wire feeding, an incorrect contact tip size or a worn contact tip. Check the wire feed system, contact tip condition and welding parameters to identify the cause.
TIG tungsten can melt or overheat because of excessive current, incorrect polarity, insufficient shielding gas, an undersized tungsten electrode or inappropriate AC settings. Select the correct tungsten size and type for the welding current and application, and verify the shielding gas and polarity.
A TIG torch may become excessively hot when the welding current exceeds its rated capacity or duty cycle, when the torch is not adequately cooled, or when the torch and consumables are not correctly matched to the application. For higher-current or extended welding operations, a water-cooled TIG torch may be appropriate.