CASE STUDY

AMPCOLOY Nozcap as a Robotic MIG / MAG Welding Nozzle

Overview:
Purpose of this case study is to analyse the weld spatter resistance properties of AMPCOLOY Nozcap.

Also to address following points:

Reduce the cleaning downtime and efforts

Cost saving by using MIG welding nozzle made of AMPCOLOY Nozcap
Increase in productivity per day by using nozzle made of AMPCOLOY Nozcap
Increasing Overall Equipment Efficiency

Weld Spatters:

The biggest enemy in any welding environment. It creates problem like messy welding area,
damages the body resting units & adds the fixture downtime. The maintenance teams have to go for additional
coating on the units or spatter protection sprays.

Problems arising due to weld spatters in the nozzle

Turbulance in the
Gas flow

Excessive cleaning
is required

Higher maintenance
cost

Increased
downtime

Trials:
Trials were conducted for Bajaj Auto Ltd. for AMPCOLOY Nozcap insert in comparison with existing chrome
plated copper nozzle.
We developed the insert type nozzle as per the following picture. This arrangement will help to keep the cost
minimum as well required only to change the insert after its optimum usage.
AMPCO METAL (INDIA) PVT. LTD.

AMPCOLOY Nozcap

Normal Chrome Plated Nozzle

Technical parameters of the robotic welding station on which trials were conducted:

Welding Station: Robotic MIG welding

Cycle Time per Job: 45 Seconds
200 Jobs per day
Welding Wire:
o Wire Dia. 1.2 mm
o Wire Material Er70C-6M
Welding Parameters:
o 260 Ampere
o 25 Volt
o Speed 1700mm / minute

Findings:

Ordinary chrome plated copper nozzle

After 50 Jobs

AMPCOLOY Nozcap
After 2000 Jobs

Existing chrome plated copper nozzle

No resistance to weld spatters
After spatter deposition around the head - excessive turbulence
to the shielding gas flow
Chrome plating is required
Anti-spatter gel or spray needs to be applied at regular intervals
Rigorous cleaning is required
High downtime for cleaning / maintenance purpose
Very low life of the Nozzle

AMPCO METAL (INDIA) PVT. LTD.

MIG welding nozzles made in AMPCOLOY Nozcap

Very high resistance to weld spatters
steady supply of shielding gases due to no spatter

No need of additional plating

No need of anti-spatter gel or spray
Very easy to clean
Very less downtime for cleaning & maintenance purpose
High life of the Nozzle

Obsevations:

Incase of existing chrome plated copper nozzle:

Cleaning is done after every 10 jobs, cleaning time approx 2-3 Mins.

Advantages of AMPCOLOY Nozcap as a MIG welding nozzle:

Very high resistance to weld spatters

Very long life
No need of additional plating
No need of anti-spatter gel or spray
Very easy to clean
Very less downtime for cleaning & maintenance purpose
High life of the nozzle

Conclusions:

95.4 %

99.2 %

Reduction in

Reduction in

Time saved

cleaning operation

cleaning time

per day

AMPCO METAL (INDIA) PVT. LTD.

59.5 Minutes

40 %
Productivity
increase per day
(79-80 additional
jobs per day)