Lincoln dual hole conductive nozzle

Lincoln dual hole conductive nozzle is a one-to-one consumable manufactured by Lincoln Electric for effect welding scenarios. It is core compatible with dual wire/Twin wire welding systems and achieves synchronous wire feeding and conduction of two welding wires through dual hole parallel design. It is specially designed for high deposition rate and high strength welding requirements and is widely used in heavy-duty manufacturing, steel structure and other mass production scenarios. It is a key component to improve welding efficiency and quality.

Core material and process advantages

Mainstream material selection

CuCrZr: As a core mainstream material, it has excellent conductivity (IACS ≥ 80%) and high strength performance. Its hardness can reach HRB ≥ 80, and its high temperature resistance (based on actual reports) is outstanding. It can withstand high temperature environments above 500 ℃ during the welding process. The electrode loss is reduced by more than 60% compared to ordinary brass materials, and the total welding cost is relatively low. It is an honest merchant in medium high current and continuous operation scenarios.

Purple copper (T2): It has excellent electrical and thermal conductivity, low current transmission loss, relatively affordable cost, suitable for low current, intermittent welding scenarios, and meets the basic needs of ordinary carbon steel welding. However, its wear resistance (based on actual reports) and high temperature resistance (based on actual reports) are weaker than chromium zirconium copper, making it more suitable for light load operations.

Detailed processing technology

Adopting CNC precision suitable drilling technology, the concentricity error of double holes is ≤ 0.03mm, the inner hole is smooth without burrs, and it is confirmed that the wire feeding resistance of the two welding wires is uniform to avoid jamming or eccentric wear problems.

The double hole spacing has been optimized and carefully matched to meet the arc coordination requirements of double wire welding, ensuring even current distribution between the two welding wires and strong consistency in weld fusion.

The surface has been specially treated to reduce welding spatter adhesion, and the front-end arc transition design reduces the risk of wire sticking. At the same time, the protective gas flow path has been optimized to improve the oxidation effect of the weld seam.

Structural design and specification parameters

Characteristics of innovative structure

Dual hole parallel design: Two independent inner holes are arranged in parallel to meet the requirements of dual wire synchronous wire feeding. Compared with a single hole conductive nozzle, the deposition efficiency is significantly improved, and it can achieve the speed suitable for forming large welds.

Dual Cam Structure: Some premium models (such as the HyperFill HD series) are equipped with a well-known dual cam design, which can evenly tighten the fit between the conductive nozzle and the diffuser, reduce wire bending and installation deviation, improve current transmission stability, and reduce resistance heating.

Quick lock installation: Using a quarter turn cam lock connection method instead of traditional threaded design, it is easy to install and disassemble, and can effectively prevent two welding wires from getting tangled, improving the efficiency of parts replacement.

Key specification parameters

Inner hole diameter: Common specifications include 0.8mm, 1.0mm, 1.2mm, 1.6mm, etc. The double hole diameter should be kept consistent and carefully matched with the wire diameter of the double wire welding (usually 0.02-0.2mm larger than the wire diameter). Mainstream models such as 0.035 inches (about 0.89mm) are suitable for thin wire effect welding, and 2.0-2.4mm hole diameter is designed for flux cored wire.

Compatible welding gun and equipment: meticulously matched with Lincoln K345-10 semi-automatic welding gun Magnum ® PRO series water-cooled/air-cooled welding guns, as well as 32P DC-400, RMD and other welding machines, are compatible with KP4481-2-HD and other one-to-one diffusers.

Size and packaging: The length is mostly standard sizes such as 50mm, and the bending options include 200mm and 300mm, meeting the requirements of complex angle welding; The packaging specifications include single pack, 10 pack, and 100 pack, which are suitable for different production needs of different scales.

Performance parameters: The rated welding current supports a wide range of 100-1500A and is compatible with GMAW (gas metal arc welding) and other processes. In robot welding scenarios, the deposition rate can reach over 24 pounds per hour, and in semi-automatic welding scenarios, the deposition rate is ≥ 18 pounds per hour, without affecting the stability of the weld pool and the quality of the weld seam.

Core Performance and Application Scenarios

Highlight performance advantages

Good deposition efficiency: The double wire synchronous welding design improves welding efficiency by more than 50% compared to traditional single wire conductive nozzles, and can complete welding of thick plates and large structural components at a suitable speed, shortening the production cycle.

Conductive heat dissipation stability: The dual cam structure provides two-point current contact, reducing resistance heating. The working temperature of the conductive nozzle is relatively low, avoiding aperture deformation or burner problems caused by high temperature, and extending the service life.

Excellent welding quality: precise positioning of double holes confirms stable wire spacing, uniform arc combustion, good fusion of welds, reduces defects such as porosity and arc deviation, and creates a beautiful shape; At the same time, it reduces splashing adhesion and lowers the subsequent polishing workload.

Strong installation convenience: The quick lock design does not require complex thread fastening, and there is no need to adjust the welding program during replacement, protecting production continuity and reducing downtime.

Typical application scenarios

Heavy machinery manufacturing: welding thick plates such as construction machinery frames and excavator structural components.

Steel structures and shipbuilding: welding of large loads such as containers, ship decks, and bridge steel structures.

Construction and Manufacturing: Mass production scenarios for building steel structures, pressure vessels, pipeline welding, etc.

Automated production line: robot welding workstation, semi-automatic high-frequency welding line, especially suitable for welding processes with high deposition rate and high strength requirements.