D/F Water-Cooled-to-the-Tip 5" & 8" Sub-Arc MIG Torches

Standard Barrels
(7/16"-3/4" Gas Cup ID)

Overview Ordering Manuals &
Drawings Accessories More Info

Overview

The D/F Direct Mount Water-Cooled-to-the-Tip Sub-Arc (SAW) Torches are the same as the Direct Mount Water-Cooled-to-the-Tip Torches. These torches feature the 1.125" smaller O.D. water-cooled nozzle for hard-to-reach, limited access areas. The D/F Machine Automatic Sub-arc positive contact assemblies are designed to provide long trouble-free service and are ideal for beam-mounted, portable tractor or semi-automatic systems for heavy fabrication environments. Submerged arc welding guns for subarc welding from D/F provide maximum control over deposition and penetration. These D/F heavy duty water-cooled weld automation torches are ideal and have been used for metal build up, hard facing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub arc applications, and applications where flux and carbide is added.

Until now Submerged Arc welding (SAW) was primarily done with an air-cooled sub arc torch. Most of the problems associated with A/C torches are caused by heat and lack of cooling. The air-cooled torches have large air-cooled power cables that get very hot carrying the power, the torches get extremely hot from the cables and from the welding process. Because of the heat with air-cooled welding you now have a hot gun holding a hot tip. Everything is so hot that the consumables break down at much higher rates. Couple this with the large sub arc welding tips that are extremely expensive, now you have the need to seek out a better solution. This is why D/F has a heavy duty water-cooled sub arc torch and it is a superior replacement to the Lincoln K231-1 Submerged Arc Contact Nozzle Assembly or the Profax Sub Arc PX-K231 Nozzle Assembly. D/F Submerged arc guns are robust and built to last. A simple and compact design makes them durable and easy to maintain. With little interaction and down time required, the D/F Automatic Water-Cooled to the Tip torches are ideal for the hot environment. The torch will last years compared to months with the competition. Due to the torches superior water cooling, the tip will last for days rather than through just a couple of parts, and will outlast the competition at least 7-to-1, and sometimes 14-to-1. Don’t forget that the D/F sub-arc tips are 1/5 of the cost of the large air-cooled sub-arc tips. The submerged arc process is widely used in heavy steel plate fabrication work. This includes the welding of structural shapes, the longitudinal seam of larger diameter pipe, the manufacture of machine components for all types of heavy industry, and the manufacture of vessels and tanks for pressure and storage use. It is widely used in the shipbuilding industry for splicing and fabricating sub-assemblies, and by many other industries where steels are used in medium to heavy thicknesses. It is also used for surfacing and buildup work, maintenance, and repair.

The major advantages of the SAW or submerged arc welding process are:

  • High quality metal weld
  • Extremely high speed and deposition rate
  • Smooth, uniform finished weld with no spatter
  • Little or no smoke
  • No arc flash, thus minimal need for protective clothing
  • High utilization of electrode wire
  • Easy automation for high-operator factor.
  • Normally, no involvement of manipulative skills

Features

  • Water Cooled Internally - Tip Recessed in Water Cooling
  • Water Cooled Externally - Gas Cup Recessed in Water Cooling
  • Up to 650 Amps Continuous Duty Cycle
  • Up to 850 Amps Continuous with Dual Power Cables
  • Adaptable to Any Wire Feeder or Power Source
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-W/C-T - Normal Duty, Collet Action (Slip-In Tip), Machine Barrel - Water-Cooled-to-the-Tip
  • HTM-W/C-T Series-A - Heavy Duty, Threaded Tip, Machine Barrel - Water-Cooled-to-the-Tip

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT w/ 5"
NOZ. (APPROX.)		 WEIGHT w/ 8"
NOZ. (APPROX.)		 COOLING
REQUIRED		 RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM-W/C-T 450 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL		 599
HTM-W/C-T 850 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL
HTM-W/C-T
(with Dual Power Cable)		 850 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL

Barrel Dimensions

MODEL LENGTH W/ 5" NOZZLE LENGTH W/ 8" NOZZLE DIAMETER OF DOCKING SPOOL BODY DIAMETER OF W/C NOZZLE
NCM-W/C-T, HTM-W/C-T 9.25" 12.25" 1.625" 1.125"

The direct mount fully Water-Cooled-to-the-Tip Docking Spool® accommodates two (2) water-cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA3, NA4, NA5, NA5R, Power Feed 10, LF72, LF74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water cooled nozzle at the lower end with superior water cooling. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®. In addition a POSIT® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.

Ordering Information (Complete Assemblies)

DESCRIPTION CODE NO. (NCM) CODE NO. (HTM)
5" Nozzle 40134 40246
8" Nozzle 40135 40247
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40134 with 4 Ft. Water-In Hose Assembly: 40134-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM-W/C-T, HTM-W/C-T 599

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM-W/C-T 5" 40134 40134 40134
HTM-W/C-T 5" 40246 40246 40246
NCM-W/C-T 8" 40135 40135 40135
HTM-W/C-T 8" 40247 40247 40247

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C Direct Mount Water-Cooled-to-the-Tip
One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

Torch Rack #30418 and Rack Mount

An optional D/F Torch Rack #30418 can be used on any torch with an 8" long, 1.125" diameter water-cooled nozzle. The rack slips right over the water-cooled nozzle and is secured with 4 set screws. The rack can then be dropped into a BUG-O BUG-5188 Rack Holder. The rack has a 32 pitch gear, and with the rack holder makes torch head positioning very easy. See the images below right. See the Torch and Rack Mount product page for more information

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Torch RackD/F Torch Rack

D/F #30421 Sub-Arc Attachment

The D/F Water-Cooled-to-the-Tip Machine Barrels used with the D/F Submerged Arc Attachment are the industry's most advanced sub-arc torches for mobile, hard automation, and robotic feeding equipment, and will help achieve new levels of welding performance and operational efficency. Whether your application is bridge decking, pressure vessels, panel line, seamers, pipe mill integrator solutions, or submerged arc robotic welding, the D/F sub arc choices are designed to improve weld quality, reduce welding and operational costs, and increase weld team productivity.

Sub-Arc

D/F Water-Cooled-to-the-Tip Sub-Arc - More Information

The D/F Water-Cooled-to-the-Tip automatic Remote Mount and Direct Mount Machine Barrels are ideal for submerged arc (SAW) welding applications. They are repairable and easy to maintain. Our consumables are always in stock and are 1/3 of the cost of competitiors'. Customers have been perpetually pleased to find out that we ship every order within 3 days of receipt of a purchase order, and that we are always willing to do our best to ship our equipment for next-day delivery.

Submerged-arc welding (SAW) involves the formation of an arc between a continuously fed electrode and the workpiece. A blanket of powdered flux, which generates a protective gas shield and a slag (and may also be used to add alloying elements to the weld pool), protects the weld zone. A shielding gas is not required. The arc is submerged beneath the flux blanket and is not normally visible during welding. SAW's ability leads to its extremely high deposition rates, which allows for more rapid heat penetration and stability of the arc. In traditional power supplies, when the wave passes from positive (EP) to negative (EN) in its half-cycle, a lag or interruption may occur in the arc, subsequently causing problems in the weld. While this factor and its related input and output issues previously limited speed and productivity, now it is resolved in advanced power equipment. For starters, it is now possible to weld AC and DC polarity in the same puddle, using the same power source. In the past different machines were necessary, and sometimes the DC and AC welds had to be laid down in different passes. Today's SAW offers the opportunity to create a weld faster and with unique, specialized properties. The benefits of AC for high deposition, stability, and the elimination of arc blow can be realized, while DCEP/DCEN enable stable penetration at much faster speeds. Because of what is happening on the back end of these new machines, welders now have many more options at the arc. Older equipment ran according to a limited set of parameters; today's power sources run and react.

