wirefeed

Wirefeed refers to a mechanism used in many welding processes to deliver filler metal from a spool to the weld area. In gas metal arc welding (GMAW, commonly called MIG) and flux-cored arc welding (FCAW), the wirefeed system advances a continuous welding wire through a guide tube and into the welding arc, where it melts to form the weld bead. The system typically includes a wire spool, drive rolls or a push-pull feeder, a contact tip, a gun liner, a guide tube, and a power supply that controls current and voltage. In some configurations the feeder is mounted to the welding power source, while in others it is integrated into the welding gun or a separate remote unit. Aluminum welding often requires a spool gun because aluminum wires are more flexible and prone to bird-nesting unless a stiff, push-pull arrangement is used.

Wire materials and diameters vary for different metals. Common filler wires include mild steel, stainless steel, and aluminum alloys, with diameters typically ranging from about 0.6 mm to 1.2 mm depending on application and wire type. The feeder may be configured as direct-drive or geared, and in some cases uses a dedicated push-pull system for longer runs or difficult wires. The feeder’s drive tension, liner length and quality, and contact-tip condition all affect feeding reliability.

Operation involves setting the wire feed speed in conjunction with arc voltage, shielding gas, and travel speed. The feed speed influences deposition rate and current; too fast can cause high current and splice defects, while too slow can lead to poor fusion and short circuits. Regular maintenance—checking drive rolls, replacing worn liners and tips, and clearing jams—reduces feed problems such as bird-nesting, tangling, or feeding jams.

Applications span manufacturing, automotive, construction, and repair work where continuous filler-metal delivery is advantageous.