Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A welding gun includes a handle portion comprising a motor configured to move electrode wire through the welding gun. A diffuser comprises an interior chamber and a plurality of openings defining exit passages from the interior chamber to an exterior of the diffuser. A barrel is located between the diffuser and the handle portion and supplies to the diffuser from the handle portion. A contact tip extends from the diffuser and comprises a front portion, a rear portion, and a contact tip bore extending therethrough configured to receive the electrode wire. A diffuser insert is disposed within the interior chamber of the diffuser, including an insert bore extending therethrough configured to receive electrode wire, and an outer surface configured to direct debris from within the interior chamber of the diffuser towards exit passages to discharge the debris. The handle portion is configured to direct a flow of the shielding gas over the motor to cool the motor.

Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A welding diffuser and contact tip assembly is provided for use with a welding apparatus. The assembly includes a diffuser with an interior chamber and a plurality of openings defining exit passages from the interior chamber to an exterior of the diffuser, and a contact tip coupled to the diffuser. The contact tip includes a front portion, a rear portion, and a contact tip bore extending therethrough configured to receive electrode wire. A diffuser insert is disposed within the interior chamber of the diffuser, including an insert bore extending therethrough configured to receive electrode wire, and an angled outer surface configured to direct debris from within the interior chamber of the diffuser towards exit passages to thereby discharge the debris to an exterior of the diffuser. In one example, the rear portion of the contact tip includes an angled outer surface defining the diffuser insert.