Nice shot of the actual metal transfer. I was involved with the welding processes with Dept. of Defense welding tank truck bodies for the gulf Wars. Getting a true spray is dependent on the gas mix and the wire size and the welding current. Smaller wire sizes will achieve spray at lower weld currents, larger wire sizes at higher weld currents. So, to try for a true spray with a particular size wire, you would need to increase not decrease the weld current, higher amperage not lower, and at some point you would need to also adjust voltage. Usually around 12% Co2 is about the limit or the way you figured it, a mix with no less than 88% argon would be a safer bet. C25 as you say will not produce a true spray no matter how high the weld current although it can be adjusted to make a nice weld. We used 98% AR and 2% O2 for welding the stainless and 90% % AR 10% CO2 for welding carbon steel with a true spray.
This was quite fascinating! Apparently CO2 has more free electrons than Argon but with slightly less CO2 it’s a more stable seemingly more conductive plasma. I’m no physicist, but that is just awesome how the the higher argon mixture ionizes so smoothly. You guys are all great but we do miss Mr. Bob.
When you change to a shielding gas with higher CO2 content you need a higher voltage to keep the arc length unchanged, that is why the arc length is shorter for the same voltage used before. Also, the transtion from globular to spray happens when you reach what is called a transition current (which becomes higher when you add more CO2). Although I understand your intent to increase arc length by decreasing WFS, you are at the same time decreasing current, which goes opposite ways from your objective (to reach the transition current). Moreover, arc constriction associated with higher CO2 content results in what is called repelled transfer, that is why it becomes harder to achieve stable spray transfer with 25% CO2 and beyond. So I do not think it is possible to reach really good results but increasing voltage and WFS would be the way to get as close as possible (maybe decreasing CTWD too). The experts may correct me if I said something wrong. Best regards!
I agree with what your saying. I think the voltage needs to go up. But I don’t think it will get anywhere as good of a spray with higher argon. The arc is so much more stable as argon is increased. So with that I think the arc is still going to be very inconsistent with c25, and cannot maintain a true spray transfer.
Argon doesn't dissipate heat away from the arc as much as other gasses. Does the argon content change with different thicknesses of wires when attempting to spray arc?
@@el1herrero Different wire thickness will change the transition current to spray. Thinner wires can achieve spray with lower current. However, the problems related to higher CO2 contents in the shielding gas will still persist.
I think going down to 035 wire will help some too. Plus it will be easier on the machine due to lower current and voltage levels to achieve the same thing. .045 ultracore or .035 er70s6 on 90/10 or 75/25 is what I use at home. Never tried to spray on c25 but I’m going to try it now just cuz I’m curious. If i had a gas mixer or could get free gas I would test to see what is the minimal mix to achieve spray threw all the parameters. Then test that gas to see how it does on globular and short circuit. Also try it on fcaw. One gas does all would be great.
I'm able to do spray transfer with 75/25 using Lincoln electric 71M with 30volts and 250-275 IPM with a Lincoln invertech 450 set on inner shield with arc control maxed out at +10 coupled to a Lincoln LN25 suitcase on ar36 plate in the 3g position.
Put it back at 425 ipm and play with the voltage and gas flow. You might not be able to get 100% spray but i know you can get a lot closer with a little more effort and tuning.
The whole point of this was to bust the comments saying shit just like this. It's not a true spray with c25. It's not a test of how close you can get. This is either you can 100% or you can't and no, you can't get 100% spray with c25.
@@spencercampbell8396 well how do you know if you only play with 1 variable? If you are not willing to go all in with experimenting then why ever bother trying? Do you think someone came up with all the different ways to weld in 1 shot only changing 1 variable a couple times? Remember to get outside the box every now and then you might surprise yourself.
@@johnnymissfire8464 I know for a fact because I've been in the industry for over 15 years and have tried it myself. This isn't anything new and to keep hearing people try to do it over and over is exhausting.
Hi there buddy, I am a welder 40h a week and something called "Arc Blow" started to happen at my job. I tried to show it to my boss at work but, when he came around, everything went alright. I also tried to explain what was going on, and he told me, he never heard something like this. Basically I am welding with a MILLERMATIC 252 ( the most resembling if not it) with a 0.35 wire size diameter. The best way that I can explain it is, that I am going in a direction and the arc is going in the total opposite direction. Leaving me a ton of projections and a "not so good looking" weld. I couldn't find any video on the entire Internet that shows that, using the GMAW process. If you can make a video that shows clearly that "Arc Blow" during the welding process and some tips and tricks on how to fix it, it would be sooooooooooo much appreciated. -Marc
Machining grinding bending etc magnetizes it and static electricity inside it causes arc to wander around and spatter. There are also powerful crane magnets that cause that but don't worry too much about it
Tried to get spray with 25% co2, got pretty much the same results you did. It kinda wants too, but it's so inconsistent and will fight you if you change the angle or inclination just a tiny bit. Globs everywhere.
Very confused because I just did some "spray transfer" on 1/2 inch carbon steel with 75/25. 565 wfs 27 V. Worked great. Not a "true" spray transfer because it needs to be 80% Ar or higher but it definitely works.
It does but I wonder if the penetration is equal to a true spray transfer. Where I previously worked at we would weld with this process at 26-28 Volts and 550-675 IPM. It is a descent process but what I hate is the spatter cleanup afterwards. I call it the Glob-Spray transfer.
When I used spray transfer in my college welding course, we used 85% Argon 15% CO2 at 20-25 CFH. Works well for us. Settings are 28 volts and 405 inches a minute.
I've done it in school with a lincoln mp. had to go way above 27.5v... was at about 28.8 I believe maybe 375wfs not 100% sure. it's been a few years since I used a mig gun.
You need at least 85%argon to achieve spray transfer. Those who say just turn up your welder are wrong if you are following a wps you would know that you would be running out of parameters. 75/25 will not complete the spray transfer there is just not enough argon. Follow the wps always.
