Arc Spray Contact Tips: Ordering the Correct Replacement

Identify the right arc spray contact tips using gun model, wire diameter and part references. Prepare a replacement-parts enquiry that avoids guesswork.

Balaji Udyog

9/28/20261 min read

Contact tips are small components with an important role in the wire and electrical path of an arc spray gun. Ordering a replacement by appearance alone can create avoidable delays. A clear identification record is more reliable than a loosely named spare.

Match the tip to the assembly

Start with the gun model and the parts drawing supplied with it. Record the wire diameter, material in use and any markings on the existing component. A similar external shape does not establish that the bore, seating arrangement and connections are the same.

Describe the reason for replacement

Distinguish routine planned replacement from a recurring performance problem. If the same issue returns quickly, document the operating history and ask for the associated feed path to be reviewed. Replacing one component repeatedly may leave an underlying alignment, delivery or setup issue unresolved.

Keep traceable spare sets

Store replacement components in labelled packs by equipment model and size. Record which set was installed and when. This makes it easier to relate later inspection results to maintenance changes and avoids mixing parts from different guns during busy production periods.

Send these details to the supplier

Equipment model and relevant parts-list reference.
Wire material and nominal diameter.
Photographs showing markings, bore and connection features.
Quantity required and whether other guides or associated parts are needed.

Can a worn tip be modified to keep it in service?

Use the manufacturer's inspection and replacement criteria. Unapproved modification changes a component that affects the process, so it should not be treated as an equivalent replacement part.

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