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26

Technical Services

Performance Improvement - Increasing Wire Diameter

What affect does increasing wire diameter have on the welding process?

Some advantages of increasing wire diameter are: better fusion/penetration, increased travel speeds, higher deposition

rates, lower price per pound, and better feedability.

Due to the physical and mechanical properties of aluminum, it is very feasible to increase wire diameter and either:

1) go faster to increase production rates or, 2) make a larger weld without slowing down. The tables below show the results

from using larger wire for each goal. The table layout shows the percent increase between each wire increment as well as

the increase if you were to “skip” a level.

Common Bead Width

Diameter (in.):

.047

.062

.071

.094

Amps

223

274

319

375

Volts

22.5

23

24

25

Wire Feed Speed (ipm)

523

366

295

180

Bead Width Target (in.)

0.45

0.45

0.45

0.45

Travel Speed (ipm)

26

35.8

42

49

Percent Increase in Travel Speed

37.7

17.3

16.7

61.5

36.9

88.5

Common Travel Speed

Diameter (in.):

.047

.062

.071

.094

Amps

225

258

264

375

Volts

23

23

23

26

Wire Feed Speed (ipm)

531

366

271

180

Travel Speed (ipm)

27

27

27

27

Bead Width (in.)

0.422

0.480

0.582

0.688

Percent Increase in Travel Speed

13.7

21.3

18.1

37.9

43.2

62.9

This is just one step toward improving performance and productivity. Other tools and techniques can be found

throughout this guide.