Used to use spray transfer all the time at a previous job welding structural steelwork, running 1mm solid wire with 80/20 mix. Would run at 29v and a wire feed speed high enough to give 220-230amps
I have done it - just play with the dials until it gets there and dont limit yourself with specs that immediately make it impossible. Kinda hard to say you gave it your best shot while also putting limits on your efforts
If you're not running to manufacturer's specs you can't garauntee a good weld/penetration/HAZ on a wide range of materials. If you're dinking around at home? Sure, but not in a shop where time is more valuable than Argon if you need spray.
Up your voltage to 29v for 1mm (0.040") wire, and adjust the inductance properly. Spray transfer is easily do-able with 80/20 mix, providing you use high enough voltage for the wire you're using
In my workplace we spray with 75 25 and 1,2 wire. Just crank the volts up to something like 35 :D. It might not be the correct code quality way to do it, but we repair old buckets and whatnot so its more cost effective and you can up ur travel speed aswell.
Not a lot of lower end mig welders will do the higher voltage necessary to get into spray with c25 gas and 0.35 wire. I think 0.30 wire would have been a better test, however if he’s not willing to over volt it wouldn’t have mattered.
I agree, I know the "recommended V setting is 27.5, but I think over-volting slightly, say 8% to compensate for the 8% reduction of Argon might do the trick. Personally, I use 75/25 and spray all the time, HOWEVER, I use a Hobart 210MVP.. I don't have the luxury of a readout showing WFS and Voltage.. So, I tend to run a higher Voltage and "tune" the WFS as I go to get that nice FAST crispy "hiss"..
How about using a welding gas Y-valve (such as the one's used to mix argon and helium) but used with an argon bottle and a 75-25 bottle? Could that be made to work and properly spray? If that works and you already had an Ar bottle for the tig welder then you can save some $$ and not have to buy another dedicated bottle for spraying
@@CLOClayton The problem is paying for extra bottles, you want at least one spare and at $350.00 a bottle that's an extra $700.00 without the gas, with the gas you can add another $200.00 for both bottles bringing it to $900.00.
My Forney 270 will do it on 75/25... I just don't think these Chinese Inverter welders have the true grit to do it without the gas helping. Not bashing, just giving my 2 cents...Because I do have an Everlast of my own, a 312 and when you start welding for minutes and minutes straight on 3/8 or bigger it just won't hold up the weld quality like a Lincoln 260 or a Forney 270, I think they are stretching their duty cycle claims.... I should say I had an Everlast 312, I sold it...just not an inverter fan for when you are primarily working on 40 ton plus heavy equipment like I do.
I used to get spray transfer with 1.2mm A18 wire running at 31 volts and 325 amps using a Danish built Migatronic welder and 80/20 ArCo2 gas. Must say though I prefered 95/5 for every thing as it was so much smoother in all types of transfer with absolutely no spatter even on relatively dirty uncleaned work.
It would be interesting to see what happens if you substituted the Argon for Helium at the same ratio. I am curious as I am led to understand that Helium is in welding a hotter gas for want of a better term. John, Australia.
Helium inside the super heated plasma field actually burns and creates more heat, so yes you do get a hotter weld from mixing percentages of helium in there. It's used sometimes on tig machines where the amperage limit of the machine is technically lower than the threshold for the weld being attempted. In WWII it was plentiful and cheap, so they used it a lot to DC weld metals today we consider to not be doable any other way than AC weld functionality. The first shielding gases used was Co2 and Helium.
@@Enonymouse_ thank you for your reply. That pardon the pun fills in more of the gaps for me. I have heard of DC welding using the TIG process on Ally and now makes sense as their would be enough heat to dispose of the oxides that are now solved by using AC Tig and other Gases. John, Australia.
I believe I can get spray transfer on my Razorweld 250k. No popping, just a smooth hiss and the wire disappears and turns into a cone-shaped arc. 0.035 wire, 29 volts, around 600ipm. Current readout says anywhere from 265 with a longer arc to 305 with a shorter arc. The gun just gets absolutely cooked though. There is a LOT of heat involved!
I weld farm machinery with 75 arg 10 oxygen 15 CO2. Today I had 27.3v 7.5ws on a 420 kempi and I had spray running fairly well. I'm Australian so the wirespeed is in metres.
2 things.... I've 100% spray transferred with c25 and .035" wire on a lincoln cv300 or 400 power source with a wire feeder, up around 29-30v, so it def is possible ...also, we have a lightning mts 275 at the shop I work at, and personally I think the mig side of it is garbage....no one in the shop can get it to weld nice on mig....lincoln powermig 210mp sitting right next to it, same gas, same wire, runs beautiful....the lincoln has a wide range of settings where it will run nice...the everlast if you're the slightest bit off one direction or the other, forget it, it won't even run....try your spray test again with a beast machine and wire feeder and see how it goes....
If you want spray out of that mix you need like 30 v and 500 ipm. You constrained your self too much with "manufacture recommendations" you wont get a perfect spray but it will be closer then what you got by turning down the wfs
You keep dropping the wire speed, you have to raise the voltage the biggest problem you have is that 75/25 does that maintain a good plasma column to help control the arc.
So can you short circuit weld with the higher concentration of argon such as 92% argon 8% co2 if so what would be the difference between that and a 75% argon 25% co2 mix? Could you use 100% argon to spray transfer?
You can definitely short circuit with a high argon mix, you just need to drop your voltage quite a bit. The difference between a 98-96%Ar + 2-4% CO2 and 75/25 is the argon content. In order to achieve ionization (spray) of the wire you NEED high amounts of argon so the gas reaches a high enough temp and turns into plasma which gives you that liquid needle at the end of your wire in spray arc. 100% Argon is only used for mig welding aluminum and tig welding. With steel wire you need CO2 to give you good penetration into the base metal.
@@MasterCheeef Tried mig with argon when I first got my welder. It..... stuck metal together. It was lumpy and I wouldn't trust it to hold up a vehicle, but if your welds aren't structurally critical and nobody's gonna look at em, it'll do in a pinch. Definitely better options if you can run down to the hardware store though.
