This was very helpful. I'm in a welding class in my highschool. Truth be told I'm not sure my instructor is very knowledgeable about spray transfer; it's evident after watching your video that what he considers a good spray weld has the voltage set too low. Thank you for helping me to better myself!
Excellent video. . . I have never welded using the spray transfer method but I do have MIG and SMAW experience. That being said I feel like I have a pretty good chance of passing my Spray Transfer test tomorrow based on what I learned in this video. Thank you
Brilliant video and explanation. I've been using spray transfer on 8mm plate, horizontal fillet and vertical down fillet with really good results . I like your video because of the possible problems and how to rectify them. Great job 👍
Great video! I watched this a few weeks ago, but had a lot of difficulty finding it again. The demonstration of settings and information is invaluable, perhaps you could add some tags or a more descriptive title (I was looking for information on how to use anti-spatter sprays, not knowing you could reduce spatter and cleanup with the correct "balancing act.") Thanks again for the great video and information.
Even that first weld was awful. The entire thing had undercut all along the top. Spray is so hot that you should never EVER use it on thin material like that. I use spray transfer at work every single day and they should never ever look that way. Spray should look very similar to pulse MIG in the flat position and have the distinct freeze rings you'd normally have. Not to mention your travel speed. See how fast you're having to go on that dinky little 1/8" material? Spray is not meant for metal that thin at all. If you really want cleaner welds with thinner metal, use 90/10 gas at like 22 volts or something. Your freeze rings are shaped like a bird's beak.
So do you have to push or can you pull the puddle with spray transfer and can there be oscillations or manipulations such as arcs or cursive e's or does it have to be a straight push or pull?
Nice presentation, very clear. I'm always looking for this kind of information: What am I supposed to SEE and HEAR when this is working right? What do I do when it's all wrong? It's pretty easy for something to get wildly out of adjustment! Today I'm trying to get a hint, see if I can do a little spray transfer with the modern toylike inverter MIG welder... and it looks like a solid "maybe", like if the machine is cranked way up, and there's a good solid work connection. I put the work clamp ON the work, I think the video hinted at that. Even if your cables are good, if you just clamp them on to a rusty painted table leg I think you're going to lose something, drop a few volts.... So, I'm thinking 180Amp Machine (Hyalong) might do it, with say .030" wire, 85-15 gas, and everything clean, machine "turned up to 11".... Swoosh! Maybe.
When it is all wrong, ( like with lots of spatter etc.) it usually needs a little more voltage or current. Some smaller machines do not have the output capability to achieve spray transfer, but if you want to try a different gas mixture 95% Argon/ 5% O2 operates in spray transfer at around 155-160amps and 23-24V with an 0.035" wire. I think 85/15 may have too much CO2 for the machine you indicated. Good Luck!
Very well done. Wondering what the flow rate or cfm for the gas should be to do this spray arc process. I'll be welding 1/8" metal with .035 wire and 92% & 8% gas. Thanks
I noticed you're using a 90%/10% CO2 when you're welding, however the chart in the beginning you showed had three different gases: 98%/2% oxygen, 95%/5% oxygen, and 92%/8% CO2; how much will the parameters differ from what you we're running at, say with 98% / 2% oxygen?
I purchased a powcon welder and the person I bought it fromwas using 75/25 with 0.035 wire. When I tested the machine it welded very hot and burnt throught 1/8" very fast set at approximately 30% on a 200 amp welder. The sound was different. I have since found that it was set for spray. This is the first I experienced spray transfer. Must move fast and it will lay down welds without ripples. All the research I have done says spray can not be accomplished with 75/25. What was happening if it wasn't spray? I have learned more on the settings and now use the setting for short circuit for most of my welding. Thanks.
You are correct technically it won't spray transfer with an 0.035" wire and 75/25. You were probably experiencing a controlled globular transfer. The way to tell is look at the size of the droplets as they are being transferred across the arc. In the conditions that you described the droplet is likely larger than the diameter o the wire. The AWS definition says something along the lines that spray transfer occurs when the droplet is equal to or less than the diameter of the wire. So when welding in spray transfer and you have reached the transition current the wire will start to become pointed and the droplets will be forced across the arc and not transferred by gravity. With all of that said, yes you can get a clean smooth weld with 75/25 in a "spray-like" transfer but it is typically too hot for most applications...and it isn't truly spray. That is how i understand it anyways.
