NEW SUBMERGED ARC & LARGE WIRE SOLUTIONS CATALOG!

NEW SUBMERGED ARC & LARGE WIRE PRODUCT CATALOG NOW AVAILABLE

Introducing our first catalog dedicated to submerged arc welding and large wire solutions! This new catalog includes our full line of products for submerged arc welding (SAW) and large wire, including some of the products highlighted in this newsletter. To request printed copies, contact customer support at 517-782-8040 or talk to your Wire Wizard® Technical Sales Expert.

CLICK HERE TO DOWNLOAD THE FULL CATALOG (PDF)


WIRE DELIVERY SOLUTIONS FOR SUBMERGED ARC (SAW) MANIPULATOR SYSTEMS

When it comes to welding wire, submerged arc (SAW) wire is the “king of beasts” and can be extremely difficult to feed. Wire Wizard® provides a full line of wire delivery equipment for SAW welding for monster wire sizes up to 7/32” (5.5 mm), including Mechanical Turn Tables, Guide Modules® for large wire, large wire conduit, Wire Pilot® Feed Assists and the high performance PowerBall® SAW Torch utilizing our patented long-lasting, high conductivity consumable design.

The setup shown below represents an optimized wire delivery system configuration for submerged arc welding with a large manipulator. Wire Pilot® Feed Assists, Guide Modules and low friction conduit for large wire are implemented to minimize the pull force on the wire feeder for smooth wire delivery and superior welding performance.

SEE THESE SOLUTIONS & MORE IN THE NEW SUBMERGED ARC & LARGE WIRE CATALOG!


THE WIRE PILOT® WIRE FEED ASSIST:
SOLVE WIRE DELIVERY PROBLEMS & FEED LONGER DISTANCES

The Wire Pilot® Pneumatic Wire Feed Assist provides a "push-pull" system to help your wire feeder move wire through the conduit in applications with a complex wire delivery setup, long distance wire feeding or where the workload on the wire feeder must be reduced. When combined with the Guide Module System, the Wire Feed Assist allows the ultimate flexibility when it comes to wire delivery and wire packages can be located 150 ft (46m) or more away from the arc. Compatible with ferrous & non-ferrous wire. Patented design.

  • Eliminates wire drag coefficient inside the conduit
  • New high torque Dual Drive Model features four drive rolls designed for large wire up to 3/16" (4.8 mm) and extra-long distance applications using standard size MIG wires
  • Extends conduit life and increases arc-on time
  • Enables longer conduit runs (150 ft/46m+), enabling centrally located wire packages and allowing the use of bulk wire in many applications that would normally require small spools
  • Prevents burn backs caused by wire feeding problems
  • Solves many feeding issues with large diameter wires
  • Operates on standard shop air, with low air consumption
  • Proudly Made in USA



WHAT APPLICATIONS CAN BENEFIT FROM A WIRE FEED ASSIST?

Robotic & Semi-automatic MIG Welding
In MIG welding, the Wire Pilot® Feed Assist is the ideal solution for long distance wire feeding and in any configuration where the wire can be difficult to feed through the wire delivery system. Many manufacturers have installed the Wire Feed Assist in order to switch to bulk wire packages instead of spools that are normally located close to the feeder. This results in substantial cost savings on both wire and reduction in downtime for wire changeout.

The Wire Feed Assist can be very beneficial when used with softer wires like aluminum. Soft wires with a low stem strength can easily cause downtime with wire delivery problems such as birdnesting at the wire feeder. Since the Feed Assist works with the wire feeder (it only pushes when the wire feeder pulls), it can safely help feed soft wire through the delivery system without damaging the wire. Utilizing the "push-pull" system the Feed Assist provides, it removes the wire skid friction and eliminates wire delivery issues with notoriously difficult to feed aluminum wire.

Submerged Arc Welding
With the ability to handle large wire as big as 3/16" (4.8 mm), the Wire Pilot® Feed Assist has been a life saver for submerged arc welding! One common setup for submerged arc welding is shown above with the manipulator system, but the feed assist has also been used on SAW systems with gantries and other configurations. Combined with Large Wire Guide Modules, the Feed Assist ensures trouble-free large wire delivery.

Laser Welding & Brazing
Laser welding & brazing, a common process in the automotive and transportation industry, requires pinpoint wire placement with precise control of the wire feed. This process typically uses silicon bronze or other wire with a softer metal alloy, resulting in many of the same feeding issues encountered with aluminum wire. The Wire Pilot® Feed Assist ensures smooth and accurate wire delivery to the feeder for flawless laser welding.

Specialty Welding Applications
The Wire Pilot® has been used by many manufacturers with unique welding needs, such as cold wire TIG welding, pipe cladding and additive manufacturing with wire. The Wire Feed Assist excels in applications such as these that require precise wire placement and/or feeding of larger wire. Below is an image of the end result in a cold wire TIG application on 6 mm thick aluminum plate after implementing the Wire Pilot® Feed Assist along with Guide Modules and wire straighteners. Not only was this manufacturer able to switch from spools to bulk wire drums, they also saw consistent, quality welds in a challenging application.


WIRE WIZARD® PRODUCT CATALOGS


Wire Delivery & Support Equipment Catalog
(9 mb)


PowerBall Torch Products Catalog
(6 mb)


Submerged Arc & Large Wire Product Catalog (5 mb)

To request printed catalogs, please call customer service at 517-782-8040 ext. 236 or email us at sales@wire-wizard.com


WIZARD TECH ONLINE TRAINING & WEBINARS
Expand your industry knowledge by learning about new products, tools and techniques to solve the toughest welding challenges. Our comprehensive online training system includes a series of training modules that cover everything from wire dispensing basics to optimizing equipment for maximum arc welding performance and productivity.

Click here for more information on the Wizard Tech Online Training Program




ELCo Enterprises, Inc. • 5750 Marathon Drive • Jackson, MI 49201
Phone: 517-782-8040 • Fax: 517-782-8039 • www.wire-wizard.com
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