@@MasterCheeef you're missing something called the sarcastic wanking motion I'm making right now. It's oh so much more interesting than your weird foibles about people who have idle hobbies getting things done and letting things that don't matter be good enough. Relax, homie. No need to be so emotional about it.
Typically you just turn the heat up instead of turning the wire down. You'd have better results that way from personal experience. Not necessarily perfect spray arc but will 90% I feel.
@Andrew Crews AkTuAlLy ThErE iS nO hEaT kNoB No shit but you can adjust the voltage and if your machine isn't a nugget you can adjust the amperage a little bit independent of the wire feed speed. Therein adjusting the hear.
I was using a esab caddy mig. They don't have a fluxcore nozzle and don't run right if you use anything other then .030 mig wire. I was using the er70 solid mig .030. It was dead of winter and I was welding step treads to the junior channel outside in shade in the freezing cold snow, ground was frozen. I cranked the volts way up and as I was welding the arc noise changed to a gentle hiss and there was no more spatter. The weld joint got hot and I had to stop. I guess this was "close" to a spray mig transfer. Almost to hot to control on the 1/8" step tread
I recently used an in-good-condition big solid copper-and-iron (?) Esab machine with enough "oomph" to chase spray conditions with with Ar-20%CO2-2%O2. It would never cleanly spray. By 400A, was on 39.something V - essentially 40V - trying to get clean transfer. Called a stop when saw a penetration bead through an 8mm (5/16") steel tube on a 25mm thick (1") plate and there was too much heat about, causing distortion. Any less V and it's spitting globules. So got a chance to see, and the answer is still "no". I think in true spray you break into spray at about 28V and you don't need rising voltage with rising Amps?? The context is the UK, where there is an immutable orthodoxy of using 20%CO2 gas for "plate" welding. Where an objective test with gases "coming through pipes through a wall" (there is no information provided about which gas is which) would have you saying much more argon-rich / less CO2 is the better choice and spray.
I think if you bumped the V up to 28 to 28.6 and WF down to around 360-80 would get it. I was spraying with 85/15 .045 and it ran great at 28 or 28.6v WF 320,it's been 13yrs ago so my memory isn't as good as it used to be.
Wondering if people use spray transfer for CWB GMAW Flat testing? I gather the gas is selected by the testing agency and that it is the 75% Argon 25% Co2 by default? Which brings me to believe that one does not use spray for testing? PS it looks like as you say, 5% more Argon and the spray could be there.
Hello friend, thank you for showing me the information I was looking for. I have a question. If the co² ratio is slightly lowered, will the spray voltage be lowered? For example, argon95%: co²5%. Because I want the spray in a thinner product. I can tell you this too
@@jaysmith4293 sometimes when I first tried it I would. Like anything it takes some practice and you have to know your settings. The only time I do it is if I already have my machine set up for tig,and I need to mig something really quick. But if you have a lower voltage machine like one of these 140 amp millers,you can use 100% argon to get more penetration on materials you otherwise wouldn't be able to weld.
@@phillhuddleston9445 co2 makes the weld hotter and Pentatrate better depending on the weld and process and material. Also expense of production of the gas
I use to have a old miller 200 with 2 crank adjusters 1 was slope and the other volts not sure what the settings were but you could adjust slope it sprayed like paint
Interesting video. Question why do you decrease the wire feed speed rather than 😮increasing it. Can you use 100% argon for spray transfer when welding steel?
So here's the issue, I'm a hydraulic rod welder. Using .045 wire 90/10 gas Lincoln 100 wire.i get pin holes I've tried spray I've even short arched.rod diameter is 3.5 inches induction hardened.i pre heat to 375 before weld and peen after every pass.
Hey guys. Awesome video as always. Question/Request. I work in automotive collision repair. On many aluminum repairs, the manufacturer calls for pulsed spray welding. What does that look like? We are usually welding fairly thin metal (no more than 2.5mm thick) and I feel like to get into spray you would burn right through that. Primarily 5000 series aluminum, .045 wire out of a push pull machine.
Its a little late i know lol. It can be done though. Set your pulse (trim/arc length/ whatever your machine calls it) lower than the average or default settings. .1 -.5 should do the trick. Than you must keep at least a 5/8 to 3/4 stick out and travel speeds have to be a little faster than you would normal short arc. The wire feed is set to a point where your getting the optimal amperage for the material your welding. Some thinner gauge you probably dont want to be anymore than 150-200 amps depending on how fast your welding
Can definitely be done, I just did it. Increase the voltage. Just because the dumb ass spec sheet states an arbitrary number, doesn't mean you need to stick to it. There are tolerances.
Wondering if multiple passes on same test pice had any effect. Or maybe the co2 was cooling and if you were lower out side specs of wire you could get a smooth spray.
Throw the inductance I know is the length of time the short is sustaining creating more of a soft puddle.. Without the short? I wonder what it would Have done during this experiment
I had one guy mention that they can get into spray on straight co2 at the very high amp spectrum.. like 400a+ is this true? i would love to see you guys test that theory but do you have a machine capable of doing that kind of amperage?
Just my 2 cents. Ran 75/25 at 27.5 and 400 for years on xray box headers fir years. Hot pass and fill on end blocks and pipe to header welds. Never had a bad shot but........i used those settings and gas with 045 wire. Could that be the difference?
Correct me if I am wrong, but does globular transfer merely exist as an observation of the arc's behavior? I ask this because I can't think of a single application where globular transfer would be permissible.
Is the function of the argon to decrease the density of the gas, compared to CO2? In that case, it might work in high places such as la Paz or Denver, but not at lower altitudes.