The direct mount fully Water-Cooled-to-the-Tip Docking Spool® accommodates two (2) water cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA-3, NA-4, NA-5, NA-5R, Power Feed 10, LF-72, LF-74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water cooled nozzle at the lower end with superior water cooling. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®. In addition a POSIT® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.

W/C Tip model torches can also be retrofit to have 2 water/out & power cables increasing the continuous duty cycle rating to 850 amps. These amperages require the use of the HTM or threaded series of chromium zirconium (CrZr) current tips.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. Water outlet temperature should not exceed 27°C (80°F). The torch’s water out & power cable is not cooled until the coolant has gone through the torch and out the water out & power cable. If water is not flowing through the D/F torch for at least 1 minute prior to striking an arc, when you apply the power and water hits the “hot” water/out & power cable, you will generate steam. Steam can damage the torches internals in seconds causing a leak. It can also blow out the torches water/out & power cable. A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc. When High-Deposition GMAW, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. Precise temperature control maintains the cooling at a constant 13°C (55°F) temperature, thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Fixed automation is a process that uses mechanized machinery to perform repetitive operations in order to produce a high volume of similar parts. In fixed automation, the sequence of processing operations is fixed by the equipment layout.

Programmable automation is an applied form of fixed automation that is capable of repeating motion, in a series of steps, for producing products in batches. Applied products in a programmable automation system are made in batch quantities ranging from several dozen to several thousand units at a time. For each new batch, the programmable automation equipment must be reprogrammed and changed over to accommodate the new product style. Programmable automation may commonly include one to three axes of torch motion and/or multiple welding arcs.

D/F Machine Specialties is the world leader in the manufacture of water-cooled torches for hard automation systems which encompasses fixed automation and programmable automation.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), and inlet (as needed) must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

Series-A Direct Mount
D/F Water-Cooled-to-the-Tip A8

Series A High Capacity Barrels
(11/16"-1" Gas Cup ID)

Overview Ordering Manuals &
Drawings Accessories More Info

Overview

The fully Water-Cooled-to-the-Tip® Robotic MIG (GMAW) Torch Models NCM-W/C-T & HTM-W/C-T are applied to a Direct Mount Docking Spool® for high current single arc welding. These robotic torches are fully water cooled internally and externally. The internal body of the torch is water cooled, thus putting the water cooling on the tip. This has increased tip life up to 14 times longer. Also, because the water cooling is on the tip, this enables customers to use our less expensive 122 slip-in copper tips for many applications. The exterior water cooled nozzle is internally water cooled as well. There are no bulky external water lines in the way leading down getting caught or getting damaged by heat. Because of the superior internal and external water cooling of this torch, you can run the full range of wires from .030"-1/8", whether your job is aluminum, steel, stainless steel, hard, cored, flux cored, stellite or inconel wire, whether your job has 1000 degree preheat, high deposition or continuous duty cycles, this is the torch. Very similar in design to the Linde ST12, Guild ST12, and Abicor Binzel AUT 750 but with improvements and new features, and proven to be a superior replacement alternative for the Linde HW13, or now called the ESAB HW13, the D/F Machine Water-Cooled-to-the-Tip® Robotic Torches are designed to provide long trouble-free service. These Automatic Water-Cooled-to-the-Tip® Torches are available in 5" and 8" lengths. Each length is available with our standard size nozzles (1.125"), and our high capacity (series A) nozzles (1.445") for more gas coverage. You can switch between the standard nozzles and high capacity nozzles if you have the correct inner parts for each. With the various models available a contact assembly selection may be made to suit individual robot torch requirements.

D/F Machine Specialties Hardfacing Gun - Water-Cooled-to-the-Tip® Hardbanding TorchThe fully Water-Cooled-to-the-Tip® direct mount Docking Spool® MIG (GMAW) automatic models NCM-W/C-T & HTM-W/C-T machine torches are for high current single arc welding. These torches are very similar in design to the Linde ST12, ESAB ST12, Guild ST12 and Abicor Binzel AUT 750 but with improvements and new features, and proven to be a superior replacement alternative for the Linde HW13, or now called the ESAB HW13, machine welding torch, and easily connects to the Linde MIG 35 or ESAB MIG 35. These torches can also be connected to subarc machines and used for MIG and sub arc on Lincoln Electric NA-5 & NA-5R submerged arc wire feeders with K148A & K148B torches, or on Miller sub-arc machines with OBT 600 & OBT 1200 torches. The D/F Machine Automatic Water-Cooled-to-the-Tip® positive contact assemblies are designed to provide long trouble-free service. These Automatic Water-Cooled-to-the-Tip® Torches are available in 5" and 8" lengths. Each length is available with our standard size nozzles (1.125"), and our high capacity (Series A) nozzles (1.445") for more gas coverage. You can switch between the standard nozzles and high capacity nozzles if you have the correct inner parts for each. With the use of the D/F sub-arc nozzle thread seals (14871 for Standard Size nozzles & 14872 for High Capacity size nozzles) these heavy duty MIG water-cooled torches can be converted and used as sub arc torches. Because of the robust design of the torch and the water-cooling on the body, nozzle and tip, downtime and consumable cost can be greatly reduced in the submerged arc process (SAW). With the various models available, an automated MIG torch selection may be made to suit individual automated welding system requirements.

Features

  • Water Cooled Internally - Tip Recessed in Water Cooling
  • Water Cooled Externally - Gas Cup Recessed in Water Cooling
  • Up to 650 Amps Continuous Duty Cycle
  • Up to 850 Amps Continuous with Dual Power Cables
  • Adaptable to Any Wire Feeder or Power Source
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-W/C-T Series-A - Normal Duty, Collet Action (Slip-In Tip), Machine Barrel - Water-Cooled-to-the-Tip, High Capacity (Series A)
  • HTM-W/C-T Series-A - Heavy Duty, Threaded Tip, Machine Barrel - Water-Cooled-to-the-Tip, High Capacity (Series A)

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT w/ 5"
NOZ. (APPROX.)		 WEIGHT w/ 8"
NOZ. (APPROX.)		 COOLING
REQUIRED		 RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM-W/C-T 450 amps 3 lbs 3.8 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL		 599
HTM-W/C-T 650 amps 3 lbs 3.8 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL
HTM-W/C-T
(with Dual Power Cable)		 850 amps 3 lbs 3.8 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL

Barrel Dimensions

MODEL Length w/ 5" Nozzle Length w/ 8" Nozzle Diameter of W/C Nozzle
NCM-W/C-T A, HTM-W/C-T A 9.25" 12.25" 1.445"

Ordering Information (Complete Assemblies)

DESCRIPTION CODE NO. (NCM) CODE NO. (HTM)
Series A5" Nozzle 40136 40248
Series A8" Nozzle 40137 40249
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40137 with 4 Ft. Water-In Hose Assembly: 40137-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM-W/C-T A, HTM-W/C-T A 599

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM-W/C-T A5" 40136 40136 40136
HTM-W/C-T A5" 40248 40248 40248
NCM-W/C-T A8" 40137 40137 40137
HTM-W/C-T A8" 40249 40249 40249

Other Documents

DESCRIPTION DOWNLOAD
Choosing the Proper Chiller
for Your Application
Torch Connection Options
W/C Direct Mount Water-Cooled-to-the-Tip®
One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

Water-Cooled-to-the-Tip® Torches - More Information

D/F Machine Specialties Hardbanding Gun - Water-Cooled-to-the-Tip® Hardfacing TorchThese D/F torches are very robust in design and fully water-cooled to the tip inside and out. This means that the contact tip is actually in the water-cooling, increasing contact tip life up to 7-to-1. The copper gas cup is also threaded into the front water-cooled nozzle assembly, potentially increasing its life to several months. The great increase in consumable life results in an equally great decrease in costs and downtime.

