Comparing Push Guns, Push-Pull Guns, and Spool Guns

Push Gun Benefits
Feeding aluminum wire through a push only system is very advantageous. The D/F Pistol is inexpensive unlike the push-pull MIG torches and spool guns on the market today. Push-pull torches are also very fragile, difficult to maintain, and have more parts. A push gun requires u-groove drive rolls to provide more surface contact with the wire, a nylon liner, and adequate drive-roll pressure. With the use of the D/F steel reinforced casing supporting the liner, the D/F Pistol Gun can push 3/64", 1/16", and 3/32" aluminum wire up to 15 feet. Because the D/F Pistol Gun can hook up to any manufacturer's wire feeder and power source, large spools of wire can be used reducing expenses, down time, and wear and tear on the torch by the changing of spools, as in a spool gun. A spool gun needs to have the roll changed after every pound of wire is used, compared with the 8 or 15 lb spool on a push-pull system. In tight spaces, the spool may limit access, requiring the operator to use a longer stickout. If the operator is using several pounds of aluminum per day, the few minutes need to change spools can add up. Also, the chance of burnback exists when the end of a spool is reached, so many operators stop when a few turns are left on the spool.

Spool Gun Limitations
Because a spool gun is larger than a push gun, it can sometimes be difficult to get close access to the weld. Also, a spool gun can only hold a 1 pound spool of aluminum wire electrode, so changeovers are frequent. In addition, these small spools typically are not the most economical way to purchase wire.

Push-Pull Gun Limitations
Typically, the greatest disadvantage of a push-pull system is that it requires the most number of components and is the most expensive. Push-pull guns are also very fragile and do not last as long.

Push Welding vs. Push-Pull Welding
A push gun also has advantages over a push-pull gun for many reasons. Typically, the greatest disadvantage of moving wire over long distances with a push-pull system is that it requires the most number of components and is the most expensive. It is very easy to mount a D/F Pistol Gun on a boom system to take all of the weight off of the gun. By mounting the wire feeder and power source on a 4-wheel cart, you can now travel great distances very easily. Push-pull guns are also very fragile and do not last as long (months vs. years). Push-pull guns are 2-3 times more expensive than the D/F Pistol. They only last up to 9 months on average, and you either have to replace the torch or rebuild by installing a new motor costing as much as $400-plus. Lastly but most importantly, because the D/F Pistol uses a 4" contact tip that is recessed in the water-cooling, not only is the arc stability increased, the tip life is increased 7-1, and there is built-in wire straightening. If the operator is using several pounds of aluminum per day, the few minutes need to change spools or replace motors can add up.

Pushing Aluminum Wire
Feeding aluminum wire through a push only system is very advantageous. Because push-only guns like D/F Pistol Gun can hook up to any manufacturer's wire feeder and power source, large 300 lb spools of wire can be used reducing expenses, down time, and wear and tear on the torch by the changing of spools as in a spool gun. A spool gun needs to have the roll changed after every pound of wire is used, compared to the large size spools used in a D/F Pistol Gun. Also, the chance of burn-back exists when the end of a spool is reached, so many operators stop when a few turns are left on the spool.

Trailer Manufacturing
When manufacturing high quality aluminum trailers, it is important to consider longevity and strength of the weld joints. With aluminum in particular, it is somewhat of a fine-tune process to get a weld that will penetrate correctly with slightly higher heat and slightly lower travel speed. Also, choosing the correct wire size is crucial to an optimally strong aluminum weld. Since the D/F Water-Cooled Pistol Gun can handle a wide range of wires, and can hook up to any power source and wire feeder to accept any necessary welding parameters, it is a superior choice for manual MIG aluminum welding and trailer manufacturing.