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A HOW-TO ON CORRECTING POOR WIRE FEEDING, STARTING WITH DRIVE
ROLL TENSION VIEW ARTICLE IN READER
By: Travis Hall, Lightning Mig product manager and operations manager, American Torch Tip Co. | (HTTP://MAGAZINE.WELDINGPRODUCTIVITY.COM/2017/APR/D
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While MIG welding is considered an easier process to learn and perform, it can be complicated at times because there ARTICLES BY TYPE
is so much technology behind it. The wire feeding process alone requires several elements, which all have to be
maintained for effective welding. Welding
(http://weldingproductivity.com/type/welding/)
How smooth does your wire feed? How often do you inspect or change your gun liner, drive rolls or inlet guides? Do (29)
you have the correct drive roll style for the welding wire you are using? Do you check your drive roll tension setting? Systems & Equipment
Are you having trouble with erratic arcs, contact tip burnback, birdnesting or excessive spatter? (http://weldingproductivity.com/type/systems-
equipment/) (18)
While that might seem like a lot of questions, the answers are important. They are good indications of whether or not Fume Extraction
you should take a closer look at your wire feeding process. (http://weldingproductivity.com/type/fume-
extraction/) (18)
Robotics
Feel the tension (http://weldingproductivity.com/type/robotics/)
When there are issues in the welding (18)
process, many times it comes back to the Cutting & Prep
drive rolls. Over-tensioned and misaligned (http://weldingproductivity.com/type/cutting-
drive rolls lead to consistency issues. The prep/) (16)
correct drive roll tension is critical to success. Safety
(http://weldingproductivity.com/type/safety/)
First, though, make sure the correct style of (13)
drive rolls is being used for the type of Consumables
welding wire. Four styles of drive rolls are (http://weldingproductivity.com/type/consumables/)
available: plastic, V-groove, U-groove and (12)
knurled. The V-groove style is recommended Plasma
for steel, the plastic and U-groove styles for (http://weldingproductivity.com/type/plasma-
aluminum and the knurled style for flux-cored cutting-prep/) (12)
wire. Laser
(http://weldingproductivity.com/type/laser-
Whatever the type of wire, it is critical that the welding/) (10)
correct drive roll tension is used. Too loose Arc
causes poor wire feeding and slippage. Too (http://weldingproductivity.com/type/arc-
tight deforms the wire, which creates more welding/) (9)
dust and metal shavings in the wire feeder, Automotive
gun and liner, leading to blockages. (http://weldingproductivity.com/type/automotive/)
(8)
Deformed wire affects feedability and wears Sawing
Blowing out and wiping down the drive wire feeder weekly is recommended
to control dust and metal shavings. out the liner and contact tip much sooner (http://weldingproductivity.com/type/sawing/)
with saw-like edges as it passes through the (8)
liner and tip. After setting the drive roll tension, check to make sure this is not happening in your process. PPE
(http://weldingproductivity.com/type/ppe/)
As for hub tension, when mounting the wire reel to the feeder, tighten the hub enough to keep the wire from unraveling (6)
or overfeeding once you let go of the trigger. Wire
(http://weldingproductivity.com/type/wire/)
As high-tech as welding equipment has become, it is still not an exact science on how to set drive roll tension. I was (6)
always told “tight, but not too tight, and definitely not too loose.” Filler Metals
(http://weldingproductivity.com/type/filler-
There are few ways to set the drive rolls, but all are similar. The only truly unacceptable method to use is cranking metals/) (6)
down the tension setting knobs with pliers. Oxyacetylene
(http://weldingproductivity.com/type/oxyacetylene/)
To correctly set tension, lay the gun out straight. Once the wire is fed through, take a wood block or metal plate and (5)
feed the wire into it. Once you get the drive rolls to slip, tighten the drive rolls a half turn more. Abrasives and Deburring
(http://weldingproductivity.com/type/abrasives-
You can also feed wire into the palm of your welding glove if it is well padded. Just make sure there isn’t a really sharp and-deburring/) (5)
point by bending the end of the wire over. Aluminum
(http://weldingproductivity.com/type/aluminum/)
Once this is done, you should have the optimum drive roll tension needed to feed the wire. If you get to where you (4)
have to tighten more, there’s a good chance you need a new liner or drive rolls. Training
(http://weldingproductivity.com/type/training/)
(4)
Good wire GMAW
Using the welding wire that best suits the application is also important to good feeding. Good wire is consistent (http://weldingproductivity.com/type/gmaw/)
throughout the entire length of the wire and from batch to batch. The cast, helix and wire diameter are all critical to (4)
maintaining a good electrical connection with a smooth and consistent wire feed. It is also important to have a Trade Shows
consistent chemical composition and lubrication of the wire. (http://weldingproductivity.com/type/trade-
shows/) (3)
If the diameter and feedability of the wire seem to be consistent, but issues still arise that you can’t pinpoint, don’t Steel
worry you aren’t going crazy. It may have to do with the chemical makeup and tolerances of the wire. At this point, (http://weldingproductivity.com/type/steel/)
bring in another wire and test it to see if the issues go away. If they do, you need to change the brand or grade of wire (3)
you are using.
