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HomeTechnologyWeld Control: What is It, and Why Do You Need It?

Weld Control: What is It, and Why Do You Need It?

The process generates extreme heat using a welding machine with over 300 amperes. This happens at the worn parts and in front of the front end of the welding torch. The worn features include the contact tip holder, the contact tip, the gas nozzle, and the diffuser. Without sufficient welding coolant, a welding torch would reach its limit very quickly, given the reflected heat of the workpiece. When working with a high current and a long duty cycle, besides using an air-cooled torch, you may also need to shift to a liquid-cooled torch. Such an application may not need a water-based coolant but a special coolant designed for such a working environment. 

Which types of welding control coolants should you use?

When using high-current welding machines, the best type is non-flammable with particularly low conductivity. Besides that, weld control should protect equipment against algae formation and corrosion. They should also circulate in the system for a long time without spoiling. So, why do you need a special weld controller? Opinions vary on whether water-based coolants are suitable for welding equipment. Many welders still use water coolant and get shocked when torch failure occurs in weld control.
What makes water a poor weld control is its conductivity. Given a conductivity value of around 700 micro siemens (µS) and more, it is still high to use with a high-current welding machine. The downside of using a water-based coolant is that it can lead to a decomposition voltage. This is when electrical energy turns into chemical energy. It occurs when the coolant goes through a power cable. Such a process causes severe metal oxidation since it generates charged oxygen atoms. Eventually, it will cause corrosion by clogging the welding torch and deposits due to electrical decline from loose oxidation particles.
This will affect the welding torch and its proper cooking channel, and particles will load the power source heavily in the weld control. The cooling system is bound to fail because circulating particles are taken to the pump, tank, and cooler. When changing the coolant, organic particles can enter the tank since some are translucent. Using water as a coolant in high-voltage welding equipment is not recommended. This is because it can cause blockages in the power source due to algae formation. 

Shortcomings of a water welding control coolant

You will experience a chemical reaction when choosing a water coolant. This occurs when current flows through the water. Using ordinary water as a welding coolant is not recommended because it may cause decomposition and dissolution of equipment since a welding system comprises various materials. Brass, which is a base component, can move to copper, which is a precious component. This may cause clogging of the welding torch due to the accumulation of particles. 

Why should you use non-flammable coolant?

Safety at your workplace is paramount in any working environment. Using a flammable coolant is dangerous since you are using high-current welding equipment. Security is guaranteed in the setting for the welder using the welding equipment and the entire cooling and welding equipment. Using safe, high-quality, and durable welding coolant equipment will improve productivity in your welding system. The lifespan of your welding equipment is increased thanks to high-quality weld control. 

When should you change your welding coolant?

It depends on the type of coolant used. It will also depend on the welding torch’s frequency and duty cycle. You will find various tools in the market for measuring the conductivity of your weld control. It would help not to wait until the recommended conductivity is exceeded. Remember that conductivity is measurable. You should always check for particle accumulation before changing your coolant.


If you intend to use a high-currency welding machine, you must find a suitable solution to cool the equipment. Please don’t rush to use a water coolant because it may cause various issues, including equipment failures and dangerous working environments. Proteus Industries offers high-quality welding coolant tools that guarantee safety, durability, and high performance. We will also guide you in choosing a suitable weld control for your welding system. 


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