ESAB has introduced a heavy industrial push-pull MIG welding system featuring the Warrior® Edge 500 DX 500-amp power source, the RobustFeed Edge DX wire feeder and new ESAB PP 350w water-cooled MIG gun. The PP 350w gun has a duty-cycle of 100% at 350 amps, comes in 20- and 35-ft lengths, features an in-line handle design with 360-degree rotating gooseneck and an optional pistol grip. The RobustFeed Edge DX comes with new synergic lines for 4xxx and 5xxx series aluminum in five WeldModes: manual, synergic MIG, pulsed MIG, SPEED and the new Craft Mode. Craft Mode uses two overlapping pulsed currents to better control heat input, provide smoother metal transfer with less spatter, and create a TIG-like bead appearance without excess gun manipulation.
“ESAB’s Warrior Edge aluminum system delivers best-in-class arc characteristics, exceptionally smooth wire feeding, reduced arc-striking defects compared to other systems and a durable gun design for harsh environments,” says Jeff Chittim, North America Senior Product Manager, ESAB. “To further optimize quality and throughput, pair this system with AlcoTec® aluminum MIG wires, which exhibit smoother wire feeding, fewer tangles, little to no shavings and excellent arc stability.”
Push-pull MIG systems maintain constant wire tension between two sets of drive rolls: one set in the feeder and one set in the gun. As a result, they solve common feeding problems, such as wire slippage, erratic arc performance, wire burning back to the contact tip, cold lap and bird nesting at the feeder rolls. ESAB’s new aluminum welding system will be available through standard distribution and online sales channels later this year. An air-cooled gun option will be available in early 2026.
Advanced and Operator-Friendly
The Warrior Edge power source with RobustFeed Edge feeder allows ordinary welders to benefit from sophisticated WeldModes, which eliminate the need for continuous training and over reliance on individual operator skill. When using a synergic WeldMode, operators can fine-tune performance simply by adjusting the wire feed speed and trim control knobs and the system will maintain optimized arc characteristics. An Arc Dynamics function, also controlled by a single knob, adjusts the arc for faster travel speed and adds stability control for specific travel speeds, better control of the weld pool, and enhanced bead geometry.
The RobustFeed Edge wire feeder includes ESAB’s TrueFlow digital gas control technology to automatically prevent insufficient gas flow and optimize flow during arc starts and welding, a common source of quality issues and gas waste. TrueFlow can save up to $650 to $1,300 per year, per machine in gas waste in typical use cases.
The Warrior Edge 500 DX has built-in connectivity and comes with a lifetime subscription to the InduSuite WeldCloud Fleet online software application.
About ESAB
ESAB is a world leader in fabrication technology. For more than 100 years ESAB has transformed industries built by fabricators, providing complete workflow solutions through our diverse portfolio of products from more than 40 of the most trusted brands in welding and cutting in the world. From industrial demands to repair and maintenance, innovators that shape the world rely on ESAB’s portfolio.
To learn more, visit ESAB.com.
