ProStar™ Twist-Free Steel Welding Wire

prostar™ twist-free steel welding wire

Straight and Clean from Beginning to End

PRAXAIR'S PROSTAR™ WELDING WIRE DELIVERS RELIABLE, PREDICTIVE PERFORMANCE WELD AFTER WELD.

ProStar “twist-free” mild steel welding wire is the right choice for consistent, high-quality welds, throughput, and quality for automated welding processes. With no cast or helix, users can avoid uneven wear on consumables—typical with standard welding wires—which can cause arc wander, over-welding, feed issues, and shut-downs.

Additionally, ProStar welding wire’s distinctively clean and smooth surface, tight chemistry, and our proprietary drawing, coating, and packaging processes further help to ensure predictive performance and consistent, high-quality welds.

To remain competitive, your automated welding operation faces a relentless demand to produce fast, high-quality welds. ProStar welding wires help you meet this demand with predictable weld placement, reduced arc wander and over-welding, improved weld quality, and less cost per foot of weld. Schedule a demo today and see how ProStar welding wire can help you improve your productivity.

ProStar Twist-Free Steel Welding Wire Body Image 1 | Praxair

 

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ProStar Welding Wire Advantages:

  • Higher productivity, lower operational costs
  • Consistent, high-quality welds
  • Proprietary manufacturing process with tight tolerances provides a premium wire for high weld quality
  • Reduced cast & helix provides predictive puddle placement
  • Tight wire chemistry & purity
  • Wire diameters .030" - .062"
  • Spools in various sizes
  • Proprietary box packaging
  • Layer level wound & random wound spools
  • 330, 660, 1200 palleted packs
  • Distinctively clean, smooth wire surface

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what does twist free mean?

What Does Twist-Free Mean in a Welding Wire?

PROSTAR™ WELDING WIRE IS THE RIGHT CHOICE FOR WELD PRODUCTIVITY AND QUALITY - FORMULATED FOR BOTH MANUAL AND ROBOTIC WELDING.

  • "Twist-free" means the drawing and packaging process results in a product with very little cast or helix - wire comes out of its packaging much straighter compared to standard wires
  • Wire and arc placement are predictable - it goes where you want and doesn't flip back and forth - helping to reduce over-welding, waste and cost/inch
  • Straighter wire creates less wear points inside a conduit, with reduced possible binding areas and less drag for more consistent feeding
  • Straighter wire creates uniform contact tip wear, which means that properly sized tips can be used and consumable costs are reduced
  • Straighter wire provides feed consistency from pack to pack
  • All of these factors contribute to greater productivity, less downtime and reduced overall welding costs
ProStar Twist-Free Steel Welding Wire Body Tab 1 | Praxair

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 FEATURES  BENEFITS
No cast or helix Minimizes arc wander, weld cost-per-inch & provides uniform tip wear
Single, high-quality mill source Provides superior consistency of tight wire chemistry & purity while improving overall weld quality & over-cast
High-tech, proprietary drawing processes Maintains consistent wire diameter within defined tolerances
Distinctly clean, consistent & smooth wire surfaces for a premium surface finish Decreases downtime from wire feed issues
Exclusive, proprietary stackable wire package containers with lifting access on four sides Reduces impact on floor space & provides faster, more efficient transportation
Inner packaging Cuts down on the effects of moisture

 

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Wire Grades

Clean Materials, Stringent Controls

HIGH-QUALITY WIRES FOR DIVERSE APPLICATIONS.

ProStar™ twist-free welding wire starts as pickled green rod coils produced under ISO-certified control to some of the tightest batch-to-batch tolerances in the industry.

Our proprietary drawing and coppering processes result in fewer scratches with less flaking or peeling to produce an extremely clean and smooth wire surface.

ProStar wire is packaged using our proprietary, twist-free winding machines. Innovative bulk packaging design helps to ensure, maintain, and deliver twist-free performance, weld after weld.