The inside line Shop Floor Productivity
(http://weldingproductivity.com/type/shop-
The gun liner is another key component of wire floor-productivity/) (2)
feeding. It is important not to have too large or small of Aerospace
a liner for the wire. This also causes feeding issues, (http://weldingproductivity.com/type/aerospace/)
causing excessive wear and premature failure. (2)
Military
The liner travels through the core tube of the gun and (http://weldingproductivity.com/type/military/)
typically sits inside the welding diffuser. There are a (2)
few different ways liners are secured at the power pin. Electric Resistance Welding
Some manufactures also have a setscrew in the (http://weldingproductivity.com/type/electric-
diffuser/tip holder to make sure the liner does not resistance-welding/) (2)
shrink or stretch when twisted. But, this can also cause Tube and Pipe
an array of issues if the screw is overtightened. If the (http://weldingproductivity.com/type/tube-
screw is missing, note the hole is not meant to be an and-pipe/) (2)
extra gas hole. Power Tools
(http://weldingproductivity.com/type/power-
A quality liner is typically made from high-carbon steel tools/) (1)
wire. It is important that the liner coils are wound tight Gases
and to have good deflection and rigidity for when the (http://weldingproductivity.com/type/gases/)
gun is bent and twisted in different directions. It is also (1)
important for the inner diameter of the liner to be Post Processing
consistent throughout to keep feedability consistent. When blowing out the cable and liner to remove debris, first (http://weldingproductivity.com/type/post-
Nylon and Teflon liners are typically used for aluminum remove the nozzle tip and diffuser. processing/) (1)
wire. Friction Stir Welding
(http://weldingproductivity.com/type/friction-
You can extend the life of the liner by blowing out the cable with compressed air to remove the dust and metal stir-welding/) (1)
shavings. ATTC recommends doing it, at minimum, when you change the liner. But depending on your shop, and if you Heavy Equipment
have access to it, we recommend doing it once a week. Another good time to blow out the cable is when changing the (http://weldingproductivity.com/type/heavy-
wire. equipment/) (1)
Resistance Welding
Blowing out and wiping down the drive rolls and wire feeder (http://weldingproductivity.com/type/resistance-
weekly is also recommended to control dust and shavings. welding/) (1)
TIG
If cleaning out the cable and liner does not fix your wire (http://weldingproductivity.com/type/tig/)
feeding issue, the liner has probably worn out. The liner is a (1)
consumable item, so don’t hesitate to replace it.

When changing the liner, it is important to lay the gun out ISSUES
straight. Make sure the cable is not twisted. Having twisted
cable when cutting the liner leads to cutting the liner at the January 2018
wrong length. Keeping the liner off the ground, feed it (http://weldingproductivity.com/issue/january-
through in short stokes making sure not to kink it. 2018/) (5)
December 2017
Once the liner is fed through, use sharp diagonal cutters or (http://weldingproductivity.com/issue/december-
welding pliers to cut the liner to the manufacturer’s 2017/) (6)
recommended cut lengths. Make sure to remove any burrs November 2017
as they can damage the wire. (http://weldingproductivity.com/issue/november-
2017/) (7)
If you are unsure of the length to cut, a good way to judge it October 2017
is when tightening down the welding diffuser. You want to (http://weldingproductivity.com/issue/october-
feel just a little bit of pressure from the liner pushing against 2017/) (7)
the diffuser on the last thread or so. The reason for this is as September 2017
you twist and move the cable, the liner, being a spring, can (http://weldingproductivity.com/issue/september-
Make sure the power pin is secured in place with the locking
mechanism so the wire doesn’t push it out. This prevents heat shrink or grow. If the liner is cut too short or long, it leads to 2017/) (6)
buildup and other issues.
