Torch And Gun Front-End Wear Matrix

This annex is for complaints caused by worn front-end parts that are often misread as machine or feeder failure.

Use it with:

Core rule

If the machine powers up and the complaint is arc quality, start quality, or short consumable life, inspect the front end before broadening the diagnosis.

Symptom matrix

Process Symptom Most likely front-end branch High-value first move
MIG poor start, burnback, erratic arc contact tip, diffuser, nozzle, gun neck heat replace tip and inspect front end
TIG hard start, tungsten contamination, poor shielding cup, collet, collet body, back cap, gas lens rebuild torch front end and regrind tungsten
Plasma no start, poor cut, short consumable life nozzle, electrode, cap, shield, cartridge replace consumables or cartridge and retest

MIG front-end workflow

  1. Replace worn contact tip first.
  2. Inspect diffuser and nozzle for heat or spatter buildup.
  3. Inspect gun neck heating and front-end thread condition.
  4. If bare-wire feed is good but arc start is not, stay in the front-end branch before blaming the feeder.

TIG front-end workflow

  1. Regrind or replace tungsten.
  2. Inspect cup, collet, collet body, back cap, and gas lens if fitted.
  3. Confirm the tungsten stickout and front-end assembly are sane for the job.
  4. If stick output is normal but TIG is not, keep diagnosis on the torch front end and gas path first.

Plasma front-end workflow

  1. Replace worn nozzle and electrode or install a known-good cartridge.
  2. Confirm cap or cartridge seating.
  3. Inspect shield and front-end surfaces for damage or contamination.
  4. If the symptom improves immediately, stop the diagnosis there.

Common false diagnoses

Escalate sooner when

Source posture