375980-002 - Thermal Arc .045 Flux-Cored Drive Roll Kit (2-Roll System)

Precision Wire Feeding for Tubular Wires

The Thermal Arc 375980-002 Drive Roll Kit is a critical accessory for welding professionals utilizing .045-inch (1.2mm) flux-cored or dual shield welding wires. In the realm of semi-automatic welding, the consistency of wire delivery is paramount to arc stability and weld quality. This kit is specifically engineered for Thermal Arc 2-roll wire feed systems, providing the exact geometry required to handle tubular wires effectively.

Optimized Geometry for Flux-Cored Applications

Tubular wires, such as flux-cored (FCAW) and metal-cored varieties, possess a hollow structure filled with flux or metal powder. This construction makes them more susceptible to deformation than solid wires. Standard V-groove drive rolls, which are designed for solid wires like ER70S-6, often require excessive tension to grip tubular wires, leading to crushing and ovalization. The 375980-002 kit features a specialized groove profile—denoted as FL/DS (Flux/Dual Shield)—which typically incorporates a knurled or serrated texture. This texture bites gently into the wire's surface, providing positive traction with minimal tension, thereby preserving the wire's roundness and ensuring smooth passage through the liner and contact tip.

System Compatibility and Performance

Designed as a complete kit for 2-roll systems, this product ensures that both the driven and idler rolls (where applicable) are matched perfectly for .045" wire. Using mismatched or worn drive rolls is a leading cause of erratic feeding, burn-back, and bird-nesting. By installing the genuine Thermal Arc 375980-002 kit, operators can restore their machine's feeding performance to factory standards. The components are manufactured from high-grade hardened steel, offering resistance to wear even under the abrasive conditions often found in heavy fabrication and structural steel environments.

Installation and Maintenance

Proper installation of the drive roll kit is essential. Users should ensure the rolls are aligned correctly with the wire guide and that the tensioner is adjusted according to the wire manufacturer's specifications. Because the FL/DS rolls provide superior grip, operators will find they need significantly less tension than with smooth rolls, extending the life of the wire feeder motor and components.