Wire sticking in tips during long welds

admin

HiI was wondering if anyone has ever had the problem of steel welding wire sticking in tips during long welds only (5 feet welded continuous in this case).  By switching brands of wire the problem goes away but the question is why.  Tips are Tweco 14-35 and the wire in both cases is ER70S-6.  Both wires appear smooth with a 24-28" cast and less than a 1/4" of helix.  Plus the diameter is kept within .034"-.036" on both wires during checks with a caliper.Any help is appreciated,Thanks,Todd
Reply:first thing that comes to mind is your drive roll tension, you may have inadvertantly corrected the problem when switching between the different brands of wire.keep the cable as straight as you can, with correct drive tension it should run smoothly. did you also replace the tip? blow out the liner?
Reply:maybe some nozzel jel or maybe try a slightly bigger tip,, wire / tip can swell when heated , next size bigger in tip may help or  just more lube
Reply:Thanks for the help.  Anymore ideas would be appreciated.  This is a large shop with 50 welding stations and the problem occurs at every station.Have a great weekend!!!