Another great feature of these torches is the fact that they have a slip-in tip, so if you have a burn back you are not dealing with all the hassle of a threaded tip. The welders love the slip-in tip! With the use of the D/F collet wrench, all you have to do is loosen the collet one half turn to remove the tip. It is not necessary to remove a gas cup in order to remove a tip. Upon getting a burnback, loosen the tip one half turn, run it a couple inches out of the torch, cut the wire with a wire cutter, put in the new tip, and begin welding again; it is that easy. With the slip-in tip you will have none of the struggles as with a threaded tip, and there is no need for removing the gas cup and using a bolt cutter or hack saw. Since the majority of hardbanding is done with 1/16” wire, most people, if not all, are below 500 amps, and because of our superior water cooling on the tip, the inexpensive slip-in tip will do a great job on 1/16” wire at those amperages. If higher amperages and larger wire sizes are needed, a heavy duty CrZr threaded tip is also available. These Water-Cooled-to-the-Tip® hardbanding guns and hardbanding torches are the most robust hardbanding welding guns in the industry.

Each D/F Automatic Welding Torch head is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, make/model Automated Welding System (Thermadyne Thermal Arc Wire Feeders, Lincoln wire feeders, Miller wire feeders, Linde/ESAB wire feeders), and inlet as needed must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

Hardbanding Torches

Hardbanding

Hardbanding is the process of depositing hardfacing alloys onto drill pipe casing tool joints, collars and heavy weight pipe in order to protect both the casing and drilling assets from wear associated with drilling practices. Hardbanding is most commonly applied to the box end of drill pipe tool joints using a MIG welding process, bonding the hardbanding alloy with the parent steel of the drill pipe. There are, however, other hardbanding application methods that are occasionally used including laser and plasma arc processes.

The need for steel repair services arose decades ago when drilling contractors and operators wanted a way to protect and extend the life of costly drill pipe and tool joint material from the wear associated with rotational and axial friction forces while drilling and tripping in and out of a well. Initially, tungsten-carbide particles were dropped into a mild-steel matrix, remaining the industry standard used for many years. However, well owners soon realized that while the tool joint was virtually free of wear, the tungsten-carbide based hardbanding was causing extreme rates of wear and occasional total failure of the well casing. The goal for the hard banding industry became clear: create a hardbanding alloy that is casing-friendly while providing adequate protection of the tool joints.

Since that time, the market has become increasingly competitive and newer, more metallurgically advanced alloys have been introduced that protect casing and drill string assets better than ever. As wells are being drilled further, faster and more directionally, new challenges arise for hardbanding alloy producers. Competitive hardbanding products must now be able to protect drilling and casing components, but also withstand increasing extreme pressures and temperatures experienced in wells today. "Staying ahead of where drilling is going" is a mantra that every hardbanding producer will have to follow in order to stay competitive. Research is producing valuable and telling results that is enabling companies to improve their existing products, as well as, work towards introducing new and innovative hardfacing alloys to protect drill pipe and casing assets like never before. These Water-Cooled-to-the-Tip® hardfacing guns and hardfacing torches are the most robust hardfacing welding guns in the industry.

As drills go deeper and the hardbanding industry stedily evolves, D/F Machine Specialties strives to meet the assocaited demands by selling quality MIG welding products for your hardbanding needs. Our Automatic MIG Water-Cooled-to-the-Tip® Machine Torches and our Open-Arc Water-Cooled Gasless Overlay Machine Torches are ideal for steel wire, stainless steel, hard, cored, flux cored, or stellite, 1000 degree preheat, high deposition or continuous duty cycles - these are the torches used by:

  • ARC Equipment Repair - Leading Manufacturer for portable and in-house hardbanding equipment and repair of hardbanding equipment
  • Hardbanding Solutions Europe - Manufacturer of Hardbanding Equipment
  • Postle Industries - Hardbanding Solutions - Home of the Most Wear Resistant, Non-Cracking Casing Friendly Hardbanding on the Market
  • CSI Inspection, LLC - Visual, Mag Particle, EMI, UT and Shear Wave Inspection Services with State of the Art Calibrated Equipment
  • Smith Services (Schlumberger) - Hardbanding Solutions, Drilling Tools & Services
  • Arnco - Wear Resistand Hardbanding Alloys for the Worldwide Petroleum Industry
  • Coffey Mfg., LLC - Manufacturer for portable and in-house Hard Banding Equipment

Hardbanding solutions for your business - whether you are oil & gas operators, drilling contractors, pipe rental companies, pipe manufacturers, or hardband applicators, hardbanding will help you:

  • Extend the life of tool joints
  • Reduce the number of times the pipe is pulled for maintenance
  • Provide faster re-application of hardbanding - 100% rebuildable
  • Non-cracking minimizes problems of spalling and cracking
  • Ease of application with minimal clean up
  • Fast delivery means reduced inventory
  • Easy re-application - 100% rebuildable without removing the previous hardbanding layers

Companies that use hardbanding solutions:

  • British Petroleum
  • Ensign Drilling
  • Exxon Mobil
  • Marathon Oil
  • RDT
  • Shell Exploration
  • Transocean
  • VAM
  • Weatherford

Hardbanding Torches

What is hardbanding?
Hardbanding is the process of depositing a layer of super hard metal onto drill pipe tool joints, collars and heavy weight pipe in order to protect both the casing and drill string components from wear associated with drilling practices.

From the Petroleum Industry Glossary:

Hardbanding is the process of laying on a coating or surface of [super-hard metal] on a [softer metal part] at a point or on an area of severe wear or abrasion - putting a hard surface on a softer metal by welding or other metallurgical process. Where it may be impractical or prohibited by structural constraints to manufacture a part from the harder metal, hard-surfacing of the part is a practical solution. Hardbanding is the term given to hardfacing drill pipe – hardbanding is a specific form of hardfacing.

How is hardbanding applied?
Hardbanding is most commonly applied using a modified MIG welding apparatus designed specifically to apply hardbanding onto a tubular surface. With this process, a continuous consumable wire electrode and a shielding gas are fed through a welding torch. An electric arc transferred between the wire electrode and parent metal melts the hardbanding wire and forms a fully metallurgically bonded hardbanding weld overlay. There are, however, other hardbanding application methods that are occasionally used including laser and plasma arc processes.

