![]() Many times when the welder's in position and they lift up their torch, that actually adds a cast anyway. If you have a poor wire cast in a manual welding situation, you can manipulate the torch by hand. Whereas, with hand welding, you're always changing the articulation or the angle of the torch. Therefore, there can be habitual problems that are very hard to trace. The reason robotic welding is trickier is because it always repeats the same positions. There is a very big difference between cast issues in manual welding and cast issues in robotic welding. ![]() Understanding how much cast you should have is exceptionally important in a robot. You get all your power from your welder to your wire from the relation between the wire cast and the contact tip. That's what's going to be your conductor. When you do that, the wire incurs friction and, by design, rubs against the inner diameter of the contact tip. If the wire doesn’t make contact on that tip, we run into microarcing and poor weld quality.īased on how weld wire is packaged - via either a spool or a barrel - all that cast does is take a curved wire and send it through a straight body, i.e. Your contact tip makes contact with the wire to help bridge current. You need cast because of your contact tip. Helix is naturally occurring and is easier to manipulate than cast. ![]() ![]() The cast is more important in robotic welding. The second is the helix, which is the natural winding geometry of the wire's radial shape. The first is the cast, which is the natural curvature of the wire. There are two physical elements of weld wire to be aware of in a robotic welding application. ![]()
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