If i remember correctly the argon is a heavier shielding gas to help keep the pool and bead cleaner by removing as much of the ambient atmosphere as possible
I worked in a shop where we short circuited with 98/2 and am in a shop now where we short circuit with 90/10 so I imagine 92/8 would still short circuit.
lol, i have an inverter stick welder that runs on 250 volt. I have it wired up to an old flux core unit that had an old power hungry transformer. because of it running 035 FCAW... when its plugged into 120 feet of 12 gauge extension cord and pushing 140-165 amps with a 70 volt hot start and a listed voltage of 24-36 volts, that 035 FCAW... burns holes in 1/8 sheet just a second or two, melts leather gloves. can feed it 240-300 IPM that's as fast as the motor can push it out... spray arc with no gas just flux core, it works... tho the amount of heat that is made from the power needed for a 5mm rod arcing thru a 1mm spot does something to the air, cant explain what its like to hmm yes i can, the mig gun feels like a rattling lawn mower handle.
Hi, I am not sure what gas I have been using at school. However, the sound and globular evidence that you used 27.5 v and turning down wfs not the opposite way which means I kept my around 480 wfs and turn up voltages to 29 v and it gave me hum sound and no spatters. Would it be called spray transfer?
if only there was a good and reasonably price gas mixing setup. already have 75/25 for mig and 100% AR for tig, switch out the 75/25 for 100 CO2 and a gas mixing setup and save from getting a 3rd tank.
Or run 90-10 mix can Short circuit weld and pulse or spray transfer as well. Or agree on run dual shield flux with c25 and call it a day on the heavy stuff.
Nice video but short answer is NO. Guys will say "up the voltage" or "slow the wire a bit more". But WTF is that getting you? Whole purpose of spray arc is high deposition rates and decent penetration on thicker steel members. You dropped almost 80 ipm and couldn't do it. So what's the use? No possible upside to this endeavour. Your producing a slower weld with unknown properties. Good experiment and proof positive that c25 isn't a hot enough gas. You really wanna have some spray arc fun? Switch to trimix fas
I am wondering why we spray transfer anyway , why not just use a dual shield wire with 75/25 , please correct me if I am wrong but I beleive you can get better penitration with dual shield than you can with spray transfer andyou can weld in any position,and you don't have to buy a more expensive gas and have more bottles of gas to maintain. I just use the Esab 7100 Ultra dual shield anytime I have to work on thicker material.I am sure Select Arc and Bohler have similar wires. So why spray transfer?
im curious, i just had a welding interview that had me do a welding test for their structural welder position. however they definitely had me run c25 gas and i could not for the life of me figure out what the deal was, it spattered a lot for it being a "spray" transfer. they are supposed to be doing my bend test over this weekend, however should i be concerned for the results due to the gas type? this would have been on 3/8ths carbon steel in the 1g position with a backing strip. like a 45 degree bevel i believe i was told, and a 1/8 gap. machine was pre set at 27.5 with a wire speed of about 440. i believe it was .045 wire as well.
That wasn't spray transfer. The only thing I would suggest would be to increase voltage. My guess is that to really get a spray transfer with 75/25 would involve much more voltage...possibly more than what the machine can supply.
Nice shot of the actual metal transfer. I was involved with the welding processes with Dept. of Defense welding tank truck bodies for the gulf Wars. Getting a true spray is dependent on the gas mix and the wire size and the welding current. Smaller wire sizes will achieve spray at lower weld currents, larger wire sizes at higher weld currents. So, to try for a true spray with a particular size wire, you would need to increase not decrease the weld current, higher amperage not lower, and at some point you would need to also adjust voltage. Usually around 12% Co2 is about the limit or the way you figured it, a mix with no less than 88% argon would be a safer bet. C25 as you say will not produce a true spray no matter how high the weld current although it can be adjusted to make a nice weld. We used 98% AR and 2% O2 for welding the stainless and 90% % AR 10% CO2 for welding carbon steel with a true spray.
This was quite fascinating! Apparently CO2 has more free electrons than Argon but with slightly less CO2 it’s a more stable seemingly more conductive plasma. I’m no physicist, but that is just awesome how the the higher argon mixture ionizes so smoothly. You guys are all great but we do miss Mr. Bob.
You forgot to pray before spray. That's main issue
🤣
What a load of c rap
When you change to a shielding gas with higher CO2 content you need a higher voltage to keep the arc length unchanged, that is why the arc length is shorter for the same voltage used before. Also, the transtion from globular to spray happens when you reach what is called a transition current (which becomes higher when you add more CO2).
Although I understand your intent to increase arc length by decreasing WFS, you are at the same time decreasing current, which goes opposite ways from your objective (to reach the transition current). Moreover, arc constriction associated with higher CO2 content results in what is called repelled transfer, that is why it becomes harder to achieve stable spray transfer with 25% CO2 and beyond. So I do not think it is possible to reach really good results but increasing voltage and WFS would be the way to get as close as possible (maybe decreasing CTWD too).
The experts may correct me if I said something wrong. Best regards!
I agree with what your saying. I think the voltage needs to go up. But I don’t think it will get anywhere as good of a spray with higher argon. The arc is so much more stable as argon is increased. So with that I think the arc is still going to be very inconsistent with c25, and cannot maintain a true spray transfer.
Argon doesn't dissipate heat away from the arc as much as other gasses. Does the argon content change with different thicknesses of wires when attempting to spray arc?
@@erikcourtney1834 Sure, I also agree with you. At the end of the day is not an ideal composition for spray, even with "proper" parameters
@@el1herrero Different wire thickness will change the transition current to spray. Thinner wires can achieve spray with lower current. However, the problems related to higher CO2 contents in the shielding gas will still persist.
I think going down to 035 wire will help some too. Plus it will be easier on the machine due to lower current and voltage levels to achieve the same thing. .045 ultracore or .035 er70s6 on 90/10 or 75/25 is what I use at home. Never tried to spray on c25 but I’m going to try it now just cuz I’m curious. If i had a gas mixer or could get free gas I would test to see what is the minimal mix to achieve spray threw all the parameters. Then test that gas to see how it does on globular and short circuit. Also try it on fcaw. One gas does all would be great.
I would like to see some bend testing on some coupons with those settings
Excellent video and “welder splaining” free. Great content, guys.
