We tested the PowerBall® MIG Welding Gun head-to-head against four other industrial MIG gun models. Throughout testing, the optimized conductivity of the PowerBall® design provided less amperage loss in the secondary circuit, faster arc starts, improved amperage consistency and more. Here are some of the areas where the PowerBall® MIG Gun excelled...

All welds throughout testing made with the following parameters:

  • 90/10 Mixed Gas CO2/Ar
  • .045” Steel Wire, 3/8” LCS Base Material
  • Spray Transfer: 240 Amps, 32 Volts, 320 WFS
  • Short Circuit: 205 Amps, 20 Volts, 260 WFS
  • PowerBall® jumper cable installed at power source
  • Data captured with the Weld Central® Optimization System

The PowerBall® jumper cable greatly improves conductivity by bypassing the resistance other guns have from transferring current through the feeder assembly. Improving amperage loss will improve arc start quality and arc consistency (reduced spatter, easier wetting out).

Improved conductivity in the PowerBall torch reduces the Arc Stabilization Period (ASP) compared to competitors. Faster arc starts improve weld quality, with the start of the weld as good as the end. Consumable life also improves since spatter is reduced.

GOOD VS. BAD ARC STABILIZATION PERIOD (ASP)
Below is an example of two welds performed during testing, one with a good ASP and one with a bad ASP, along with how these welds appear in the graphs generated by the Weld Central® Optimization System. A weld with a bad ASP will have a longer period of volatility when first establishing the arc.

Consistent Amperage =
Consistent Quality
More consistent amperage means welds are consistently performed at the correct parameters, resulting in consistent weld quality with less rework
In addition to superior performance in these three key areas, the PowerBall® MIG Gun also had faster heat dissipation, cooling down at a faster rate than the other guns tested with a lower maximum handle temperature, making it an ideal solution for high heat / long duty cycle applications. Contact your Wire Wizard Technical Sales Expert for more information or to request a trial and see the results for yourself!

A Midwestern US manufacturer in the RV industry was experiencing problems with burn backs on multiple robotic welding cells. Additionally, they were seeking a better way to position their bulk wire drums that would make them more easily accessible without causing additional issues.

After measuring the wire pull force with a Wire Draw Gauge, it was discovered the cause of these problems was excess wire friction, with pull force readings over 4 lbs on multiple weld cells. Sets of 90° Wire Guide Modules were installed at the top of the weld cell walls and low friction Extra Flexible Conduit with strain relief connectors was utilized in the weld cell interior to eliminate the excess wire friction. The 90° Guide Modules also allowed the drums of wire to be located side-by-side against the cell wall, making them more easily accessible when performing wire changeout. Wire pull force measurements were then taken again with the new equipment installed:

 90° Guide Modules were installed on top of the interior & exterior of the weld cell wall.

After optimizing the wire delivery system, the pull force on the wire improved dramatically resulting in increased welding productivity with the elimination of excess burn backs.


DOES IT TAKE A MONSTER TO MOVE YOUR WIRE???

Got a challenging wire delivery problem? Before blaming it on the ghosts haunting your weld cells, contact the Wire Wizard Engineering Team at ineedawizard@wire-wizard.com for solutions to reduce burn backs and downtime caused by excessive wire skid friction.

JOSÉ LUIS CALDERON NAMED AS FIELD SERVICE TECHNICIAN FOR NORTHERN MEXICO

We are pleased to announce the hiring of José Luis Calderon as our new Field Service Technician for Northern Mexico. He will be providing field support to customers with onsite service, troubleshooting and installation of Wire Wizard's full product line. He brings with him over 17 years of technical expertise and welding in the railroad manufacturing sector. Calderon will utilize his skills and experience to solve welding challenges at facilities throughout Northern Mexico, with a strong focus on maximizing productivity through innovative welding optimization solutions.

To request printed catalogs, please call customer service at 517-782-8040 ext. 1 or email us at sales@wire-wizard.com


ELCo Enterprises, Inc. • 5750 Marathon Drive • Jackson, MI USA 49201
Phone: 517-782-8040 • wire-wizard.com