Setting up roller tension for aluminium.

[auswelder]

Hi,

Just wondering what the proper procedure is to setup the tension for welding aluminium. It's a 4 roll drive feeder, with U grove rollers. Each set of rollers has a seperate adjuster, i know there are some welders out there that just have the one adjuster.

Should they both be adjusted the same so they apply the same ammount of pressure? Should I adjust both of them at the same time or disconnect one pair of rollers?

Any advice would be good

Thanks

 

[runnach]

I've never used a 4 roll setup on steel let alone alloy, knowing the potential problems setting wire tension using alloy, I'd tend to use one only, do away with the roll closest to wire spool, however, an experienced member may have a better idea than me, so maybe using all 4 is best?

Cheers.........

 

[craigthewelder]

I always use all 4 rollers. I try and keep the pressure as even as possible, but I'm talking really, really light pressure. I only ever use 4043 wire which is really soft, if your using 50** wire then i guess you could get away with using a bit more pressure.

 

[Richm]

as above, use lightest pressure possible

 

[auswelder]

Thanks I will have a play around with it tomorrow. Have had a few problems with the wire burning back to the tip, not sure if its related to this or not. Always use 5356 wire.

So if I back the rollers off till the wire doesnt feed through and then apply half a turn or so, that would be right?

Thanks

 

[matt1978]

I have just offered some advice on another simerla thread, so I have just copied and pasted here

Hi Mate,

I didn't mean change as in modify your existing rollers, I ment 'change' as in buy the right rollers and swap them on your wire feeder

There are 3 main types of roller. a U, V and Knurled.

U Shape is for soft wires, Alu, Mig Brazing wires etc

V Is for Steel, CrNi's etc

Knurled is for Flux cored wires etc

The U shape is like a half round and helps to prevent the softer wires from being de-formed as would happen if you used the same rollers you use for steel as for Alu. This can then lead to feed problems and birds nesting.

Also, don't have too much or too little pressure on the rollers, as either is just as bad.

I don't know the pressure scales on the feed system on your machine, but on ours we only need put the pressure arms down to about 2 to 2.5 on the scale. This is plenty.

You can tell you have enough as once you have fed the wire through the torch and contact tip, you should be able to apply some pressure with the flat palm of your hand to the end of the wire and it should begin to push your hand back. If it cant push your hand back then the wire should slip on the rollers, it shouldnt birds nest/snag up.

Your always better using 4-rd if possible, as it spreads the pressure out over a wider surface area on the wire.

Have u changed the liner in the torch?