Good video Jason! I remember being thrilled to get to use 75% 25% instead of straight CO2. 😊
I'm able to do spray transfer with 75/25 using Lincoln electric 71M with 30volts and 250-275 IPM with a Lincoln invertech 450 set on inner shield with arc control maxed out at +10 coupled to a Lincoln LN25 suitcase on ar36 plate in the 3g position.
Put it back at 425 ipm and play with the voltage and gas flow. You might not be able to get 100% spray but i know you can get a lot closer with a little more effort and tuning.
The whole point of this was to bust the comments saying shit just like this. It's not a true spray with c25. It's not a test of how close you can get. This is either you can 100% or you can't and no, you can't get 100% spray with c25.
@@spencercampbell8396 well how do you know if you only play with 1 variable? If you are not willing to go all in with experimenting then why ever bother trying? Do you think someone came up with all the different ways to weld in 1 shot only changing 1 variable a couple times? Remember to get outside the box every now and then you might surprise yourself.
@@johnnymissfire8464 I know for a fact because I've been in the industry for over 15 years and have tried it myself. This isn't anything new and to keep hearing people try to do it over and over is exhausting.
@@johnnymissfire8464 try welding with high explosives .. no gas or electricity variables there.. just ferrules and a rake for laminating sheet..
@@philanderingwhitecollartra8281 ok send me some and i will git right on it👍
Hi there buddy, I am a welder 40h a week and something called "Arc Blow" started to happen at my job.
I tried to show it to my boss at work but, when he came around, everything went alright.
I also tried to explain what was going on, and he told me, he never heard something like this.
Basically I am welding with a MILLERMATIC 252 ( the most resembling if not it) with a 0.35 wire size diameter.
The best way that I can explain it is, that I am going in a direction and the arc is going in the total opposite direction. Leaving me a ton of projections and a "not so good looking" weld.
I couldn't find any video on the entire Internet that shows that, using the GMAW process.
If you can make a video that shows clearly that "Arc Blow" during the welding process and some tips and tricks on how to fix it, it would be sooooooooooo much appreciated.
-Marc
Machining grinding bending etc magnetizes it and static electricity inside it causes arc to wander around and spatter. There are also powerful crane magnets that cause that but don't worry too much about it
Tried to get spray with 25% co2, got pretty much the same results you did. It kinda wants too, but it's so inconsistent and will fight you if you change the angle or inclination just a tiny bit. Globs everywhere.
Going to try this on a multimatic 255 soon. I suspect I may have to go with a 90/10 mix.
As close as one can get with out doing it. Great demo, thank you.
Around here we use 80/20 for short circuit and spray. Works fine.
Same
Very confused because I just did some "spray transfer" on 1/2 inch carbon steel with 75/25. 565 wfs 27 V. Worked great. Not a "true" spray transfer because it needs to be 80% Ar or higher but it definitely works.
It does but I wonder if the penetration is equal to a true spray transfer. Where I previously worked at we would weld with this process at 26-28 Volts and 550-675 IPM. It is a descent process but what I hate is the spatter cleanup afterwards. I call it the Glob-Spray transfer.
Dropplets > the diameter of the wire is not spray transfer. Very nice video! Im saving this for future instruction for sure.
That’s crazy for me to see that just gas can effect the weld that much I’m still rather new at welding and learning
When I used spray transfer in my college welding course, we used 85% Argon 15% CO2 at 20-25 CFH. Works well for us. Settings are 28 volts and 405 inches a minute.
I've done it in school with a lincoln mp. had to go way above 27.5v... was at about 28.8 I believe maybe 375wfs not 100% sure. it's been a few years since I used a mig gun.
That’s all I use at my job I have it at 28 volts and max out the wire feed which is like 7 or 8 hundred inch a min
@@SulfuricDrop3 jesus dude what size wire do you use for that? and are you using 75/25?
@@gamerboi111 it’s 35 and idk what the gas is cause they don’t have bottles it’s all piped in
Use 0.45 wire. 34v and 400 ws and 75/ 25 gas
That will get it
yup i run almost exactly that, works lovely. (36v, wire speed absolute max, dont know the number for it lol)
You need at least 85%argon to achieve spray transfer. Those who say just turn up your welder are wrong if you are following a wps you would know that you would be running out of parameters. 75/25 will not complete the spray transfer there is just not enough argon. Follow the wps always.
Agreed 100%. but some just won’t get it.
Sacraficing a quality weld with 75/25 i use 90-10
Used to use spray transfer all the time at a previous job welding structural steelwork, running 1mm solid wire with 80/20 mix.
Would run at 29v and a wire feed speed high enough to give 220-230amps
Hi, I'm new in mig mag welding.
So, you say we can spray with 82 argon and 18 co2?
@@benicurea5205if youre machine can put out a high enough arc voltage, yes.
Spray with bug spray too
I have done it - just play with the dials until it gets there and dont limit yourself with specs that immediately make it impossible. Kinda hard to say you gave it your best shot while also putting limits on your efforts
If you're not running to manufacturer's specs you can't garauntee a good weld/penetration/HAZ on a wide range of materials.
If you're dinking around at home? Sure, but not in a shop where time is more valuable than Argon if you need spray.
@@Taskarnin - but that was not the criteria was it? The question at hand was COULD it be done. Not was it proper or wise.
Up your voltage to 29v for 1mm (0.040") wire, and adjust the inductance properly. Spray transfer is easily do-able with 80/20 mix, providing you use high enough voltage for the wire you're using
what inductance would you suggest then if your trying to help the transition to spray? 0 percent?
In my workplace we spray with 75 25 and 1,2 wire. Just crank the volts up to something like 35 :D. It might not be the correct code quality way to do it, but we repair old buckets and whatnot so its more cost effective and you can up ur travel speed aswell.
Not a lot of lower end mig welders will do the higher voltage necessary to get into spray with c25 gas and 0.35 wire.
I think 0.30 wire would have been a better test, however if he’s not willing to over volt it wouldn’t have mattered.