an array of issues. August 2017
(http://weldingproductivity.com/issue/august-
2017/) (6)
Here’s a tip July 2017
(http://weldingproductivity.com/issue/july-
The wire feeding process finishes with the contact
2017-issue/) (7)
tip. A good tip, key to uptime and achieving
June 2017
consistent long-lasting welds, has smooth and
(http://weldingproductivity.com/issue/june-
consistent inner diameters. For different
2017/) (6)
applications, such as robotic or manual welding,
May 2017
tips require certain inner diameters. This is
(http://weldingproductivity.com/issue/may-
important to keeping wire feeding smoothly with a
2017/) (7)
good electrical connection.
April 2017
(http://weldingproductivity.com/issue/april-
When is it time to change a contact tip? When the
2017/) (6)
wire starts to wander or you notice significant wear
March 2017
on the ID of the tip. You see what is typically known
(http://weldingproductivity.com/issue/march-
as keyholing.
2017/) (6)
February 2017
Some contact tips can be rotated to create a new
(http://weldingproductivity.com/issue/february-
wear point to extend their life. Dual threads allow
2017/) (6)
you to reseat the tip 180 degrees, and some
January 2017
threadless designs allow you to freely turn the tip
(http://weldingproductivity.com/issue/january-
and then secure it into place.
2017/) (6)
December 2016
Make sure the tip is securely in place. A good
(http://weldingproductivity.com/issue/december-
securing method is important for any tip style. Use
2016/) (6)
welding pliers and be careful not to scratch the OD
A wire entering the inlet guide at a bad angle produces detrimental November 2016
of the tip, as this can attract spatter. copper shavings.
(http://weldingproductivity.com/issue/november-
2016/) (7)
One issue with tips having too many threads is that it’s hard to get that tip out when burnback occurs. You will probably
October 2016
have to cut the wire at the back and feed the wire through again.
(http://weldingproductivity.com/issue/october-
2016/) (8)
This is why some contact tip manufacturers have gone more and more to using 1/4-1 whole turns to remove tips, and
September 2016
some have gone to completely threadless designs.
(http://weldingproductivity.com/issue/september-
2016/) (7)
(https://www.youtube.com/watch?v=q4qONylrDAY)
August 2016
(http://weldingproductivity.com/issue/august-
 One problem with a design where the nozzle 2016/) (5)
secures the tip in place is the common, but July 2016
incorrect, occurrence of welding front ends being (http://weldingproductivity.com/issue/july-
used as hammers or just the rough environment in 2016/) (5)
general. This can cause the piece holding the tip June 2016
securely in place to come loose, which creates (http://weldingproductivity.com/issue/june-
resistance and causes overheating, burnback and 2016/) (7)
other feeding issues. May 2016
(http://weldingproductivity.com/issue/may-
Several factors can affect and contribute to smooth, 2016/) (5)
or not so smooth, wire feed. Set yourself up for April 2016
success by keeping up on the basics, and making (http://weldingproductivity.com/issue/april-
sure you have products that are meant to be used 2016/) (6)
together. March 2016
When mounting the wire reel, tighten the hub enough to keep the wire
(http://weldingproductivity.com/issue/march-
from unraveling or overfeeding once you let go of the trigger. Instead of working with suppliers that make and sell 2016/) (7)
February 2016
products based on price, partner with (http://weldingproductivity.com/issue/february-
suppliers that sell products based on best 2016/) (5)
practices and solutions. Doing so can January 2016
bring a lot of value to your operation. (http://weldingproductivity.com/issue/january-
2016/) (5)
Not everyone needs the most premium November / December 2015
product, but a product that is cheaper, in (http://weldingproductivity.com/issue/november-
the long run, can end up being much more december-2015/) (7)
expensive. The key is to get the necessary September / October 2015
product for the welding application to (http://weldingproductivity.com/issue/september-
achieve the desired results. october-2015/) (7)
July / August 2015
American Torch Tip Co. (http://weldingproductivity.com/issue/july-
(http://americantorchtip.com/) august-2015/) (8)
May / June 2015
(http://weldingproductivity.com/issue/may-
Comments june-2015/) (8)
March / April 2015
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