How often does hardbanding have to be reapplied?
Depending on drilling conditions and hardbanding performance, hardbanding will have to be reapplied anywhere from several weeks to many months of service. Hardband re-application is a costly and time consuming process which usually involves transporting drill string components to inspection or other facilities that are capable of hardbanding operations. Mobile hardbanding units may also be deployed to or near drilling operations for on-site application. Use of these machines depends on the availability or supply of units offered in any given area.

What are the different types of hardbanding?
Hardband products can generally be divided up into two categories: Tungsten Carbide (non casing-friendly) and Casing Friendly hardband products. Casing friendly material can be metallurgically classified as “chromium-carbide”, “Titanium Carbide”, “Niobium Boride”, and other, based materials.

What is "cracking hardbanding", and why does it crack?
Cracking hardbanding describes a hardbanding product that exhibits what is referred to in the hardfacing world as “check relief cracking”. “Check relief cracking” occurs when low-melting phases form over grain boundaries as the molten weld puddle cools. In other words, a specific type of carbide forms on the grain boundaries of the microstructure that create stress as the material cools immediately after being deposited on the parent metal – as a result, fine cracks form. Hardfacing materials that exhibit cracking cannot be used for structural uses, though for abrasion or wear resistance they are widely acceptable, as in the case of hardbanding for tool joint and other drill string component applications.

What is Hardfacing?
Hardfacing is gaining more and more importance in the most varied fields of modern engineering. In the case of wear, corrosion and other types of surface attack, the application of hardfacing permits the economical reconditioning of many structural members. Reconditioning may comprise workpieces subjected to metal-to-metal wear such as rollers, crane wheels, shafts, rails or which are subjected to metal-to-mineral wear, like building machinery, conveyor screws, excavator bucket edges, etc.

The possibilities of hardfacing not only lie in the field of reconditioning, but more and also in the manufacture of new tools and components. In this manufacturing process, a non-alloyed or low-alloy steel is used as carrier material to which are imparted special properties by welding on a suitable high quality weld metal. Decisive factor in hardfacing is the knowledge of the wear conditions, that is, whether it is a frictional wear caused by metal or minerals, corrosion, cavitation, erosion or temperature. The selection of the welding consumable to be used will depend on these conditions. Besides this, it is most important to know the composition of the base metal to be surfaced, because of the measures likely to be taken, such as preheating and/or post weld treatment..

What are the Various Demands that Hardfacing will Satisfy?
Depending on the use of the workpiece to be hardfaced, the weld metal shall meet the most varied demands. These can be cited as follows:

In some cases, more than one of these modes of load may occur simultaneously, so that the weld metal must posses the respective properties. Hence, a conscientious selection of the proper weld metal will be a must. Of course, there doesn't exist a weld metal possessing all these properties in full measure. Nevertheless, in most cases it will be possible to find a satisfactory compromise in practice.

  1. Hardness in the As-Welded Condition
  2. Red Hardness under Thermal Loads
  3. Resistance to Metal-to-Metal Wear
  4. Abrasion Resistance to Frictional and Grinding Wear
  5. Impact Strength
  6. Corrosion Resistance
  7. Resistance to Scaling

How Can Hardfacing be Used to Recondition Tools?
An interesting field of application in hardfacing is reconditioning of hardened tools, such as shear blades, punching dies, cutting edges, deep-drawing tools, etc. For this purpose, the so-called “step hardening weld method” has proven a success. Welding is carried out in the delayed transformation range which is situated between the perlite and bainite zones of TTT-curves of the steel in question. Thereby, the hardenability of the steel is taken into account. Generally, the temperature range in which welding shall be carried out is from 400°C to 600°C. This means, that step welding is based on the fact that in such steels the transformation of austenitic is clearly delayed within a certain temperature range. The sequence of operations is as follows:

  1. Slow heating of the workpiece to its hardening temperature. At this temperature the structure becomes austenitic.
  2. Cooling to step temperature; that is, to the range in which the delay in austenitic transformation (according to TTT-diagram) is most pronounced.
  3. Welding the workpiece at this temperature.
  4. Cooling the workpiece to room temperature in still air or better in oil (50°C to 150°C).
  5. Tempering to the respective temperature which in the case of high-speed steels lies in the range of 550°C to 570°C.
  6. Machining the weld area.
Standard Direct Mount
D/F Water-Cooled-to-the-Tip 5" & 8" Standard MIG Torches

Standard Barrels
(7/16"-3/4" Gas Cup ID)

Overview Ordering Manuals &
Drawings Accessories More Info

Overview

The fully Water-Cooled-to-the-Tip® Models NCM-W/C-T & HTM-W/C-T Direct Mount Automatic Machine Torches offer the same features as those described for the machine barrels above. These torches feature the 1.125" smaller O.D. water-cooled nozzle for hard-to-reach, limited access areas. Very similar in design to the Union Carbide Linde ST-12, ESAB ST-12, Guild ST-12, and Abicor Binzel AUT 750 but with improvements and new features, and proven to be a superior replacement alternative for the Linde HW-13, or now called the ESAB HW-13, machine welding torch, the D/F Machine Automatic Water-Cooled-to-the-Tip® positive contact assemblies are designed to provide long trouble-free service. These D/F heavy duty water-cooled weld automation torches are ideal and have been used for metal build up, hard banding, hard facing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub arc applications, and applications where carbide is added.

The direct mount fully Water-Cooled-to-the-Tip® Docking Spool® accommodates two (2) water-cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA3, NA4, NA5, NA5R, Power Feed 10, LF72, LF74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water cooled nozzle at the lower end with superior water cooling. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®. In addition a POSIT® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.

Features

  • Water Cooled Internally - Tip Recessed in Water Cooling
  • Water Cooled Externally - Gas Cup Recessed in Water Cooling
  • Up to 650 Amps Continuous Duty Cycle
  • Up to 850 Amps Continuous with Dual Power Cables
  • Adaptable to Any Wire Feeder or Power Source
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-W/C-T - Normal Duty, Collet Action (Slip-In Tip), Machine Barrel - Water-Cooled-to-the-Tip
  • HTM-W/C-T - Heavy Duty, Threaded Tip, Machine Barrel - Water-Cooled-to-the-Tip

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT w/ 5"
NOZ. (APPROX.)		 WEIGHT w/ 8"
NOZ. (APPROX.)		 COOLING
REQUIRED		 RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM-W/C-T 450 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL		 599
HTM-W/C-T 650 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL
HTM-W/C-T
(with Dual Power Cable)		 850 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL

Barrel Dimensions

MODEL Length w/ 5" Nozzle Length w/ 8" Nozzle Diameter of W/C Nozzle
NCM-W/C-T, HTM-W/C-T 9.25" 12.25" 1.125"

Ordering Information (Complete Assemblies)

DESCRIPTION CODE NO. (NCM) CODE NO. (HTM)
Standard 5" Nozzle 40134 40246
Standard 8" Nozzle 40135 40247
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40134 with 4 Ft. Water-In Hose Assembly: 40134-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM-W/C-T, HTM-W/C-T
(All 5" Nozzles) 		599

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM-W/C-T 5" 40134 40134 40134
HTM-W/C-T 5" 40246 40246 40246
NCM-W/C-T 8" 40135 40135 40135
HTM-W/C-T 8" 40247 40247 40247

