An exceptional weld spatter resistive antispatter material. MIG welding nozzles made in AMPCOLOY® Nozcap have following benefits:  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

1. AMPCO METAL (INDIA) PVT. LTD.
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.
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.
Problems arising due to weld spatters in the nozzle
Turbulance in the
Gas flow
Excessive cleaning
is required
Higher maintenance
cost
Increased
downtime

2. AMPCO METAL (INDIA) PVT. LTD.
Normal Chrome Plated Nozzle AMPCOLOY® Nozcap
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:
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
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
Ordinary chrome plated copper nozzle
After 50 Jobs
AMPCOLOY® Nozcap
After 2000 Jobs

3. AMPCO METAL (INDIA) PVT. LTD.
Obsevations:
Incase of existing chrome plated copper nozzle:
 Cleaning is done after every 10 jobs, cleaning time approx 2-3 Mins.
Conclusions:
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
95.4 %
Reduction in
cleaning operation
59.5 Minutes
Time saved
per day
40 %
Productivity
increase per day
(79-80 additional
jobs per day)
99.2 %
Reduction in
cleaning time