265257 - Miller 1/16" Polished U-Groove Drive Roll Kit for Aluminum (4-Roll)

Precision Feeding for Aluminum Welding

The Miller 265257 Kit is a specialized drive roll set designed specifically for the unique challenges of feeding aluminum MIG wire. Aluminum is significantly softer than steel or stainless steel, making it prone to deformation, crushing, and shaving if fed through standard V-groove rolls. This kit features a precision-machined U-groove geometry that cradles the wire, providing the necessary traction for feeding without altering the wire's cross-sectional shape. This is essential for maintaining consistent electrical contact at the contact tip and ensuring a stable arc.

This kit is configured for 4-roll wire drive systems, providing four synchronized rolls to maximize feeding force while minimizing the pressure applied to the wire at any single point. The rolls are sized for 1/16-inch (1.6mm) wire, a common diameter for industrial aluminum fabrication. A standout feature of this kit is the polished finish on the rolls. Unlike standard knurled or rough-machined rolls, the polished surface eliminates sharp edges that could shave small particles of aluminum off the wire. These shavings, if generated, can accumulate in the gun liner or contact tip, leading to burn-backs and erratic feeding. By using polished rolls, operators ensure a cleaner wire path and reduced downtime for maintenance.

Genuine Miller OEM parts guarantee compatibility with your Miller wire feeder, ensuring that the drive rolls align perfectly with the inlet and outlet guides. Proper alignment is critical in aluminum welding to prevent birdnesting (wire tangling) at the feeder. Whether you are welding thick aluminum plate in a shipyard or fabricating intricate components, the Miller 265257 kit provides the reliability needed for high-quality aluminum welds.