A manufacturer of attachments for heavy construction equipment was not happy with the performance and durability of their current MIG welding guns. Their heavy duty application required a heavy duty MIG gun that could withstand high heat and high duty cycle welds with large diameter cored wire. The poor cooling of their current MIG guns caused them to be too hot for the operator to handle and also resulted in premature failure of welding consumables.

Frustrated with the ongoing performance issues, they decided to trial PowerBall® 500 Amp MIG guns that feature patented technology with superior conductivity and cooling. Welders quickly noticed less heat build-up in the handle, improved welding quality and a significant increase in consumable life. After a successful trial, they are now in the process of converting their entire facility over to PowerBall® 500 Amp MIG guns.

See the difference PowerBall® technology can make at your facility! Visit our website or contact your Wire Wizard Technical Sales Expert to request a PowerBall® semi-automatic or robotic MIG gun trial package.

The stream of current flowing through the GMAW secondary circuit runs into points of high electrical resistance at each terminal. Often overlooked, this resistance can result in poor energy efficiency causing excess heat buildup, amperage loss at the arc and reduced cable service life. This is especially true with traditional welding cables with crimped lugs.

To boost energy efficiency at each terminal, PowerBall® Ultrasonically Welded (USW) Cables feature a patented design with consolidated copper lugs. With traditional crimped cables, current flows through individual copper strands crimped together, resulting in reduced conductivity. With PowerBall® cables, the copper strands are fused together as one solid mass, eliminating electrical resistance at the terminal.
  • Consolidated copper connection at the cable lug joints increases energy efficiency
  • Reduces electrical resistance from 20 – 50+ micro-ohms (crimped cables), to only 7–10 micro-ohms
  • Stronger joints result in consistent performance throughout cable service life, as well as enhanced durability
  • Eliminate the risk of poorly crimped cables that can significantly impact welding performance
  • USW connections are featured in PowerBall® semi-automatic MIG guns, robotic MIG torches and WizardGear® Robot Cable Management Kits

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