Other Documents

DESCRIPTION DOWNLOAD
Choosing the Proper Chiller
for Your Application
Torch Connection Options
W/C Direct Mount Water-Cooled-to-the-Tip®
One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

Torch Rack #30418 and Rack Mount

An optional D/F Torch Rack #30418 can be used on any torch with an 8" long, 1.125" diameter water-cooled nozzle. The rack slips right over the water-cooled nozzle and is secured with 4 set screws. The rack can then be dropped into a BUG-O BUG-5188 Rack Holder. The rack has a 32 pitch gear, and with the rack holder makes torch head positioning very easy. See the images below right. See the Torch and Rack Mount product page for more information

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Torch RackD/F Torch Rack

D/F #30421 Sub-Arc Attachment

The D/F Water-Cooled-to-the-Tip® Machine Barrels used with the D/F Submerged Arc Attachment are the industry's most advanced sub-arc torches for mobile, hard automation, and robotic feeding equipment, and will help achieve new levels of welding performance and operational efficiency. Whether your application is bridge decking, pressure vessels, panel line, seamers, pipe mill integrator solutions, or submerged arc robotic welding, the D/F sub arc choices are designed to improve weld quality, reduce welding and operational costs, and increase weld team productivity.

Subarc

D/F Water-Cooled-to-the-Tip® - More Information

The D/F Water-Cooled-to-the-Tip® automatic Remote Mount and Direct Mount Machine Barrels are ideal for hardbanding applications. They are repareable and easy to maintain. Our consumables are always in stock and are 1/3 of the cost of competitiors'. Customers have been perpetually pleased to find out that we ship every order within 3 days of receipt of a purchase order, and that we are always willing to do our best to ship our equipment for next-day delivery.

The direct mount fully Water-Cooled-to-the-Tip® Docking Spool® accommodates two (2) water cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA-3, NA-4, NA-5, NA-5R, Power Feed 10, LF-72, LF-74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water cooled nozzle at the lower end with superior water cooling. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®. In addition a POSIT® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.

The W/C Tip Torches can run the complete line of D/F standard size C122 DHP contact tips and the complete line of D/F standard size CrZr (chromium zirconium) long-life contact tips, as well as any custom current tip configuration you may need. .030" (.8mm), .035" (.9mm), .045" (1.2mm), .052" (1.4mm), 1/16" (1.6mm), 3/64" (1.2mm), 5/64" (2mm), 3/32" (2.4mm), 1/8" (3.2mm) and other diameters.

W/C Tip D/F Machine Specialties torches are standard equipped with 1 water/out & power cable are rated at 650 amps (continuous duty cycles). These ratings are, however, dictated by the contact tip. The NCM (slip-in) series of contact tips is rated up to 450 amps (continuous duty cycles). If your welding application requires amperage above 450, you must change to the heavy duty threaded CrZr (chromium zirconium) series of contact tips.

These automatic machine welding assemblies are designated by torch models. The model NCM (slip-in Contact Tip) has a current capacity 450 amps in argon shielding. Like the ESAB ST-12, these accommodate slip-in current tips fastened by a collet action nut. The wire diameter range with hard wire is .030"-1/16", cored wire .035"-1/8", and aluminum wire range of .035"-3/32".

The torch model HTM (Threaded Contact Tip) has a current capacity range of 650 amperes. Rating will be contingent on the combination of current tip and shielding gas to be used. The model HTM employs threaded CrZr (chromium zirconium copper) current tips and will accommodate .030" - 1/16" hard wire, .035" – 1/8" cored wire and 3/64" - 3/32" aluminum wires.

In some instances C122 DHP is adequate, but for stainless steel and stiff, high column strength or abrasive wires such as flux cored / metal cored, CrZr is the correct choice. D/F Machine Specialties can increase several key characteristics creating a higher-quality consumable with increased conductivity, even higher softening temperature and improved hardness. This means a reduction in "arc start failures" and increased tip life. Copper chromium zirconium (CuCrZr) contact tips increase productivity.

W/C Tip model torches can also be retrofit to have 2 water/out & power cables increasing the continuous duty cycle rating to 850 amps. These amperage require the use of the HTM or threaded series of chromium zirconium (CrZr) current tips.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. Water outlet temperature should not exceed 27°C (80°F). The torch’s water out & power cable is not cooled until the coolant has gone through the torch and out the water out & power cable. If water is not flowing through the D/F torch for at least 1 minute prior to striking an arc, when you apply the power and water hits the “hot” water/out & power cable, you will generate steam. Steam can damage the torches internals in seconds causing a leak. It can also blow out the torches water/out & power cable. A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc. When High-Deposition GMAW, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. Precise temperature control maintains the cooling at a constant 13°C (55°F) temperature, thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Fixed automation is a process that uses mechanized machinery to perform repetitive operations in order to produce a high volume of similar parts. In fixed automation, the sequence of processing operations is fixed by the equipment layout.

Programmable automation is an applied form of fixed automation that is capable of repeating motion, in a series of steps, for producing products in batches. Applied products in a programmable automation system are made in batch quantities ranging from several dozen to several thousand units at a time. For each new batch, the programmable automation equipment must be reprogrammed and changed over to accommodate the new product style. Programmable automation may commonly include one to three axes of torch motion and/or multiple welding arcs.

D/F Machine Specialties is the world leader in the manufacture of water-cooled torches for hard automation systems which encompasses fixed automation and programmable automation.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), and inlet (as needed) must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

22° & 45° Torches
D/F Water-Cooled 22° & 45° Curved MIG Torches

W/C Curved 22° & 45° Machine Barrels

Overview Ordering Manuals &
Drawings Accessories

Overview

The versatile Water-Cooled Machine Torch models NCC/LRN, HTC/LRN, NCC/N, & HTC/N can be used for a wide range of applications. The machine barrels may be applied to either a remote or direct mount Docking Spools®. With the various angles (22°, 35°, 45°, 60° and 90°) and lengths available (Long Reach 12.5" and Short 5"), a selection may be made to suit individual requirements.

The versatile D/F quick change Water-Cooled Automatic Torch models NCM/LRN, HTM/LRN, NCM/N, & HTM/N can be used for a wide range of automatic applications. With the various angles and lengths available, a selection may be made to suit individual automation requirements.

The composite modular design of the rugged, yet flexible, quick-disconnect model LRN (Long Reach 10" composite water-cooled nozzle) and the model N (short 5" composite water-cooled nozzle) torches allow the user to quickly change the swanneck (gooseneck) or cable assembly while maintaining tool center point, assuring accurate repeatability and continuous precision welding. These D/F automatic torches have a compact, stainless steel, water-cooled nozzle designed specifically to withstand unusually large amounts of reflected heat build-up and prolonged duty cycles. Water circulates internally through the docking spool to the nozzle and the tip, keeping the torches running cooler, and thus the torch and consumables last longer. Mounting is easy by directly plugging in the torch to any wire feeder with one of the many different wire feeder adapters. In the event that a component has to be adjusted or replaced, the docking spool makes this torch entirely serviceable and easy to repair or replace in seconds.

These welding assemblies are designated by torch models. The models NCM/LRN & NCM/N (slip-in contact tip) have a current capacity 500 amps in argon shielding. These accommodate slip-in current tips fastened by a collet action nut. The wire diameter range with hard wire is .030"-1/16", cored wire .035"-1/8", and aluminum wire range of .035"-3/32".

