While there may be a difference in quality, you may be experiencing something else entirely. If you’ve developed a wire feed speed (WFS), voltage, and current for the wire you typically use, it’s unrealistic to think a different wire brand will run exactly like the old one using the same welding parameters. You’ll likely need to change one or more settings to make the new wire run at its best. Many wire manufacturing variables affect welding parameters: Wire Diameter. American Welding Society specification A5.10 requires wire diameter to be within 0.001 to 0.002 inch of nominal, but wire manufacturers control diameter to tighter tolerances. Also, each manufacturer aims for a slightly different diameter based on its specific manufacturing process. Even a diameter difference of 0.001 in. can require welding parameter adjustment between wire brands. Surface Quality. Wire surface smoothness affects how the wire conducts current from the contact tip. Surface Oxide. Aluminum oxide is an electrical insulator. The amount of aluminum oxide on the wire surface affects welding voltage. Wire Lubricant. Wire manufacturers either lubricate the wire surface or leave it bare. This affects how the wire conducts current from the contact tip. Wire Cast and Helix. Wires with different cast and/or helix make contact with the contact tip bore differently and require different welding parameters. Don’t assume that your new wire is of poor quality. Adjust your welding parameters so the wire performs at its best.