KP1695-035A - Lincoln Electric Drive Roll Kit for .035 Aluminum Wire, 2-Roll System

Technical Overview of the Lincoln Electric KP1695-035A

The Lincoln Electric KP1695-035A is a specialized drive roll and wire guide kit engineered specifically for the transport of .035-inch (0.9 mm) aluminum welding wire. Unlike standard V-groove or knurled drive rolls used for mild steel and flux-cored wires respectively, this kit utilizes a precision-machined U-groove profile. This geometry is critical for aluminum applications because aluminum wire is significantly softer and more malleable than steel. A standard V-groove tends to bite into the wire, causing deformation that changes the cross-sectional shape of the wire, leading to poor contact tip fitment and erratic arc characteristics. The U-groove provides sufficient friction for traction while distributing the compressive force over a larger surface area, maintaining the wire's roundness.

A key technical feature of the KP1695-035A is the inclusion of a split wire guide. Aluminum wire has low column strength, making it highly susceptible to buckling—commonly referred to as "bird nesting"—in the space between the drive rolls and the gun receiver bushing. The split wire guide in this kit is designed to bridge this gap, providing continuous support to the wire column as it leaves the drive rolls. This drastically reduces the unsupported length of the wire, thereby increasing the critical buckling load and ensuring reliable feeding even when the torch cable is curved or resistance in the liner increases.

This kit is designed for Lincoln Electric 2-roll wire feeding systems. It is directly compatible with industrial-grade feeders including the LN-25X®, LN-25 PRO®, Power Feed®, and Active8X™ series. The kit includes two drive rolls and the necessary inner and outer wire guides to complete the installation. Proper installation of this kit is essential for achieving X-ray quality aluminum welds, as consistent wire feed speed is a primary variable in maintaining stable voltage and amperage in GMAW processes.