The torch models HTM/LRN & HTM/N (threaded contact tip) have a current capacity range of up to 650 amperes. Rating will be contingent on the combination of current tip and shielding gas to be used. The model HTM employs threaded CrZr (chromium zirconium copper) current tips and will accommodate .030" - 1/16" hard wire, .035" - 1/8" cored wire and 3/64" - 3/32" aluminum wires.

Standard assemblies have torch necks (water-cooled nozzles) that are either straight or bent at 22°, 35°, 45°, 60° or 90°, available in different lengths, and with cable assemblies and replacement docking spool bodies. The LRN & N series torches also share common consumables with the complete D/F product line.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. If you are currently having problems using the Tregaskiss Tough Gun I.C.E™ (Integrated Cooling Enhancer) because of high amperages, long duty cycles resulting in torches overheating, expensive gas diffusers, and short consumable life, this series of D/F Automatic Water-Cooled Torches is a superior alternative. There are no exterior water lines that can be damaged running down the outside of the torch. The D/F LRN torches are completely water-cooled throughout. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Features

  • Quick-Change - Interchange Between Short, Long, Straight or Curved Goosenecks
  • Fully Water-Cooled Internally - Gas Cup Recessed in Water Cooling
  • Up to 500 Amps Continuous Duty Cycle
  • Adaptable to Any Wire Feeder or Power Source
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCC-N - Normal Duty, Collet Action (Slip-In Tip), Curved - Short 5" Nozzle
  • HTC-N - Heavy Duty, Threaded Tip, Curved - Short 5" Nozzle
  • NCC-LRN - Normal Duty, Collet Action (Slip-In Tip), Curved - Long Rreach Nozzle
  • HTC-LRN - Heavy Duty, Threaded Tip, Curved - Long Rreach Nozzle

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT (APPROX.) COOLING
REQUIRED		 RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCC-N 400 amps 4 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL		 541NB
(All 22° & 45°)
HTC-N 500 amps 4 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL
NCC-LRN 400 amps 4.7 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL
HTC-LRN 500 amps 4.7 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL

Barrel Dimensions

MODEL LENGTH DIAMETER OF W/C NOZZLE
NCC-LRN 22°, HTC-LRN 22° 12.625" 1.125"
NCC-N 22°, HTC-N 22° 8.500" 1.125"
NCC-LRN 45°, HTC-LRN 45° 12.250" 1.125"

Ordering Information (Complete Assemblies)

DESCRIPTION CODE NO.
COMPLETE
ASSEMBLIES		 COMPLETE
BARREL ONLY
NCC-N Curved 22° 5" 40172 48227
HTC-N Curved 22° 5" 40187 48227
NCC-LRN Curved 22° Long Reach 40174NB 48225NB
HTC-LRN Curved 22° Long Reach 40189NB 48225NB
NCC-LRN Curved 45° Long Reach 40173NB 48221NB
HTC-LRN Curved 45° Long Reach 40188NB 48221NB
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40174NB with 4 Ft. Utilities: 40174NB-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCC-LRN, HTC-LRN, NCC-N, HTC-N
(All 22° & 45°)		 541NB

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCC-LRN 22° 40172 40172 40172
HTC-LRN 22° 40187 40187 40187
NCC-N 22° 40174 40174 40174
HTC-N 22° 40189 40189 40189
NCC-LRN 45° 40173 40173 40173
HTC-LRN 45° 40188 40188 40188

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

Straight N & LRN
D/F Water-Cooled Straight 5" & Long Reach MIG Torches

Straight Short & LRN Machine Barrels

Overview Ordering Manuals &
Drawings Accessories

Overview

The versatile MIG Water-Cooled Machine Barrel Models NCM/LRN - HTM/LRN can be used for a wide range of applications. The machine barrels may be applied to either a remote or direct mount Docking Spool®. With the various angles (22°, 35°, 45°, and 60°) and lengths available (Long Reach 12.5" and Short 5"), a selection may be made to suit individual requirements.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. If you are currently having problems using the Tregaskiss Tough Gun I.C.E™ (Integrated Cooling Enhancer) because of high amperages, long duty cycles resulting in torches overheating, expensive gas diffusers, and short consumable life, this series of D/F Automatic Water-Cooled Torches is a superior alternative. There are no exterior water lines that can be damaged running down the outside of the torch. The D/F LRN torches are completely water-cooled throughout. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), and inlet (as needed) must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

Features

  • Quick-Change - Interchange Between Short, Long, Straight or Curved Goosenecks
  • Fully Water-Cooled Internally - Gas Cup Recessed in Water Cooling
  • Up to 500 Amps Continuous Duty Cycle
  • Adaptable to Any Wire Feeder or Power Source
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-N - Normal Duty, Collet Action (Slip-In Tip), Machine Barrel - Short 5" Nozzle
  • HTM-N - Heavy Duty, Threaded Tip, Machine Barrel - Short 5" Nozzle
  • NCM-LRN - Normal Duty, Collet Action (Slip-In Tip), Machine Barrel - Long Rreach Nozzle
  • HTM-LRN - Heavy Duty, Threaded Tip, Machine Barrel - Long Rreach Nozzle

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT (APPROX.) COOLING
REQUIRED		 RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM-N 400 amps 4 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL		 541NB
HTM-N 500 amps 4 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL
NCM-LRN 400 amps 4.7 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL
HTM-LRN 500 amps 4.7 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL

Barrel Dimensions

MODEL LENGTH DIAMETER OF W/C NOZZLE
NCM-LRN, HTM-LRN 12.625" 1.125"
NCM-N, HTM-N 9.250" 1.125"

Ordering Information

DESCRIPTION CODE NO.
COMPLETE
ASSEMBLIES		 COMPLETE
BARREL ONLY
NCM-N Straight 5" 40216 48240
HTM-N Straight 5" 40217 48240
NCM-LRN Straight Long Reach 40171 48121
HTM-LRN Straight Long Reach 40186 48121
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40217 with 4 Ft. Utilities: 40217-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM-N, HTM-N, NCM-LRN, HTM-LRN 541NB

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM-N 40216 40216 40216
HTC-N 40217 40217 40217
NCM-LRN 40171 40171 40171
HTM-LRN 40186 40186 40186

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

Standard Barrels
D/F Water-Cooled Automatic Docking Spool®/Weld Body Combination

Standard Barrels
(7/16"-3/4" Gas Cup ID)

Overview Ordering Manuals &
Drawings Accessories

Overview

D/F Machine Specialties Docking Spool/Weld Body Combination on a BUG-O Piper PlusThese Direct Mount MIG Welding Torches - Docking Spool®/Weld Body Combination accommodate two (2) different size outside diameter gas nozzles for varying gas coverage, and five (5) different lengths of water-cooled nozzle assemblies for limited access or hard to reach areas. Whether you are running steel, metal cored, or aluminum wire, the correct torch can be chosen for a neat and clean installation, and for optimum performance for your application. This arrangement is readily adaptable to dedicated or automatic welding applications. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®/Weld Body Combination, and a Water-Cooled Nozzle. The Docking Spool®/Weld Body Combination is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water-cooled nozzle at the lower end. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®/Weld Body Combination. In addition a Posit® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.

