PowerBall® Consumables recently went through production testing at a large tier 1 automotive production facility seeking out a solution that provided superior performance. The facility produces a high volume of parts with multiple welds on each, and the testing was monitored over approximately 5,000 welds. Data was collected with the Weld Central® DAQ & Optimization System. At the end of the testing, PowerBall® consumables showed a number of advantages over the other brands tested, including improved arc starts and noticeably less heat & spatter build-up. The heat build-up was apparent on many of the contact tips after testing, as shown below:

Additionally, a comparison was done to discover if there was a difference in performance between the PowerBall® 360° and 220° Robotic Welding Torch. It is commonly known in the industry that with many robotic torches, performance is often sacrificed when utilizing a 360° instead of a 220° torch.

High level findings after the testing include:

• Improved tip performance and consumable life at end of the production cycle
• Noticeably less heat and spatter buildup with PowerBall® consumable design
• Faster & more consistent arc starts, reducing potential for weld defects
• Better arc stability, which is linked to spatter adhesion and weld quality
• Performance of the PowerBall® 360° torch was nearly equal to that of the 220° model

Contact your Wire Wizard Technical Sales Representative for more details on our production testing and how PowerBall® Torch Products can boost your productivity.