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spray welding

6.4K views 17 replies 12 participants last post by  MoonRise  
Andy,

Spray transfer is one of the three ways that a MIG weld can be done; short-circuit transfer, globular transfer, and spray transfer.

see http://www.esabna.com/EUWeb/MIG_handbook/592mig1_7.htm for some more info. Read through the rest of the ESAB MIG section, and the other educational info available on the ESAB, Lincoln, and Miller websites.
 
Pulsed spray transfer is a variation of spray transfer. The electronics will vary the volt/amp/power through the filler wire to pulse some metal (in the form of tiny molten metal spray droplets) across the arc to the workpiece and then cycle down briefly but not extinguish the arc, and then pulse again. Many times a second.

But the transfer mode that is occurring is still spray transfer. Where the defining characteristic is that the wire melts in the arc and transfers across the arc to the workpiece as tiny droplets smaller in diameter than the wire diameter (like a fine spray). The sound is a "hiss" instead of the characteristic "sizzle" sound of short-circuit transfer. Globular transfer is in the transition past short-circuit transfer where the wire is no longer hitting the workpiece as a wire (and short-circuiting itself to the workpiece, hence "short-circuit transfer") but is melting before it reaches the workpiece and typically 'globs' up or forms molten metal droplets bigger than the wire diameter.

Short-cicrcuit transfer is a low-energy transfer mode. Spray transfer is a high-energy transfer mode. High-energy means things get hot, fast. Things like the torch, the machine, your hands and helmet, all that. Oh, and the weld too.

And no, your Lincoln 100HD does not have the power to achieve spray transfer with steel wire. It -may-, if everthing goes just right, be just able to nudge into spray mode with thin aluminum wire of 0.030 dia and plain argon gas. And then the duty-cycle will kick in or the wire will birds-nest. Doh!