These MIG welding torch assemblies are designated by models. The model NCM has a current capacity 400 amperes in argon shielding at 100% duty cycles. These accommodate slip-in current tips fastened by a collet action nut. The wire diameter range is .030” through 1/16” with hard wire, .035” through 1/8” with cored wire and 3/64” through 3/32” aluminum.

The model HTM has a current capacity range of 500 amperes at 100% duty cycles. Rating will be contingent on the combination of current tip and shielding gas used. The model HTM employs threaded CuCrZr current tips accommodating .030” through 1/16” hard wire, .035” through 1/8” cored wire, and 3/64” through 3/32” aluminum.

An optional D/F Torch Rack #30418 can be used on any torch with an 8" long, 1.125" diameter water-cooled nozzle. The rack slips right over the water-cooled nozzle and is secured with 4 set screws. The rack can then be dropped into a BUG-O BUG-5188 Rack Holder. The rack has a 32 pitch gear, and with the rack holder makes torch head positioning very easy. See the images below right.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. Water outlet temperature should not exceed 27°C (80°F). The torch’s water out & power cable is not cooled until the coolant has gone through the torch and out the water out & power cable. If water is not flowing through the D/F torch for at least 1 minute prior to striking an arc, when you apply the power and water hits the “hot” water/out & power cable, you will generate steam. Steam can damage the torches internals in seconds causing a leak. It can also blow out the torches water/out & power cable. A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc. When High-Deposition GMAW, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. Precise temperature control maintains the cooling at a constant 13°C (55°F) temperature, thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), and inlet (as needed) must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

Features

  • Water-Cooled Docking Spool® Body & Nozzle
  • Small Frontal Area for Hard-to-Reach Locations
  • Two (2) Different-Size W/C Nozzle Assemblies for Numerous Gas Cup IDs (7/16”-3/4”)
  • Nozzle Length may be Extended by Five (5) Different-Length W/C Nozzle Assemblies
  • Withstands Preheat Upwards of 900 Degrees
  • Optional Torch Holding Rack for Easy Mounting

Model Explanation

  • NCM - Normal Duty, Collet Action (Slip-in Tip), Machine Barrel
  • HTM - Heavy Duty, Threaded Tip, Machine Barrel

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM 400 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL		 510
HTM 500 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL

Barrel Dimensions

MODEL LENGTH W/ 3" NOZZLE LENGTH W/ 4" NOZZLE LENGTH W/ 5" NOZZLE LENGTH W/ 8" NOZZLE LENGTH W/ 9-25/32" NOZZLE DIAMETER OF W/C NOZZLE
NCM, HTM 7.25" 8.25" 9.25" 12.25" 14.25" 1.125"

Ordering Information

Complete Assemblies

DESCRIPTION CODE NO.
NCM HTM
Short 3" 40120 40140
Inter. 4" 40121 40141
Long 5" 40122 40142
Long 8" 40131 40151
Long Reach 11" 40123 40143
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40120 with 4 Ft. Water-In Hose Assembly: 40120-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM, HTM 510

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM 3" 40120 40120 40120
HTM 3" 40140 40140 40140
NCM 4" 40121 40121 40121
HTM 4" 40141 40141 40141
NCM 5" 40122 40122 40122
HTM 5" 40142 40142 40142
NCM 8" 40131 40131 40131
HTM 8" 40151 40151 40151
NCM 11" 40123 40123 40123
HTM 11" 40143 40143 40143

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C Direct Mount Docking Spool®
Weld Body Combination One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

Torch Rack #30418 and Rack Mount

An optional D/F Torch Rack #30418 can be used on any torch with an 8" long, 1.125" diameter water-cooled nozzle. The rack slips right over the water-cooled nozzle and is secured with 4 set screws. The rack can then be dropped into a BUG-O BUG-5188 Rack Holder. The rack has a 32 pitch gear, and with the rack holder makes torch head positioning very easy. See the images below right. See the Torch and Rack Mount product page for more information

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Torch RackD/F Torch Rack

Series-A Barrels
D/F Water-Cooled Automatic Docking Spool®/Weld Body Combination

Series A High Capacity Barrels
(11/16"-1" Gas Cup ID)

Overview Ordering Manuals &
Drawings Accessories

Overview

The Direct Mount MIG Welding Torches - Docking Spool®/Weld Body Combination offer the same features as those described above with the capability of providing larger I.D. gas nozzles for varying gas coverage, and by its design offers a steady, smooth, non-turbulent gas flow for high-volume production welding of a repetitive nature.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. Water outlet temperature should not exceed 27°C (80°F). The torch’s water out & power cable is not cooled until the coolant has gone through the torch and out the water out & power cable. If water is not flowing through the D/F torch for at least 1 minute prior to striking an arc, when you apply the power and water hits the “hot” water/out & power cable, you will generate steam. Steam can damage the torches internals in seconds causing a leak. It can also blow out the torches water/out & power cable. A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc. When High-Deposition GMAW, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. Precise temperature control maintains the cooling at a constant 13°C (55°F) temperature, thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), and inlet (as needed) must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

Features

  • Water-Cooled Docking Spool® Body & Nozzle
  • Small Frontal Area for Hard-to-Reach Locations
  • Two (2) Different-Size W/C Nozzle Assemblies for Numerous Gas Cup IDs (11/16"-1”)
  • Nozzle Length may be Extended by Five (5) Different-Length W/C Nozzle Assemblies
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-A - Normal Duty, Collet Action (Slip-in Tip), Machine Barrel - High Capacity (Series A)
  • HTM-A - Heavy Duty, Threaded Tip, Machine Barrel - High Capacity (Series A)

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM-A 400 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL		 510
HTM-A 500 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL

Barrel Dimensions

MODEL LENGTH W/ 3" NOZZLE LENGTH W/ 4" NOZZLE LENGTH W/ 5" NOZZLE LENGTH W/ 8" NOZZLE LENGTH W/ 9-25/32" NOZZLE DIAMETER OF W/C NOZZLE
NCM-A, HTM-A 7.25" 8.25" 9.25" 12.25" 14.25" 1.445"

Ordering Information

Complete Assemblies

DESCRIPTION CODE NO.
NCM HTM
Short 3" 40125 40145
Inter. 4" 40126 40246
Long 5" 40132 40152
Long 8" 40133 40153
Long Reach 11" 40127 40147
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40125 with 4 Ft. Water-In Hose Assembly: 40125-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM, HTM 510

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM A3" 40125 40125 40125
HTM A3" 40145 40145 40145
NCM A4" 40126 40126 40126
HTM A4" 40146 40146 40146
NCM A5" 40132 40132 40132
HTM A5" 40152 40152 40152
NCM A8" 40133 40133 40133
HTM A8" 40153 40153 40153
NCM A11" 40127 40127 40127
HTM A11" 40147 40147 40147

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C Direct Mount Docking Spool®
Weld Body Combination One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196

BIG MIG® NCM15, HTM15
D/F Machine Specialties Water Cooled BIG MIG NCM-15 MIG Torch

