079601 - Miller 1/16 Aluminum U-Groove Drive Roll Kit for 2-Roll Feeders

Precision Wire Feeding for Aluminum Applications

The Miller 079601 Drive Roll Kit is an essential accessory for industrial welding operations utilizing 1/16-inch aluminum or other soft alloy wires. Designed specifically for Miller MIG welders and wire feeders equipped with a two-roll drive system, this kit addresses the unique challenges associated with feeding soft filler metals. Unlike steel wires, aluminum has low column strength and is susceptible to deformation if compressed too tightly by standard V-groove or knurled rolls. This deformation can lead to cross-sectional distortion, increased friction within the liner, and the generation of metal shavings that eventually cause feed failures or "bird-nesting" at the drive assembly.

This kit features precision-machined U-Groove drive rolls. The U-shaped profile cradles the wire, providing sufficient surface area for traction without biting into the material. This ensures a consistent wire feed speed, which is critical for maintaining a stable arc and achieving high-quality aluminum welds. The geometry of the groove allows the drive rolls to push the wire effectively while maintaining its round shape, preserving the integrity of the wire surface and ensuring smooth travel through the gun liner and contact tip.

In addition to the two drive rolls, the 079601 kit includes a specialized inlet wire guide. The inlet guide plays a pivotal role in the feeding system by aligning the wire as it enters the drive assembly, minimizing drag and preventing misalignment that could lead to feeding issues. By replacing both the rolls and the guide simultaneously, operators ensure a complete optimization of the wire feed path for soft wires. This genuine Miller Electric component is manufactured to strict tolerances, ensuring perfect compatibility with designated Miller 2-roll wire feed systems and providing long-lasting durability in demanding industrial environments.

Implementing the correct drive roll geometry is a fundamental step in setting up a MIG welding system for aluminum. The Miller 079601 kit provides a reliable, OEM solution that eliminates common feeding frustrations, allowing welders to focus on arc control and bead appearance rather than equipment troubleshooting.