@@nathanfarquharson9307 it took me a while but i managed to finally get a true spray on my machine a rebel 235 (EU version) on 0.8mm 0.030 wire on 26v and 12.8m wire feed.. its a fine balancing act as i found out lol but i have now to try get spray going correctly on 1.0mm/0.040 wire on 26v as that is my max.. gas played a huge part in my progress as i went from a 83 mix to 93 and that changed everything as far as spray stabilty goes
Hi im in the uk using C15 ( 85 /15 ) here's my problem ? we use 0.039mm wire ( 1mm ) so what would be the optimum parameters for welding using 27.5 V what would my wire speed be yours is 600 Ipm I need a Meters per minute approx Thank you for the Video
You don’t need meters per minute, not being a prick but you need to pay attention to the silica that is deposited on the bead surface…… the colour ranges from very light caramel to dark brown and all the way to black….. you don’t want black, you want to be getting a caramel colour, more towards the light end of the range, that goes for both dip transfer (shirt circuit) and spray transfer… the colour gives you your temperature. As for voltage, you can’t get spray below 25 volt’s so just crank your machine to 3/4 of its maximum wire feed speed then set the bolts to around 30 volts, from there you can fine tune depending on the results…. The tip of the wire should be pointed, and the arc will be conical with an arc length, measured from the tip of the wire to the weld pool, of about 5mm….If that gap is say 10mm then you either need to increase wire speed or decrease the volts….. I jump from dip to spray depending on which weld I’m doing and I think I spray at around 13-14 meters a minute, .09 dis wire, argoshield gas and the volts are about 30-31 and that’s just a light bead….. play with the settings and have fun, try setting your machine up for dip just by listening to the sound it makes, should sound like bacon frying….. I shouldn’t have smoked that joint earlier!!!🤣🤣🤣🤣
Nice video! I would like to see some videos on mig pulse like some of the newer everlast mig welders have. I'd love to use spray arc out of position or on thinner material. Would mig pulse help?
I love spray on a butt joint or a lap joint or an outside corner. But every time I try to weld a fillet it the horizontal position it undercuts the shit out of the top plate. The arc eats up the metal like 1/4 inch away from the toe of the weld. I may just be set too hot.
very informative video thank you very much I'm looking forward to start trying to do this stupid question but can you do multiple passes with spray transfer welding would temperature be an issue possible causes between passes I'm new to welding so simple questions from me
Yes James Johnson you can do multiple passes as well. I run 27 volts at 425 ipm. Which the company I work for doesn't want anything under 27 volts. But the answer is yes you can. Just make sure you run your bead at a good steady pace so you don't burn through or have any undercut on your previous welds.
I'm not sure why you're saying you need a minimum of 80% argon for spray tranfer, when the very chart you posted @ 1:25 shows the exact amount of argon mix needed. 98% is the minimum needed for true spray tranfer.
What you're talking about is still globular tranfer. For "true" spray transfer, a mixture of at least 98% argon is needed with 2% oxygen on mild steel. 99% argon and 1% oxygen for stainless steel. See "The Welding Handbook, 9th edition, Volume 2, Table 4.1. Globular to spray transfer currents", as per the American Welding Society.
Bulllshit....been there done that on a bet made in the shop yes you can !....but welding with 100% CO2 sucks. In any case you can spray transfer with any gas when you are running .045-.052 wire with a quality wire feed and Constant Voltage 400 amp or bigger machine running over 32 volts
@@Migman2020 I've run many rolls of wire in Spray-transfer....Miller-Matic 200...no actual voltmeter on that one, but 24-26+ volts and you need close to 175 amps with .035" solid wire...a little lower current with .030". I used 90% Argon, 8% C02, 2% Oxygen usually called "98-2" it is 90/8/2.......there is also 92/8 Argon-C02...and most every gas supplier has their own 'secret' mixes.. You will not get spray transfer with less than 80%+ argon...
Probably one of the best videos on spray transfer and how to manage it with machine settings.
This was very helpful. I'm in a welding class in my highschool. Truth be told I'm not sure my instructor is very knowledgeable about spray transfer; it's evident after watching your video that what he considers a good spray weld has the voltage set too low. Thank you for helping me to better myself!
Excellent video. . . I have never welded using the spray transfer method but I do have MIG and SMAW experience. That being said I feel like I have a pretty good chance of passing my Spray Transfer test tomorrow based on what I learned in this video. Thank you
Brilliant video and explanation. I've been using spray transfer on 8mm plate, horizontal fillet and vertical down fillet with really good results . I like your video because of the possible problems and how to rectify them. Great job 👍
Great video! I watched this a few weeks ago, but had a lot of difficulty finding it again. The demonstration of settings and information is invaluable, perhaps you could add some tags or a more descriptive title (I was looking for information on how to use anti-spatter sprays, not knowing you could reduce spatter and cleanup with the correct "balancing act.") Thanks again for the great video and information.
