A push-pull welding gun works by utilizing two wire feeders – one in the welding machine itself (the "push") and another integrated into the gun handle (the "pull") – to ensure smooth and consistent wire feeding, particularly over long distances.
Here's a breakdown of the process:
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The Push Feeder: The main wire feeder, located in the welding machine, starts the process by pushing the welding wire through the cable towards the welding gun.
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The Pull Feeder: The key component of a push-pull system is the motorized wire feeder located inside the gun handle. This feeder actively pulls the wire from the cable and feeds it through the gun's nozzle to the weld puddle.
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Synchronized Operation: The push and pull feeders are synchronized to work together. This coordination is crucial. The pull feeder doesn't simply yank the wire; instead, it assists the push feeder, reducing friction and preventing the wire from buckling or bird-nesting within the cable.
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Longer Cable Lengths: The primary advantage of a push-pull system is its ability to handle longer cable lengths (typically 25-50 feet). Standard welding guns often struggle with wire feed issues when the cable is long, due to increased friction. The pull feeder overcomes this limitation.
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Softer Wires: Push-pull guns are particularly beneficial when welding with softer, more easily deformed wires, such as aluminum. Aluminum wire is prone to buckling and kinking in standard setups, but the push-pull system's dual-feeding mechanism significantly reduces these problems.
In essence, a push-pull welding gun employs a collaborative feeding system where the welding machine pushes the wire and the gun simultaneously pulls it, ensuring reliable wire delivery, especially when using long cables or soft wires.