I agree, I know the "recommended V setting is 27.5, but I think over-volting slightly, say 8% to compensate for the 8% reduction of Argon might do the trick. Personally, I use 75/25 and spray all the time, HOWEVER, I use a Hobart 210MVP.. I don't have the luxury of a readout showing WFS and Voltage.. So, I tend to run a higher Voltage and "tune" the WFS as I go to get that nice FAST crispy "hiss"..
Did you try adjusting your inductance?
How about using a welding gas Y-valve (such as the one's used to mix argon and helium) but used with an argon bottle and a 75-25 bottle? Could that be made to work and properly spray?
If that works and you already had an Ar bottle for the tig welder then you can save some $$ and not have to buy another dedicated bottle for spraying
Put two bottles on your welder with valves like oxy/acet
@@CLOClayton The problem is paying for extra bottles, you want at least one spare and at $350.00 a bottle that's an extra $700.00 without the gas, with the gas you can add another $200.00 for both bottles bringing it to $900.00.
No, you need a proportional gas mixer.
My Forney 270 will do it on 75/25... I just don't think these Chinese Inverter welders have the true grit to do it without the gas helping. Not bashing, just giving my 2 cents...Because I do have an Everlast of my own, a 312 and when you start welding for minutes and minutes straight on 3/8 or bigger it just won't hold up the weld quality like a Lincoln 260 or a Forney 270, I think they are stretching their duty cycle claims.... I should say I had an Everlast 312, I sold it...just not an inverter fan for when you are primarily working on 40 ton plus heavy equipment like I do.
What welder you recommend?
Think the voltage need to be increased a bit to get a better spray
One of THE most awesomest, descriptive weld videos I've seen! Don't know how you captured it, but, awesome....thanks!
I used to get spray transfer with 1.2mm A18 wire running at 31 volts and 325 amps using a Danish built Migatronic welder and 80/20 ArCo2 gas. Must say though I prefered 95/5 for every thing as it was so much smoother in all types of transfer with absolutely no spatter even on relatively dirty uncleaned work.
It would be interesting to see what happens if you substituted the Argon for Helium at the same ratio. I am curious as I am led to understand that Helium is in welding a hotter gas for want of a better term.
John, Australia.
Helium inside the super heated plasma field actually burns and creates more heat, so yes you do get a hotter weld from mixing percentages of helium in there.
It's used sometimes on tig machines where the amperage limit of the machine is technically lower than the threshold for the weld being attempted.
In WWII it was plentiful and cheap, so they used it a lot to DC weld metals today we consider to not be doable any other way than AC weld functionality. The first shielding gases used was Co2 and Helium.
@@Enonymouse_ thank you for your reply.
That pardon the pun fills in more of the gaps for me. I have heard of DC welding using the TIG process on Ally and now makes sense as their would be enough heat to dispose of the oxides that are now solved by using AC Tig and other Gases.
John, Australia.
@@joandar1 Greetings from California!
I believe I can get spray transfer on my Razorweld 250k. No popping, just a smooth hiss and the wire disappears and turns into a cone-shaped arc. 0.035 wire, 29 volts, around 600ipm. Current readout says anywhere from 265 with a longer arc to 305 with a shorter arc. The gun just gets absolutely cooked though. There is a LOT of heat involved!
I weld farm machinery with 75 arg 10 oxygen 15 CO2. Today I had 27.3v 7.5ws on a 420 kempi and I had spray running fairly well. I'm Australian so the wirespeed is in metres.
1.2m wire.
You can spray with C25, but you need alot more wire and volts to do it. 900-1000 IPM and 35-37 volts just about does it.
2 things.... I've 100% spray transferred with c25 and .035" wire on a lincoln cv300 or 400 power source with a wire feeder, up around 29-30v, so it def is possible ...also, we have a lightning mts 275 at the shop I work at, and personally I think the mig side of it is garbage....no one in the shop can get it to weld nice on mig....lincoln powermig 210mp sitting right next to it, same gas, same wire, runs beautiful....the lincoln has a wide range of settings where it will run nice...the everlast if you're the slightest bit off one direction or the other, forget it, it won't even run....try your spray test again with a beast machine and wire feeder and see how it goes....
Really cool process!!!
Yes you right it is cool!
Awesome video footage and thanks for clearing up why I couldn't git the spray action I was used to with 90/10
When i was taking my courses I had to do a 2foot spray transfer weld, This stuff gets HOT, be ready to deal with tons of heat for a long time.
That'll separate the men from the boys....can't cheat and hold the gun by the neck anymore!
If you want spray out of that mix you need like 30 v and 500 ipm. You constrained your self too much with "manufacture recommendations" you wont get a perfect spray but it will be closer then what you got by turning down the wfs
You keep dropping the wire speed, you have to raise the voltage the biggest problem you have is that 75/25 does that maintain a good plasma column to help control the arc.
So can you short circuit weld with the higher concentration of argon such as 92% argon 8% co2 if so what would be the difference between that and a 75% argon 25% co2 mix? Could you use 100% argon to spray transfer?
You can definitely short circuit with a high argon mix, you just need to drop your voltage quite a bit. The difference between a 98-96%Ar + 2-4% CO2 and 75/25 is the argon content. In order to achieve ionization (spray) of the wire you NEED high amounts of argon so the gas reaches a high enough temp and turns into plasma which gives you that liquid needle at the end of your wire in spray arc. 100% Argon is only used for mig welding aluminum and tig welding. With steel wire you need CO2 to give you good penetration into the base metal.
@@MasterCheeef Tried mig with argon when I first got my welder. It..... stuck metal together. It was lumpy and I wouldn't trust it to hold up a vehicle, but if your welds aren't structurally critical and nobody's gonna look at em, it'll do in a pinch. Definitely better options if you can run down to the hardware store though.
@@LifeInJambles you're missing something called "integrity". Take pride in your work or be a hack for rest of your life.
@@MasterCheeef you're missing something called the sarcastic wanking motion I'm making right now. It's oh so much more interesting than your weird foibles about people who have idle hobbies getting things done and letting things that don't matter be good enough.
