Spray transfer mig

[brokenbiker]

i have only ever broken into spray transfer once, on a 3 phase 400 amp machine that was set up by a seasoned welder.

Can any old mig hit spray or is there a minimum voltage required and a minimum wire rate etc?

(I know my planned 160 amp inverter isn't going to hit it, just curious and fancied another lesson about welding )

 

[matt1978]

Voltage is the biggest key, the smaller the wire diameter the less Voltage and WFS requires required to get into Spray.

If you had some 0.6mm wire you could probably do it on your smaller machine

 

[brokenbiker]

Really? That's interesting to know.

Am I right in thinking that spray produces a much hotter weld than dip transfer would at the same settings? Or is it just hotter because of the voltages being higher?

 

[HughF]

Higher argon levels require lower voltage to enter spray. Spray transfer with 75/25 needs a lot more voltage than 95/5 for a given wire diameter. I can get .8 into spray with argoshield heavy at around 26v iirc.

 

[matt1978]

You cannot have the same settings for Dip as you do for Spray on the same Wire diameter.

Dip/Mixed/Spray are just names for the arcing phases as you increase the Voltage and wire feed rates as the material thickness that you need to weld gets thicker.

Very briefly, Dip is used to describe to lower voltage ranges and is typically for thinner material and bridging gaps. The wire is rapidly touching the weld pool, when it touches it creates a short circuit, when the short circuit occurs the wire acts like a fuse and the current rises rapidly until the wire cannot take anymore, this causes like a mini explosion and this is at the point the wire is detached into the weld pool and the cycle repeats again.

Spray is to describe the higher voltage ranges and after ignition the wire does not touch the work piece again. It is pretty much a spatter free process.

Mixed arc is used to describe anything that falls between Dip and Spray where as the material thickness requires a voltage level which is too high to remain in Dip but not high enough to get into Spray. It's horrible and you get very large coarse spattering

 

[brokenbiker]

Will have to experiment when I get my mig then. Will be using 95% argon so will see what happens

 

[Robotstar5]

Spray transfer sounds different as well, more of a hiss.

 

[Richard.]

What matt calls mixed is known as globular transfer. It's like the dip but with larger droplets making contact with the weld pool less frequent. You get varying arc widths depending on how much you increase the voltage.

 

[matt1978]

Short Arc, Dip Transfer

Mixed, Intermediate, Globular

Spray

Are the names to look out for

 

[brokenbiker]

Jody on wtat has a vid that shows a huge difference between dip and spray. Just go to his channel and search spray transfer, 2 vids pop up, the longest is the best

 

[dom501]

We use 400 amp 3 phase mig's at work and I was thinking that same thing. As when I went to college you learnt about it. We use Butters ISO mig 400's, 4 course 4 fine settings For everything I generaly weld on B1 or B2 (B course 2 fine). I'm thinking this is more globular transfer, if I turn it up to anything above C4 I reckon it starts to spray.
I am no expert but I'm not sure that could be achieved with a domestic 240v welding pot.

 

[Daneishwelder]

Can you vertical up mig weld with 1.0 wire?

 

[Richard.]

Yes. In dip transfer. (Solid wire)

 

[HughF]

Spray transfer is for downhand positions only, fillets and buts... Pulse spray is what you need if you want to spray out of position.

 

[Daneishwelder]

This is what I'm working with the settings are to spray transfer 5mm mild steel what would you re men's to vertical up if possible ?

 

[Woody.v8]

Spray transfer is for downhand positions only, fillets and buts... Pulse spray is what you need if you want to spray out of position.

You say this but i often spray OV (overhead) when the conditions allow.

 

[HughF]

Good for you, if you can control the puddle out of position under spray conditions, go for it. I've only ever believed what I was told and have only used it downhand.

 

[Daneishwelder]

Yes. In dip transfer. (Solid wire)

What is dip. ( short circuit ). I can't get the weld to hold it just falls

 

[Richard.]

What joint, plate thickness you using? 0.8 is better but it can be done in 1.0. Yes dip is short arc. What current you using. Is it a root is it square edged.

 

[HughF]

Start a new thread to discuss the problems you are having with the vertical up solid wire welds. Don't spam this one.