16S-45 - Tweco Style 16S-45 Heavy Duty .045" Contact Tip (25-Pack)

Technical Overview of the 16S-45 Contact Tip

The GEN16S-45 is a high-performance, heavy-duty contact tip designed as a direct replacement for the Tweco 16S-45 (OEM part number 1160-1104). Engineered specifically for use with .045-inch (1.2mm) welding wire, this consumable is a critical component for maintaining electrical conductivity and arc stability in MIG welding processes. The tip is manufactured from a premium copper alloy, selected for its optimal balance of hardness and electrical conductivity, ensuring efficient current transfer from the welding gun to the wire.

This specific model belongs to the 16S series, characterized by its heavy-duty construction suitable for welding applications ranging up to 600 amps. It is designed to interface seamlessly with Tweco Spray Master series MIG guns and the Eliminator front-end consumable system. The tip features a standard threaded base that fits securely into compatible gas diffusers, specifically the EL52CT-16 and HD54-16 models. The heavy-duty wall thickness provides superior thermal mass compared to standard duty tips, allowing for better heat dissipation during prolonged welding cycles. This thermal management is essential for preventing tip deformation and keyholing, which can lead to erratic arc characteristics.

The internal bore is precision-drilled to tight tolerances to ensure smooth wire feeding while maintaining sufficient electrical contact. Loose tolerances can lead to micro-arcing inside the tip, while overly tight tolerances can cause wire drag and feeding issues. The GEN16S-45 strikes the ideal balance for professional industrial applications. Supplied in a pack of 25, these tips are intended for high-volume fabrication environments where consumable inventory management and uptime are critical operational factors.