Everything you need to know about Wire Feeder

Wire Feeder

Wire feeders are used to add filler metallic for the duration of robotic welding. This approves flexibility in setting up a number of welding wire feed charges to swimsuit precise necessities for an assembly.

Normally, the MIG wire feeder for robotic welding is set up on the robotic arm, separate from the strength supply.
Everything you need to know about Wire Feeder
The wire feeding device ought to be matched to the welding system and the kind of energy supply being used. Basically, there are two primary types of wire feeders.

The first kind is used for the consumable electrode wire manner and is acknowledged as an electrode wire feeder. As we know, the electrode is a section of the welding circuit, and the melted metallic from the electrode crosses the arc to emerge as the weld deposit.

There are two exclusive sorts of electrode wire feeders. The constant-power strength supply requires a voltage-sensing wire feed gadget in which the feed charge might also be altering continuously.

The constant-voltage gadget requires a consistent feed fee at some stage in the welding operation. The second kind of wire feeder is acknowledged as a bloodless wire feeder and is specially used for gasoline tungsten arc welding.

Voltage-sensing Wire Feeder

A feeder, commonly in a suitcase or pelican box, can run on a steady voltage (CV) energy supply or, oddly enough, a steady present-day (CC) energy source. The latter strength supply is generally related to the SMAW and GTAW processes, now not wire processes. When this feeder is run on CV, it is a steady pace feeder the place the wire feed velocity (amperage) is set on the feeder and the voltage (arc length)

Voltage-sensing Wire Feeder
Source: Bumi

However, when it is going for walks on a CC energy source, the strength supply gives amperage and the feeder WFS knob sets a relative voltage and wire feed speed. As contact-tip-to-work distance (CTWD) changes, which the voltage sensing lead is sensing at the workpiece, voltage (arc length) modifications as does wire feed speed. For example, when CTWD increases, wire feed velocity (WFS) will increase and strive to limit the accelerated arc length. Conversely, when CTWD decreases, the WFS slows down in an strive to extend the shortened arc length.


While the dance between WFS and arc size is in no way ending, as CTWD is usually changing, the CC energy supply is presenting a regular current. The voltage sensing feeder used to be designed particularly so human beings with CC solely electricity sources, like ancient Lincoln generators, may want to run sure flux-cored wires. This feeder is durable, portable, and versatile (can run on each CC and CV).

  • They are most efficient for out of doors subject use.
  • These feeders run off arc voltage and, thus, don’t make use of a managed cable.
  • This is a large benefit as the wire feeder can go some distance as the strength cables extend.
  • Also, manipulate cables required for regular velocity feeders are each high priced and fragile.
  • This feeder, when used on a CC energy source, can solely run gas/ self-shielded cored wires or strong wire in a spray transfer.

Selecting the Right Portable Welder

When buying a new wire feeder, one of the first matters you want to decide is the place you are going to be doing most of your welding. If you are going to be crawling via a porthole at the shipyards on Monday, riding out to a faraway development website on Tuesday, and returned in the keep on Wednesday, then your fine wager is a transportable unit. Once you’ve got installed that you want a transportable wire feeder, subsequent you may choose to study which kind of feeder exceptional fits your needs.

Voltage Sensing or Constant Speed?
Suitcase wire feeders come in two categories: voltage sensing and consistent speed. Voltage sensing feeders function on arc voltage. This prevents the need to manage twine between the energy supply and the feeder.

A voltage sensing wire feeder can be paired with both a steady voltage (CV) or a steady cutting-edge (CC) energy source. These feeders normally have a CC/CV change interior of the case. Be positive it is in the proper function earlier than welding.

In summary, when assessing the number transportable wire feeders, you may desire to reflect on consideration on the following key features:

  • Type of energy supply paired with the feeder
  • Convenience (voltage sensing) vs. far off manipulate (constant speed)
  • Durability
  • Weight and balance
  • Ergonomics (carrying handle, anxiety adjustment, set off hold)
  • Easily serviceable
  • Overload and over-heating safety

Triplex Wire

The triplex wire is used for overhead, single section carrier, and also carries three-character wires twisted around each other wire. Hence it got this name.

Triplex Wire

The two insulated conductors are known as the “hot” legs of the provider whilst the naked (uninsulated) wire is the impartial wire of the service.

This triplexed cable is desirable for use as a drop cable from a pole to the carrier entrance of a structure, or as the secondary distribution between poles. The cable must be restrained to 600V section to section and now not exceed 90˚C.

What part of a wire feeder is used to pull the electrode wire off the spool and push it to the gun?
Most feeders have a burn-back circuit that permits the welding modern to continue to be on for a quick length of time after wire feeding has stopped, to enable the wire to burn again precisely the proper quantity for the subsequent arc initiation.

The feed rolls every now and then referred to as pressure rolls. It also pulls the wire off the spool/reel and pushes it through a feed cable or conduit. These rolls need to typically be changed to accommodate every distinctive wire diameter and feed a mixture of sizes.

Electrical Feeders

Feeders are majorly used for the transmission of electrical energy. It does the transmission of strength from the producing station or substation to the distribution points.

Electrical Feeders

There is no intermediate tapping and via that, the waft of contemporary will be equal for the sending and the receiving section. Feeders are the conducting gadget that is used for the transmission of strength to the essential load middle we ought to get steady voltage from the feeder.

Causes of Welding Porosity

Porosity is precipitated through the absorption of nitrogen, oxygen, and hydrogen in the molten weld pool which is then launched on solidification to grow to be trapped in the weld metal. Nitrogen and oxygen absorption in the weld pool normally originate from negative gasoline shielding.

Even 1% of air entrainment in the gasoline will cause porosity and more amount of gasoline will cause bigger damage to the weld. Hydrogen is one such gas that can be obtained from moisture and can be dried as a constituent on electrodes (workpiece metal).

Surface coatings like primer paints and floor remedies such as zinc coatings may also generate copious quantities of fume all through welding.

Low-zinc primers are weldable and need to be pointed out separately. The primer’s thickness is recommended to be less than what the manufacture has recommended as it might lead to excessive porosity production.


What type of wire is best used with U-cogged drive rolls?
U-groove force rolls are designed for use with aluminum wires or different very tender materials. When the use of gentle wires such as aluminum is done, it is necessary to keep away from marring the wire floor and mashing of the wire.

How is the wire feed speed change with a linear feed system?
Liner feed systems are completely different from any sort of standard feeding system as they have different functionality and structure. It has a motor with a hollow shaft. The wire is fed via the hollow portion of the shaft. It is light-weight and consumes less power as it has no sophisticated arrangement of rollers.