Even that first weld was awful. The entire thing had undercut all along the top. Spray is so hot that you should never EVER use it on thin material like that. I use spray transfer at work every single day and they should never ever look that way. Spray should look very similar to pulse MIG in the flat position and have the distinct freeze rings you'd normally have. Not to mention your travel speed. See how fast you're having to go on that dinky little 1/8" material? Spray is not meant for metal that thin at all. If you really want cleaner welds with thinner metal, use 90/10 gas at like 22 volts or something. Your freeze rings are shaped like a bird's beak.
Really great info, thank you my friend:)
Thank you, bery informative.
I believe you can obtain spray transfer mode when mig welding aluminum at a much lower voltage?
Excellent lesson Nathan, many thanks!
This video is fantastic.
9:00. You're molesting the duty cycle.
1130. Lower the gas about 3-5 .
Keep it up. This is real ! Thanks
So do you have to push or can you pull the puddle with spray transfer and can there be oscillations or manipulations such as arcs or cursive e's or does it have to be a straight push or pull?
Nice presentation, very clear. I'm always looking for this kind of information: What am I supposed to SEE and HEAR when this is working right? What do I do when it's all wrong? It's pretty easy for something to get wildly out of adjustment! Today I'm trying to get a hint, see if I can do a little spray transfer with the modern toylike inverter MIG welder... and it looks like a solid "maybe", like if the machine is cranked way up, and there's a good solid work connection. I put the work clamp ON the work, I think the video hinted at that. Even if your cables are good, if you just clamp them on to a rusty painted table leg I think you're going to lose something, drop a few volts.... So, I'm thinking 180Amp Machine (Hyalong) might do it, with say .030" wire, 85-15 gas, and everything clean, machine "turned up to 11".... Swoosh! Maybe.
When it is all wrong, ( like with lots of spatter etc.) it usually needs a little more voltage or current. Some smaller machines do not have the output capability to achieve spray transfer, but if you want to try a different gas mixture 95% Argon/ 5% O2 operates in spray transfer at around 155-160amps and 23-24V with an 0.035" wire. I think 85/15 may have too much CO2 for the machine you indicated. Good Luck!
@@nathanfarquharson9307 very valuable information! *high fives* 😊👍🏾
Very well done. Wondering what the flow rate or cfm for the gas should be to do this spray arc process. I'll be welding 1/8" metal with .035 wire and 92% & 8% gas. Thanks
Great video. Very informative. Thanks you.
Excellent explanation of the things to look for.
is there a general formula to compute amperage for a given voltage & wire feed speed?
I noticed you're using a 90%/10% CO2 when you're welding, however the chart in the beginning you showed had three different gases: 98%/2% oxygen, 95%/5% oxygen, and 92%/8% CO2; how much will the parameters differ from what you we're running at, say with 98% / 2% oxygen?
I purchased a powcon welder and the person I bought it fromwas using 75/25 with 0.035 wire. When I tested the machine it welded very hot and burnt throught 1/8" very fast set at approximately 30% on a 200 amp welder. The sound was different. I have since found that it was set for spray. This is the first I experienced spray transfer. Must move fast and it will lay down welds without ripples. All the research I have done says spray can not be accomplished with 75/25. What was happening if it wasn't spray? I have learned more on the settings and now use the setting for short circuit for most of my welding. Thanks.
You are correct technically it won't spray transfer with an 0.035" wire and 75/25. You were probably experiencing a controlled globular transfer. The way to tell is look at the size of the droplets as they are being transferred across the arc. In the conditions that you described the droplet is likely larger than the diameter o the wire. The AWS definition says something along the lines that spray transfer occurs when the droplet is equal to or less than the diameter of the wire. So when welding in spray transfer and you have reached the transition current the wire will start to become pointed and the droplets will be forced across the arc and not transferred by gravity. With all of that said, yes you can get a clean smooth weld with 75/25 in a "spray-like" transfer but it is typically too hot for most applications...and it isn't truly spray. That is how i understand it anyways.
