Funis conductive nozzle

FRONIUS conductive nozzle is a core welding consumable designed specifically for the FRONIUS series welding gun and compatible with European standard welding guns. It is widely suitable for robot automation welding and manual gas shielded welding scenarios, and has become an excellent choice for the industrial welding industry with precision suitable for processing, stable conductive performance, and practicality. The detailed introduction is as follows:

Definition and core role

Funis conductive nozzle is a key component at the end of gas shielded welding gun. Its core function is to carefully guide the welding wire and stably transmit the welding current, confirm the continuous and stable combustion of the arc, and at the same time, cooperate with protective gas to isolate the air and avoid oxidation of the weld seam. Its performance directly affects the welding quality, and can effectively reduce defects such as wire jamming, splashing, arc deviation, and porosity. It is a core vulnerable part that protects welding efficiency and weld formation aesthetics, especially suitable for one-to-one welding guns and robot welding systems such as Funis AW4000.

Material selection and process characteristics

Mainstream materials:

Purple copper (T2): It has excellent electrical and thermal conductivity, low current transmission loss, moderate cost, and is suitable for conventional load welding scenarios. It is a cost-effective choice that can meet the needs of ordinary manual welding and intermittent operations.

CuCrZr: On the basis of maintaining good conductivity, its hardness, performance, and high temperature resistance (based on actual reports) are significantly better than copper, and its service life is longer than ordinary brass material. It is a reliable material for high-strength, high-frequency welding and robot automation welding. Some products use high-purity CuCrZr copper to further improve conductivity stability and practicality.

Aluminum Welding One on One: A customized one-to-one conductive nozzle designed for the characteristics of fast thermal conductivity, low melting point, and easy oxidation of aluminum welding wire. The inner hole has a high degree of fit with the aluminum welding wire, reducing friction loss and avoiding wire jamming and burner problems.

Processing technology: High speed drilling, extrusion molding, and CNC lathe precision machining operations are adopted. Some excellent products use well-known thick walled copper tube technology to make the grain structure of the inner hole denser and form a wear-resistant (based on actual reports) hard layer on the inner wall. The surface of the inner hole has high smoothness and no burrs. The aperture size is carefully controlled, usually 0.02-0.2mm larger than the corresponding wire diameter, which not only protects smooth wire feeding but also ensures stable conductive contact, reducing wire wear and current fluctuations.

Structural design and specification parameters

Appearance structure: The overall shape is cylindrical, with a standard threaded interface design, easy to install and disassemble, and can be securely connected to the Funis welding gun conductive seat at a suitable speed, with a tight fit and no risk of gas leakage. Some models optimize their structure to meet the welding requirements of robots, improving the directionality and stability of wire feeding.

Core specifications:

Interface and size: covering various thread specifications such as M6, M8, M10, etc., with lengths including 28mm, 30mm, 32mm, 35mm, 40mm and other common sizes, such as M6 × 28, M8 × 30, M8 × 35, M10 × 40 and other mainstream models.

Inner hole diameter: commonly used sizes are 0.8mm, 1.0mm, 1.2mm, 1.4mm, and 1.6mm, with 1.2mm being the most versatile specification. Aluminum welding is labeled as 1.2A for each pair, and the corresponding diameter of carbon steel, stainless steel, and aluminum welding wire is carefully matched.

Compatible Welding Gun: Designed specifically for the FRONIUS series welding gun, compatible with all FRONIUS style welding guns and European style welding guns with corresponding threaded conductive nozzle seats. It can directly replace original accessories and has strong replaceability.

Packaging: Standard packaging of 10 pieces/box and 30 pieces/box is commonly used, and some industrial batch packaging can meet the needs of large-scale production, facilitating inventory management and suitable replacement speed.

Other parameters: The working temperature can reach 1000 ℃, the melting point is 1200 ℃, the rated welding current is high and supports 500A, the net weight is about 0.02kg, and it is compatible with cooling methods such as water cooling.

Performance Highlights

Stable conductivity: The combination of excellent copper material and meticulous processing technology results in low resistance and uniform current transmission. Even under high current conditions, it can maintain smooth arc combustion, uniform and beautiful weld formation, and reduce welding defect rate.

Smooth wire feeding: The inner hole has high smoothness and low friction resistance, and the dense inner wall created by reputation technology further reduces wire wear. When adapted to special materials such as aluminum welding wire, it can also avoid wire jamming and nozzle blockage problems, and is compatible with manual welding and robot automation welding equipment.

Strong practicality: Chromium zirconium copper material has high temperature resistance (based on actual reports) and outstanding wear resistance. Purple copper material has excellent thermal conductivity, which can avoid high-temperature deformation caused by long-term welding; Through structural optimization, some products have increased their service life by more than 50% compared to ordinary conductive tips, reducing replacement frequency and usage costs.

Wide adaptability: Strictly following the Funis welding gun standard, the thread interface matching is high, and it has strong compatibility with related consumables such as protective nozzles and conductive seats. At the same time, it supports various welding needs such as aluminum welding, carbon steel welding, stainless steel welding, etc., and can be customized to adapt to special scenarios.

Application scenarios

Suitable for gas shielded welding operations with different current levels of 0.8-500A, widely used in industrial scenarios such as steel structure welding, mechanical manufacturing, automotive manufacturing, aluminum alloy processing (such as door and window frames, new energy equipment aluminum structural components), sheet metal processing, automated production lines, etc. Suitable for processes such as CO ₂ gas shielded welding and argon mixed gas shielded welding, it can meet the welding needs of medium thick plates and also adapt to high-frequency batch production robot welding systems. It is an excellent consumable material in the industrial welding industry that combines universality and specialization.