The result is a wire product featuring reliable feeding and predictive welding performance that is consistent from pack to pack. This means less downtime due to clogged liners, unevenly worn consumables, and feed issues; less over-welding due to predictable placement of the weld puddle; and reduced overall weld cost-per-foot.

ProStar Twist-Free Steel Welding Wire Body Tab 2 | Praxair

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DRUM SIZE ER70S-3 ER70S-6 Automotive ER70S-6 Professional ER80SD-2/90SD-2
  Available Wire Diameter (in)
330 lb (150 kg) .035 .040  X .035 .040 .045 .052  .035 .052
660 lb (299 kg) .035 .045 .052 Available early 2019 .030 .035 .040 .045 .052  .045
1,200 lb (544 kg) .035 .045 .052  .035 .045 .052 .030 .035 .040 .045 .052 .062  .045 .052 .062

ProStar wires are also available in a number of diameters on a variety of spool sizes.

 

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feed systems

Advance Your Wire's Delivery

PRAXAIR FEED SYSTEMS FOR FERROUS AND NON-FERROUS MATERIALS, INCLUDING TUBULAR WIRES.

Four reasons why you should equip your automated welding system with ProStar™ Conduit.

1. Reduce Burn-Backs

ProStar conduits reduce pull tension issues that are associated with weld wire burn-backs at the contact tip.

ProStar Twist-Free Steel Welding Wire Body 1 Tab 3 | Praxair

2. Reduce Weld-Necking

ProStar conduits minimize uneven pull tension between the resting state and slack consumption, which is the cause of weld necking just after the weld starts.

ProStar Twist-Free Steel Welding Wire Body 1 Tab 3 | Praxair

3. Reduce Over-Welding

ProStar conduits reduce pull tension to help improve your weld accuracy and precision, further decreasing the need to over-weld.

ProStar Twist-Free Steel Welding Wire Body 3 Tab 3 | Praxair

4. Facilitate Wire Farms

For high productivity weld cells and multiple shifts per day, a wire farm that incorporates ProStar wire and Praxair's 24/7 feed system can eliminate wire changeouts and downtime.

ProStar Twist-Free Steel Welding Wire Body 4 Tab 3 | Praxair

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24/7 Systems

ProStar 24/7 System

ELIMINATE CELL DOWNTIME WITH CONTNUOUS DELIVERY OF WELDING WIRE TO THE ROBOTIC CELL.           

Eliminate downtime caused by manual wire changeouts.

Praxair’s 24/7 wire feed system helps improve and protect the productivity of your robotic MIG welding cells. Each “wire farm” consists of two 1,200 lb drums of ProStar wire, the 24/7 system swing arm and stand, RW 24/7 butt welder, and 24/7 die.

Praxair’s 24/7 feed system is designed to serve a robotic cell sequentially from two wire drums — enabling continuous delivery of welding wire and avoiding downtime.

ProStar Twist-Free Steel Welding Wire Body 1 Tab 4 | Praxair

 

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ProStar 24/7 System Components

24/7 Butt Welder

Joins mild steel wires of various diameters. Set the welding current to Position One for .030 to .062 diameter wires. Select Position Two to weld 5/32 diameter wire.

ProStar Twist-Free Steel Welding Wire Body 2 Tab 4 | Praxair

24/7 Die Set

With shaving plates available for many wire diameters, the 24/7 die set ensures a consistent diameter across the welded seams when drums are joined together by removing the resultant flash and any burrs from the welding process.

ProStar Twist-Free Steel Welding Wire Body 3 Tab 4 | Praxair

24/7 Swing Arm

Prior to the first drum being spent, its wire end is welded to wire start in the full drum. As the wire source transitions from drum to drum, the swing arm simultaneously rotates to supply wire from the full drum.

ProStar Twist-Free Steel Welding Wire Body 4 Tab 4 | Praxair

 

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