1. Causes of failure of the conductive tip itself
The wear of the contact tip itself originates from the friction at the contact tip outlet caused by the friction of continuous wire feeding under the rising temperature of the contact tip. During robot welding, it often leads to calibration errors and affects production efficiency.
We should find ways to reduce the temperature of the contact tip, including focusing on the composition of the contact tip and the processing of the structure of the contact tip. The material of the contact tip:
Brass, red copper, chromium zirconium copper and other materials, among which brass is the worst, red copper is slightly better, and chromium zirconium copper is the best; even ceramic components are added to the conductive tip to increase wear resistance.
Secondly, the processing accuracy of the contact nozzle. Due to the accuracy of the processing equipment or other problems, the smoothness and concentricity of the inner hole of the contact nozzle are not good enough.

2. Reasons such as wire straightening and surface finish
The welding wire is often packaged in cylinders or coils, and has burrs or ribs, so it may affect the contact between the welding wire and the contact tip. During welding, the contact tip should provide minimal friction under the premise of stable conduction.
Contact tip life with dirty wire may be only one-third that with clean wire;
To judge the quality of the welding wire, the degree of annealing stress relief of the welding wire is reflected in its straightening properties. The test is:
Check whether the welding wire can bend automatically at 50mm in front of the welding gun nozzle. Bending in front means that the welding wire is too soft, and bending in the back means that it is too hard. Hard welding wire is the most expensive for the conductive tip;
Secondly, whether the wire feeding hose from the wire feeder to the welding gun is bent will also cause the welding wire to bend.

3. Arc instability leads to arc flashback
One cause includes poor arc ignition, unstable arc, poor wire feeding, cleanliness of the workpiece surface, etc., but it does not necessarily affect the performance of the contact tip itself. The welding failure at this time is roughly related to the characteristics of the welding power source and the quality of the welding wire. , wire feeding effect, wire feeding hose and contact nozzle structural design, etc.
When the conductive points in the welding wire and contact tip often change, their lifespan is only half of that when the conductive points are stable;

4. Wire feeding speed or deposition amount
Relatively speaking, the smaller the diameter, the shorter the service life of the contact tip. With the same current of 300A, the filling (melting) amount per unit time of 1.2 and 1.6 welding wires is basically the same.
The length of the 1.2 welding wire is twice that of the 1.6. That is to say, for the same current and the same time, the wear amount of the 1.2 contact tip is almost twice that of the 1.6 contact tip.
Assume that both the 1.6 and 1.2 contact tips are worn by 0.2mm. This 0.2mm is 12.5% of the 1.6 and 16.7% of the 1.2. The 1.2 wire has a larger runout range.