Just like waiting in a long line at the airport to get through security, a long line from your wire source to the feeder or the feeder to the MIG gun can cause a lot of friction and frustration. A manufacturer utilizing a long track system had this exact issue and turned to Wire Wizard for a better solution to reduce excess wire friction that was causing poor welding performance, reduced consumable life and excess wear on their torch liners.

First, the 50' track setup was outfitted to reduce friction points in the wire delivery system, while giving the operator better flexibility when welding lengthy trailers. Low friction Extra Flexible Conduit was utilized along with a set of Wire Guide Module assemblies to allow full use of the track system without compromising the wire delivery to the feeder.

After the wire delivery setup was optimized, PowerBall® Elliptical Wire Torch Liners were installed on their MIG guns with 25' cables. The elliptical wire used in PowerBall® liners offers a significant advantage over round wire liners since it has fewer contact points between the wire and the liner. This can make a huge difference in applications like this that require a 25' liner, and along with the improved wire delivery setup the manufacturer's welding performance improved with 2-3X longer service life over their previous torch liners.