Relax, homie. No need to be so emotional about it.
Typically you just turn the heat up instead of turning the wire down. You'd have better results that way from personal experience. Not necessarily perfect spray arc but will 90% I feel.
@Andrew Crews AkTuAlLy ThErE iS nO hEaT kNoB
No shit but you can adjust the voltage and if your machine isn't a nugget you can adjust the amperage a little bit independent of the wire feed speed.
Therein adjusting the hear.
@Andrew Crews I think he means voltage.
I've gotten closer than that with 380ipm and 31.5v but obviously the right gas is needed. What about 100% argon?
I wonder if you used a smaller wire or increased the voltage, if that would have a better effect
you have to bump up the voltage, it works fine for me but at work we have an older, non digital, welder
I would let to see 75/25 with Hobart fabcore 86r 1/16 wire. (spray transfer)
Thanks for the update the Millermatic 210 uses 75/25 and we can't still make a smooth weld
I was using a esab caddy mig. They don't have a fluxcore nozzle and don't run right if you use anything other then .030 mig wire.
I was using the er70 solid mig .030. It was dead of winter and I was welding step treads to the junior channel outside in shade in the freezing cold snow, ground was frozen. I cranked the volts way up and as I was welding the arc noise changed to a gentle hiss and there was no more spatter. The weld joint got hot and I had to stop. I guess this was "close" to a spray mig transfer. Almost to hot to control on the 1/8" step tread
Very interesting
Can you get into spray transfer using 100 percent argon when welding steel? Certainly you can when welding aluminum.
i do it all the time with .045 volts around 28 on up
I recently used an in-good-condition big solid copper-and-iron (?) Esab machine with enough "oomph" to chase spray conditions with with Ar-20%CO2-2%O2. It would never cleanly spray. By 400A, was on 39.something V - essentially 40V - trying to get clean transfer. Called a stop when saw a penetration bead through an 8mm (5/16") steel tube on a 25mm thick (1") plate and there was too much heat about, causing distortion. Any less V and it's spitting globules. So got a chance to see, and the answer is still "no".
I think in true spray you break into spray at about 28V and you don't need rising voltage with rising Amps??
The context is the UK, where there is an immutable orthodoxy of using 20%CO2 gas for "plate" welding. Where an objective test with gases "coming through pipes through a wall" (there is no information provided about which gas is which) would have you saying much more argon-rich / less CO2 is the better choice and spray.
I think if you bumped the V up to 28 to 28.6 and WF down to around 360-80 would get it.
I was spraying with 85/15 .045 and it ran great at 28 or 28.6v WF 320,it's been 13yrs ago so my memory isn't as good as it used to be.
Wouldn’t It be best to up the wire diameter?
Wondering if people use spray transfer for CWB GMAW Flat testing? I gather the gas is selected by the testing agency and that it is the 75% Argon 25% Co2 by default? Which brings me to believe that one does not use spray for testing? PS it looks like as you say, 5% more Argon and the spray could be there.
Hello friend, thank you for showing me the information I was looking for.
I have a question. If the co² ratio is slightly lowered, will the spray voltage be lowered? For example, argon95%: co²5%.
Because I want the spray in a thinner product.
I can tell you this too
You have to turn up the voltage, don't care about wire parameters! Higher Volts is the answer
I think perhaps so as well
Now I'm curious about just running pure argon instead of mix.
For those of us with TIG set ups, what about 100% argon?
Yes, you can spray with 100% argon. Ans you can do it at a lower voltage and wire speed because it is so hot due to the argon
Did you get undercut?
@@jaysmith4293 sometimes when I first tried it I would. Like anything it takes some practice and you have to know your settings. The only time I do it is if I already have my machine set up for tig,and I need to mig something really quick.
But if you have a lower voltage machine like one of these 140 amp millers,you can use 100% argon to get more penetration on materials you otherwise wouldn't be able to weld.
@@FreedomInc So why do they even sell welding gas with CO2 if pure argon works better?
@@phillhuddleston9445 co2 makes the weld hotter and Pentatrate better depending on the weld and process and material. Also expense of production of the gas
It’s a no go
Millermatic 210 uses 75/25 and Is posible to run spray Transfer for steel but Not at the reference table they print at the Doors machine.
I use to have a old miller 200 with 2 crank adjusters 1 was slope and the other volts not sure what the settings were but you could adjust slope it sprayed like paint
Can you do a 4f lap joint, 7018 1/8 rod, with 1/2"× 2"×10" plates? I'm having a tough time in school with that one
Interesting video. Question why do you decrease the wire feed speed rather than 😮increasing it. Can you use 100% argon for spray transfer when welding steel?
Im going to give it a go tomorrow see what I get.
So here's the issue, I'm a hydraulic rod welder. Using .045 wire 90/10 gas Lincoln 100 wire.i get pin holes I've tried spray I've even short arched.rod diameter is 3.5 inches induction hardened.i pre heat to 375 before weld and peen after every pass.
Have you tried ER70S-6?
Hey guys. Awesome video as always.
Question/Request. I work in automotive collision repair. On many aluminum repairs, the manufacturer calls for pulsed spray welding.
What does that look like? We are usually welding fairly thin metal (no more than 2.5mm thick) and I feel like to get into spray you would burn right through that. Primarily 5000 series aluminum, .045 wire out of a push pull machine.
Its a little late i know lol. It can be done though. Set your pulse (trim/arc length/ whatever your machine calls it) lower than the average or default settings. .1 -.5 should do the trick. Than you must keep at least a 5/8 to 3/4 stick out and travel speeds have to be a little faster than you would normal short arc. The wire feed is set to a point where your getting the optimal amperage for the material your welding. Some thinner gauge you probably dont want to be anymore than 150-200 amps depending on how fast your welding
Voltage up dude. Way up. Increase the runout and adjust the burnback
Where's Bob " the man" Moffet? Argon (more of it) makes a world of difference. 75/25 gets an E for effort though.