W/C "BIG MIG®" 1000 Amp Machine Barrel HTM15

Overview Ordering Manuals &
Drawings Accessories More Info

Overview

D/F Machine Specialties® has been committed to producing the finest American made welding products available on the market today. D/F's MIG (Gas Metal Arc Welding) & TIG (Gas Tungsten Arc Welding) torches have been used exclusively with welding automation equipment by Lincoln Electric, Miller Electric, Linde/ESAB, and Thermadyne for over 40 years. For automated welding systems, hard automation, high deposition, high current density, and large wire diameters that require preheat and high amperage, a D/F heavy duty water-cooled weld automation torch is ideal and has been used for large diameter aluminum welding, metal build up, hardbanding, hardfacing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub-arc applications, and applications where carbide is added like with the Welding Alloys Multi Surfacer: custom designed automated welding equipment. Our torches have been designed, tested, used and continuously upgraded for more than 40 years, in almost every type of environment. The flexibility of D/F Machine Specialties automatic welding torches makes them ideal for all fabrication applications. Our torches are suitable for GMAW, pulsed GMAW and FCAW processes. They provide a wide range of travel, wire feed, and oscillation parameters to accommodate various materials, thicknesses and joint designs. Due to the fact that there are varying requirements for each MIG welding application, this series of D/F torches is tailored to fit each of these unique applications and falls under the "specialties", hence the name D/F Machine Specialties, and requires a 2-3 week delivery upon receipt of a purchase order. We highly recommend that customers also purchase a backup torch to reduce downtime due to the fact that these are custom torches and have a 2-3 week delivery upon receipt of order.

The fully Water-Cooled-to-the-Tip direct mount 1000 Amp BIG MIG® (GMAW) automatic models NCM15 & HTM15 machine torches are for high current single arc welding. If you are using the Linde ST-12, Guild ST-12 or Binzel AUT 750 and feel the need to have a larger, more robust torch that can carry more amperes with more water-cooling, the 1000 Amp BIG MIG® is the torch for you. The BIG MIG® can plug directly into the Lincoln Electric NA-5 & NA-5R, LF-72, LF-74, Power Feed® 84, ESAB Aristo, MIGMaster, Duradrive, MIG 4 HD, and Miller wire feeders and sub-arc machines. With the use of the D/F sub-arc nozzle thread seals these heavy duty MIG water-cooled torches can be converted and used as sub arc torches. Because of the robust design of the torch and the water-cooling on the body, nozzle and tip, downtime and consumable cost can be greatly reduced in the submerged arc process (SAW). With the various models available, an automated MIG torch selection may be made to suit individual automated welding system requirements.

The “BIG MIG®” 1000 Amp High Current Machine Barrel is recommended for mechanized welding applications where production demands the maximum durability and quality for mechanized gas metal arc welding. The model NCM15 as provided will accommodate 4” slip-in current tips fastened by a collet action nut. The model HTM15 will accommodate 7/16“ threaded current tips by utilizing a tip adapter nut. The water-cooled nozzle accepts threaded gas nozzles ranging from 3/4” through 1-1/4” inner diameter. This barrel is primarily for wire diameters from 1/16” through 7/32” (1.6mm through 5.6mm). Maximum current capacity applicable to the models NCM15/HTM15 is 1000 amperes. Direct mounting is accomplished by connecting the torch to the welding head or wire drive using a feeder adapter.

BIG MIGThe “BIG MIG®” has two Water Out & Power Cables, increasing the continuous duty cycle rating to 1000 amps. There are also two lugs on the body of the BIG MIG® torch that can accept two to four 4/0 cables. These ratings are, however, dictated by the wire size which determines the appropriate contact tip.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. Water outlet temperature should not exceed 27°C (80°F). The torch’s water out & power cable is not cooled until the coolant has gone through the torch and out the water out & power cable. If water is not flowing through the D/F torch for at least 1 minute prior to striking an arc, when you apply the power and water hits the “hot” water/out & power cable, you will generate steam. Steam can damage the torches internals in seconds causing a leak. It can also blow out the torches water/out & power cable. A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc. When High-Deposition GMAW, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. Precise temperature control maintains the cooling at a constant 13°C (55°F) temperature, thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), and inlet (as needed) must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.

Features

  • Water-Cooled Inner Body & Nozzle
  • Heavy-Duty Construction for Long-Lasting Durability
  • Small Frontal Area for Hard-to-Reach Locations
  • Withstands Extreme Conditions - 900° Preheat, 1000 Amps
  • Torch Longevity - Years vs. Months

Model Explanation

  • NCM - Normal Duty, Collet Action (Slip-in Tip), Machine Barrel
  • HTM - Heavy Duty, Threaded Tip, Machine Barrel

Model Specifications

MODEL CURRENT
CAPACITY		 WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED WIRE
DIA. RANGE		 INSTRUCTION
MANUAL
NCM15, HTM15 1000 amps 11.8 lbs 1 gallon/min .030"-5/32" (.8m-4mm) Hard/Cored,
3/64"-1/4" (1.2mm-6.5mm) AL		 750

Barrel Dimensions

MODEL LENGTH BODY DIAMETER
NCM15, HTM15 16" 2.750"

Ordering Information

Complete Barrel Only

DESCRIPTION CODE NO.
NCM15, HTM15 11620

Complete Assemblies

DESCRIPTION CODE NO.
2 Ft. 3 Ft. 4 Ft. 5 Ft. 6 Ft. 7 Ft. 8 Ft. 10 Ft. 12 Ft. 15 Ft.
NCM15, HTM15 11622 11623 11624 11625 11626 11627 11628 11629 11630 11631

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM15, HTM15 750

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM15, HTM15 11620 11620 11620

Other Documents

DESCRIPTION DOWNLOAD
Choosing the Proper Chiller
for Your Application
Torch Connection Options
W/C BIG MIG® Machine Barrel
One-Sheet

Utility Station #45188 - Dual Power Cable

45188 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water-in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cables are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45188D/F Utility Station #45188

Threaded Current Tips

TORCH MODELS WIRE TYPE WIRE SIZE CODE NO.
All HTC, HTM, CTW, CW-T, MTW
Threaded Tips
(Tip provides 1/8" set back)		 Hard .035" (.9mm) 15116
.045" (1.2mm) 15117
.052" (1.2mm) 15121
1/16" (1.6mm) 15118
5/64" (2mm) 15119
3/32" (2.4mm) 15120
7/64" (2.8mm) 15122
1/8" (3.2mm) 15105
5/32" (4mm) 15150
All HTC, HTM, CTW, CW-T, MTW
Threaded Tips
(Tip provides 3/8" set back)		 Cored .035" (.9mm) 15101
.045" (1.2mm) 15106
.052" (1.2mm) 15112
1/16" (1.6mm) 15107
5/64" (2mm) 15108
3/32" (2.4mm) 15109
7/64" (2.8mm) 15110
1/8" (3.2mm) 15111
5/32" (4mm) 15113
All HTC, HTM, CTW, CW-T, MTW
Threaded Tips
(Tip provides 1/8" set back)		 Aluminum 3/64" (1.2mm) 15126
1/16" (1.6mm) 15125
5/64" (2mm) 15087
3/32" (2.4mm) 15148
1/8" (3.2mm) 15123
5/32" (4mm) 15151
  1. D/F Water-Cooled MIG Torches - Direct Mount
  2. D/F Open-Arc Water-Cooled Gasless Hardfacing Machine Torch - Direct Mount
  3. D/F Air-Cooled MIG Torches - External Shielding & Gasless - Direct Mount
  4. D/F Air-Cooled MIG Torches - Direct Mount