Abstract: A drive roll is disclosed that is useable in a wire feeder for advancing a wire. The drive roll includes a first side, a second side offset from the first side, and an annular surface between the first side and the second side. An annular groove is formed in the annular surface and defines an engagement surface. Pluralities of lands are spaced along the engagement surface and pluralities of notches are formed in the engagement surface for engaging and advancing the wire. An engagement ratio is defined between the total land area of the plurality of lands and the total notch area of the plurality of notches calculated at the engagement surface. The engagement ratio defines a drive roll that accurately engages and advances the wire over a longer period of use.

Abstract: A drive roll is disclosed that is useable in a wire feeder for advancing a wire. The drive roll includes a first side, a second side offset from the first side, and an annular surface between the first side and the second side. An annular groove is formed in the annular surface and defines an engagement surface. Pluralities of lands are spaced along the engagement surface and pluralities of notches are formed in the engagement surface for engaging and advancing the wire. An engagement ratio is defined between the total land area of the plurality of lands and the total notch area of the plurality of notches calculated at the engagement surface. The engagement ratio defines a drive roll that accurately engages and advances the wire over a longer period of use.

Abstract: A drive roll (180) adapted and configured to feed weld wire (54) comprises first and second opposing sides (238, 239) and an outer body surface (290). The outer body surface (290) comprises a base body surface (BBS), and at least one elevated wire interface (244) extending outwardly from and along at least a major portion of the base body surface. The elevated wire interface (244) can rotationally drivingly engage the weld wire (54), which enables the drive roll (180) to advance the weld wire (54) along e.g. a desired path of travel such as to a welding arc.