Controlled Cast and Helix Aluminum Wire

Specification

Applications and Solutions

• Robotic Welding Lines: Essential for all automated systems where the torch position is fixed, and consistent stick-out is mandatory for stable arc length control.

• Long Conduit Systems: Welding in large fabrication halls (shipbuilding) or with long reach torches where minimizing friction drag is crucial for reliable feeding.

• High-Speed Welding: Ensuring continuous, uninterrupted wire delivery at feed rates exceeding 20m/min without slip or jamming.

• Push-Pull Torches: Minimizing the required push force on the wire, which is a common failure point in push-pull systems used for aluminum.

FAQ

• Q: What is the ideal cast for aluminum MIG wire?A: The ideal cast is typically a relatively wide diameter (e.g., 400mm to 600mm) that ensures the wire is relaxed and straightens easily as it exits the contact tip, minimizing erratic arc starts.

• Q: How does helix affect the welding process?A: Excessive helix (corkscrewing) causes the wire to rub heavily against the inside of the contact tip and liner, leading to extreme friction, erratic electrical contact, and premature tip wear. High helix also causes the wire tip to circle the target area.

• Q: Can I use wire with poor cast/helix in a spool gun?A: Yes, but the spool gun’s direct drive mechanism will be heavily stressed, and the manual welding process will be made significantly more difficult by inconsistent stick-out and arc wandering.