Can gap too big or inconstant!
- blank cutting (especially development) not within tolerance
- inconstant overlap – Z-bar worn (—> for “overlap variation“ see also here )
- wire tension not correct
- calibration crown inconstant (for example due to worn bearing)
- wrong adjustment of „overtravel“ of final pusher system (see instruction manual of your welder)
- „backlash“ in final pusher system due to worn bearing or linear guides
- copper wire profile not correct