![]() Start with the drive roll pressure very loose. Drive roll tension should be adjusted so that it is not too tight, but not too loose. ![]() There is no cut-and-dry answer as to the exact pressure needed to ensure proper drive roll pressure. Over-tightened drive roll tension causes all of these problems in addition to placing excessive pressure on the drive shaft that could wear out a gear box or drive motor by misaligning it. Wear out the grooved surfaces of the rolls and you have poor friction to feed the wire properly. Deformed wire will wear grooves into the contact tip limiting electrical conductivity and also causing poor feedability. ![]() Too tight and you can crush the wire and flake off the coating, deform the wire, wear out the rolls, and damage the motor.įlaked coating will cause these small flakes to enter the liner, further limiting the simple feedability of the wire to the puddle. Too loose and you have no wire feeding into the puddle. Over-tightening this will force the drive motor to work harder just to get the wire off of the spool and will lead to welding problems.ĭrive roll pressure is a very common problem in wire welding. This should be just tight enough to keep the wire from de-coiling when you stop feeding a full spool at maximum wire feed speed. The hub tension is simply a means to keep the wire from de-coiling off of the spool when wire feeding stops. On a large drum of wire, this function may be served by a mechanism that traces around the spool. It is important not to over-tighten the hub tension, which allows the spool of wire to turn. You should begin troubleshooting the system by ensuring the wire is not obstructed anywhere along its path from the spool tension to the contact tip and everywhere in-between. Regardless if you are using one-pound spools, large drums, or larger coils of wire, the mechanical feedability of the wire plays an important role in determining arc quality and weldability. Failure within any of these systems will result in sub-optimal welding performance, including reduced productivity and increased downtime for reworking bad welds. However, the wire feed system uses a more complicated mechanical system than the others to deliver the welding wire to the weld pool and the current to the wire, resulting in more potential problems in the functioning of the welding equipment.Īccurately troubleshooting these problems when they arise or, better yet, avoiding them before they arise, is crucial to maximizing the benefits that these processes offer.įor troubleshooting purposes, the wire welding system can be divided into three distinct categories based on function – wire delivery, gas supply and electricity transmission. MIG (GMAW) and flux-cored (FCAW) welding, commonly referred to as “wire welding,” offer the potential for significant gains in productivity compared to stick welding.
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