ESAB Feed Rolls FAQs
Straight answers to the questions people ask most when choosing replacement V-groove and U-groove feed rolls for a wire feeder.
What is the difference between a V-groove and a U-groove feed roll?
A V-groove has angled sides that grip the wire at two points. It suits hard wires such as solid mild steel and stainless steel. A U-groove has a rounded, smooth channel that holds the wire's shape without biting into it, so it suits soft wires, mainly aluminium.
Using the wrong shape can slip, flatten or mark the wire. Cored wires usually need a V-groove with a knurled (toothed) surface instead of a plain one.
How do I match a feed roll to my wire size?
The groove is machined for a particular wire diameter, usually shown on the roll as a size in millimetres or inches. Choose the roll that covers the diameter printed on your wire spool.
A groove that is too large lets the wire slip and feed erratically, while one that is too small can squeeze or shave the wire and clog the liner. Always match roll, liner and contact tip to the same wire diameter.
Why do some rolls show two sizes?
Many rolls have a different groove on each face, so one roll covers two neighbouring wire sizes. Only one groove works at a time, so make sure the size you need is the one in the working position, as shown by the markings.
If you fit the roll the wrong way round for the wire in use, the grip is wrong, which can over-tension and deform the wire and cause poor feeding. Check the markings each time you change wire.
How do I tell which roll type I have now?
Look at the groove: a pointed V, a rounded U, or a V with fine teeth (knurling). Look also for the size markings on the face of the roll. Compare them with the wire you currently run.
If the markings have worn away, measure the wire you use and check your welder's manual for the roll types and sizes it takes. If you are not sure, our team can help you identify the right one for your machine.