Can definitely be done, I just did it. Increase the voltage. Just because the dumb ass spec sheet states an arbitrary number, doesn't mean you need to stick to it. There are tolerances.
Is it a certain welder you are using or is it just a normal mig welder? Is it special wire? Thank you
Normal welders and wire should be able to spray weld with the right gas and settings as long as if is powerful enough to do so.
Wondering if multiple passes on same test pice had any effect. Or maybe the co2 was cooling and if you were lower out side specs of wire you could get a smooth spray.
Throw the inductance I know is the length of time the short is sustaining creating more of a soft puddle.. Without the short? I wonder what it would Have done during this experiment
I had one guy mention that they can get into spray on straight co2 at the very high amp spectrum.. like 400a+ is this true? i would love to see you guys test that theory but do you have a machine capable of doing that kind of amperage?
Just my 2 cents. Ran 75/25 at 27.5 and 400 for years on xray box headers fir years. Hot pass and fill on end blocks and pipe to header welds. Never had a bad shot but........i used those settings and gas with 045 wire. Could that be the difference?
Just did it last night at work gotta get out of parameters 782 ipm 31.5 on volts she violent but it's a true spay
What the fuck lol
Great video! Are we talking only solid wire?
I would like to see, 75/25 with Hobart fabcore 86r 1/16 wire in spray transfer.
Thank you very much….
NOW I know what “spray” transfer means.
29v 400ipm with .045 is as close as I've gotten with 75/25
So which was the better weld?
Oops forgot about 95-5 argon oxygen. or you can switch to 5 % Helium it's both Hotter and cleaner
Correct me if I am wrong, but does globular transfer merely exist as an observation of the arc's behavior? I ask this because I can't think of a single application where globular transfer would be permissible.
Is the function of the argon to decrease the density of the gas, compared to CO2? In that case, it might work in high places such as la Paz or Denver, but not at lower altitudes.
If i remember correctly the argon is a heavier shielding gas to help keep the pool and bead cleaner by removing as much of the ambient atmosphere as possible
On the opposite side of things is it possible to short circuit with 92/8?
I worked in a shop where we short circuited with 98/2 and am in a shop now where we short circuit with 90/10 so I imagine 92/8 would still short circuit.
You can run mig on 100% co2 if you wanted, it's pretty common. Argon is just better all around.
With dual shield and 100% co2 you can spray.
lol, i have an inverter stick welder that runs on 250 volt. I have it wired up to an old flux core unit that had an old power hungry transformer. because of it running 035 FCAW... when its plugged into 120 feet of 12 gauge extension cord and pushing 140-165 amps with a 70 volt hot start and a listed voltage of 24-36 volts, that 035 FCAW... burns holes in 1/8 sheet just a second or two, melts leather gloves. can feed it 240-300 IPM that's as fast as the motor can push it out... spray arc with no gas just flux core, it works... tho the amount of heat that is made from the power needed for a 5mm rod arcing thru a 1mm spot does something to the air, cant explain what its like to hmm yes i can, the mig gun feels like a rattling lawn mower handle.
Hi, I am not sure what gas I have been using at school. However, the sound and globular evidence that you used 27.5 v and turning down wfs not the opposite way which means I kept my around 480 wfs and turn up voltages to 29 v and it gave me hum sound and no spatters. Would it be called spray transfer?
if only there was a good and reasonably price gas mixing setup. already have 75/25 for mig and 100% AR for tig, switch out the 75/25 for 100 CO2 and a gas mixing setup and save from getting a 3rd tank.
Or run 90-10 mix can Short circuit weld and pulse or spray transfer as well. Or agree on run dual shield flux with c25 and call it a day on the heavy stuff.
@@kylecasetta4091 I do run dual for heavy stuff but cleanup kinda blows and changing wire too.
Why didn’t you try turning up the cfm on the gas? I think it would have helped.
Nice video but short answer is NO. Guys will say "up the voltage" or "slow the wire a bit more". But WTF is that getting you? Whole purpose of spray arc is high deposition rates and decent penetration on thicker steel members. You dropped almost 80 ipm and couldn't do it. So what's the use? No possible upside to this endeavour. Your producing a slower weld with unknown properties. Good experiment and proof positive that c25 isn't a hot enough gas. You really wanna have some spray arc fun? Switch to trimix fas
Is the arc a different colour due to the extra argon in the true spray transfer shot?
I am wondering why we spray transfer anyway , why not just use a dual shield wire with 75/25 , please correct me if I am wrong but I beleive you can get better penitration with dual shield than you can with spray transfer andyou can weld in any position,and you don't have to buy a more expensive gas and have more bottles of gas to maintain. I just use the Esab 7100 Ultra dual shield anytime I have to work on thicker material.I am sure Select Arc and Bohler have similar wires. So why spray transfer?
Dual shield is nice... and easy.
Turn your amperage up.
im curious, i just had a welding interview that had me do a welding test for their structural welder position. however they definitely had me run c25 gas and i could not for the life of me figure out what the deal was, it spattered a lot for it being a "spray" transfer. they are supposed to be doing my bend test over this weekend, however should i be concerned for the results due to the gas type? this would have been on 3/8ths carbon steel in the 1g position with a backing strip. like a 45 degree bevel i believe i was told, and a 1/8 gap. machine was pre set at 27.5 with a wire speed of about 440. i believe it was .045 wire as well.
Ran about 375 wire speed and 25v on my mts 275, seemed to have a better result than you guys did.
That wasn't spray transfer. The only thing I would suggest would be to increase voltage. My guess is that to really get a spray transfer with 75/25 would involve much more voltage...possibly more than what the machine can supply.
Depending on machine.
We used 95/5 for spray transfer. Never used 75/25. Tried it it ran like shit. We were running 0.45 100s wire.
Straight argon work?
At 400ipm, I saw ball bearings flying off the weld. Lol
We use 98/2 for spray. 98 argon 2 oxygen
I mean you could have dropped down to 360 wire speed like the esop recommends for attempting spray on 75/25. But I get why you didn’t.