@@nathanfarquharson9307 it took me a while but i managed to finally get a true spray on my machine a rebel 235 (EU version) on 0.8mm 0.030 wire on 26v and 12.8m wire feed.. its a fine balancing act as i found out lol but i have now to try get spray going correctly on 1.0mm/0.040 wire on 26v as that is my max.. gas played a huge part in my progress as i went from a 83 mix to 93 and that changed everything as far as spray stabilty goes
Hi im in the uk using C15 ( 85 /15 ) here's my problem ? we use 0.039mm wire ( 1mm ) so what would be the optimum parameters for welding using 27.5 V what would my wire speed be yours is 600 Ipm I need a Meters per minute approx
Thank you for the Video
You don’t need meters per minute, not being a prick but you need to pay attention to the silica that is deposited on the bead surface…… the colour ranges from very light caramel to dark brown and all the way to black….. you don’t want black, you want to be getting a caramel colour, more towards the light end of the range, that goes for both dip transfer (shirt circuit) and spray transfer… the colour gives you your temperature. As for voltage, you can’t get spray below 25 volt’s so just crank your machine to 3/4 of its maximum wire feed speed then set the bolts to around 30 volts, from there you can fine tune depending on the results…. The tip of the wire should be pointed, and the arc will be conical with an arc length, measured from the tip of the wire to the weld pool, of about 5mm….If that gap is say 10mm then you either need to increase wire speed or decrease the volts….. I jump from dip to spray depending on which weld I’m doing and I think I spray at around 13-14 meters a minute, .09 dis wire, argoshield gas and the volts are about 30-31 and that’s just a light bead….. play with the settings and have fun, try setting your machine up for dip just by listening to the sound it makes, should sound like bacon frying….. I shouldn’t have smoked that joint earlier!!!🤣🤣🤣🤣
Well done and informative video! Thank you for taking the time to make this video...
Nice video! I would like to see some videos on mig pulse like some of the newer everlast mig welders have. I'd love to use spray arc out of position or on thinner material. Would mig pulse help?
I love spray on a butt joint or a lap joint or an outside corner. But every time I try to weld a fillet it the horizontal position it undercuts the shit out of the top plate. The arc eats up the metal like 1/4 inch away from the toe of the weld. I may just be set too hot.
Try a little back step with a slight pause after your forward movement. Also dont hold a 45° angle on the fillet. Relax to about 35°
very informative video thank you very much I'm looking forward to start trying to do this stupid question but can you do multiple passes with spray transfer welding would temperature be an issue possible causes between passes I'm new to welding so simple questions from me
Yes James Johnson you can do multiple passes as well. I run 27 volts at 425 ipm. Which the company I work for doesn't want anything under 27 volts. But the answer is yes you can. Just make sure you run your bead at a good steady pace so you don't burn through or have any undercut on your previous welds.
I'm not sure why you're saying you need a minimum of 80% argon for spray tranfer, when the very chart you posted @ 1:25 shows the exact amount of argon mix needed. 98% is the minimum needed for true spray tranfer.
Thank you for this video
When you were welding at 29.5 volts why didn't you turn up the wire speed
Pity It won’t allow me to upvote this video more than once
What you're talking about is still globular tranfer. For "true" spray transfer, a mixture of at least 98% argon is needed with 2% oxygen on mild steel. 99% argon and 1% oxygen for stainless steel.
See "The Welding Handbook, 9th edition, Volume 2, Table 4.1. Globular to spray transfer currents", as per the American Welding Society.
Great vidoe
Whats the right setting to weld a 3/4 plate to 3/8 one ?
Max power to start, set wire speed from there. Bless the work piece with the cutting torch before hand.
Sir i have a question.is it possible to make spray transfer on 💯 percent. Co2?
..No...you need at least 80% Argon....90% is better...
Bulllshit....been there done that on a bet made in the shop yes you can !....but welding with 100% CO2 sucks. In any case you can spray transfer with any gas when you are running .045-.052 wire with a quality wire feed and Constant Voltage 400 amp or bigger machine running over 32 volts
@@dougankrum3328 What if I use flux cored wire instead of solid wire?
Nope it won’t spray it will run super hot short circuit. The argon gives the arc the ability to maintain spray.
@@Migman2020 I've run many rolls of wire in Spray-transfer....Miller-Matic 200...no actual voltmeter on that one, but 24-26+ volts and you need close to 175 amps with .035" solid wire...a little lower current with .030". I used 90% Argon, 8% C02, 2% Oxygen usually called "98-2" it is 90/8/2.......there is also 92/8 Argon-C02...and most every gas supplier has their own 'secret' mixes..
You will not get spray transfer with less than 80%+ argon...
thank you very much.
I would not spray on 1/8 in material to much heat
He using 035
Dude...... read your charts before "giving a lesson".
Your own charts contradicted you, both charts!
operator error