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.