268850 - Miller XR .062 Aluminum Drive Roll Kit - Polished

Precision Feeding for Soft Aluminum Alloys

Achieving high-quality aluminum welds requires more than just the right power source; it demands a wire feeding system tuned to the unique properties of the material. The Miller 268850 Drive Roll Kit is engineered specifically for feeding .062-inch aluminum wire through XR series push-pull systems. Unlike steel, aluminum wire has low column strength and is easily deformed. This kit addresses these challenges with a specialized polished U-groove design that cradles the wire rather than crushing it.

Why Polished Rolls Matter
Standard drive rolls often employ knurling or sharp V-grooves to grip hard wires. However, using these on aluminum results in "shaving"—where small flakes of aluminum are stripped off the wire. These shavings accumulate in the drive housing and liner, increasing friction and leading to the dreaded "bird-nesting" or burn-back. The Miller 268850 features a highly polished surface that provides adequate traction through surface area contact rather than mechanical indentation. This ensures the wire remains round and smooth as it enters the liner, facilitating consistent wire feed speeds essential for pulse MIG and spray transfer modes.

Compatibility and Performance
This kit is the designated replacement for the legacy part number 195591. It is compatible with Miller's XR series feeders, which are industry standards for aluminum welding in shipbuilding, trailer manufacturing, and aerospace applications. The .062-inch size is commonly used for higher deposition rates on thicker materials. By ensuring your feeder is equipped with the Miller 268850, you are protecting your equipment from premature wear and ensuring that your weld parameters remain stable throughout the job.

Maintenance of your wire feed system is crucial. Worn drive rolls can slip, causing erratic arc starts and porosity. Replacing them with this genuine Miller kit restores the mechanical efficiency of your feeder, allowing for precise control over wire delivery. Trust in Miller engineering to support your most demanding aluminum fabrication tasks.