Welds look good, you forgot the settings.
I'd thought I'd try to start a thread on the various aspects of spray arc/pulse spray welding with MIG.
As this is a area of welding that the Newbies and even some of the older guys aren't familiar with, I want to challenge any and all experts or even amateurs to post up welds, comments, types of machines they use to do it, settings, gas mixture etc.
Here's some of mine. I may have posted some of these pics before that I did with my ESAB with C18 gas from AirGas but never explained that it was a spray process. I used ESAB wire with ER70-S6 rating. These melted my helmet btw. RIP HF 49.00 special.
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
Welds look good, you forgot the settings.
Real world weldin.
When I grow up I want to be a tig weldor.
Unfortunately,
ESAB doesn't give voltage settings... But wire feed about 6.25 out of 10. High range with heat setting at 4 out of 10. 280 amp rated welder. I have wanted a digital output for my machine, but never got around to ponying up the $$$ for the add on.
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
The price on the V/A meter has dropped significantly. When I bought my machine 3 years ago, the meter was in the $350 range. I priced it a again a few months ago, and it was down to $85. So, I bought one for my unit.
To keep the Migmaster 250 theme of this thread going, I'll add a couple weld pictures for you. Nothing special, I was just playing with the unit, so the welds were ran on scrap. I didn't have the meter yet, so I don't know the output on these. The voltage was set to high coarse/ 2 fine with a wire speed dial setting just shy of 8. I was running 98/2 oxy at the time. I just switched to 90/10COČ last Friday, but I haven't had an opportunity yet to run the ESAB with it.
Absolutely perfect, from beginning to ending. No crater.
That Hobart wire...what is the AWS classification? I don't recognize that one.
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
This was 3x3x3/16 angle 6" long welded to 2x3/16 flat bar, 1/8" gap, flat position, with welding table acting as backing plate, Millermatic 350P, pulse, 300 ipm, .035 ER70S-6.
MM350P/Python/Q300
MM175/Q300
DialarcHF
HTP MIG200
PowCon300SM
Hypertherm380
ThermalArc185
Purox oa
F350CrewCab4x4
LoadNGo utilitybed
Bobcat250
XMT304/Optima/Spoolmatic
Suitcase12RC/Q300
Suitcase8RC/Q400
Passport/Q300
Smith op
I don't see the pics...
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
Sorry, the computer crashed when I was tryin to get the pics onto the post. They're kinda blurry but here they are--
backside-
MM350P/Python/Q300
MM175/Q300
DialarcHF
HTP MIG200
PowCon300SM
Hypertherm380
ThermalArc185
Purox oa
F350CrewCab4x4
LoadNGo utilitybed
Bobcat250
XMT304/Optima/Spoolmatic
Suitcase12RC/Q300
Suitcase8RC/Q400
Passport/Q300
Smith op
seeing these pics makes me want a bigger mig so bad.im guessing when u do spray u need to move a bit faster then u normaly would?
I definitely fall into the newbie area, so much so that I have to ask ... what is spray arc / pulse spray welding? The welds looks fantastic.
It deposits metal faster, faster yes. But it is also not for really light gauge material as the process generates lots of heat. Speed of forward movement depends on the type of weld as well.
Here's a textbook definition
In spray transfer very fine droplets or particles of the wire are rapidly projected through the arc from the end of the electrode to the work piece in the direction in which the electrode is pointed. While in the process of transferring through the welding arc, the metal particles do not interrupt the plow of current and there is virtually a constant "spray" of material. Spray transfer requires a high current density. With high current the arc becomes a steady quiet column with a well defined narrow incandescent cone shape. The use of argon (or suitable high argon content mix) is necessary because it produces a "pinching" effect on the molten tip of the electrode permitting only small droplets to form and transfer during the welding process. With high heat input, heavy wire electrodes will melt readily and deep weld penetration becomes possible. Since the individual drops are small, the arc is stable and can be directed where required.
Pulse is similar, except that through automatic modulation of the current allows the weld to cool while the current drops into the globular transfer range momentarily before returning to spray range. It helps in out of position welds.
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
Just a few more questions.
Would you only use spray transfer on heavy guage material where good penetration is needed?
Do you need a special type of welding machine to do it?
I can see the welds are very neat, but why and when would you use spray transfer?
Thanks again.
I have the pulse feature on my (new to me) MM350P. I haven't gotten to play with it much but it makes a hell of a sound cranked up on pulse! I don't understand the wire setting in the pulse mode, I don't think it reads it in ipm.
Dewayne
Dixieland Welding
MM350P
Lincoln 100
Some torches
Other misc. tools
I think that you will need a machine that goes well over 180 amps and machines able to generate 28 volts or greater, to sustain any extended sessions of spray. Some people report being able to do it with smaller machines, but I am suspicious that they are "nearly" at spray levels and at the higher end of globular transfer.
Any material over about 3/16 is a candidate if controlling the heat or possble warpage is not an issue. Generally, I only use it on 5/16 or greater material.
As to why and when:
Any time a neat clean job with no cleanup is prefered is a reason. Also time factors could be a consideration.
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
The 180 amp units don't output enough voltage to spray an .030 or .035 wire. With 98/2 oxy, some of the 200-210 amp units output the necessary 24 -25 load volts to spray an .030 or .035 @ 200+ amps. I had to go this route for a few years with my MM 210, until I had the funds to purchase a 250+ amp unit.
I found a few more weld pics. the first two were produced with my Millermatic 210, and the third was produced with the Millermatic 251 that I sold to purchase my Migmaster 250.
All three are just on scrap , because I was dialing the unit in.
do u think a HH140 could get to globular transfer on straight argon. my guess is no. i might just have to go to my buddys and use his 210 hobart
I don't think you could get close. However, I haven't tried it with such a light machine. I doubt it has enough arc density.
Esab Migmaster 250
Lincoln SA 200
Lincoln Ranger 8
Smith Oxy Fuel setup
Everlast PowerPlasma 80
Everlast Power iMIG 160
Everlast Power iMIG 205
Everlast Power iMIG 140E
Everlast PowerARC 300
Everlast PowerARC 140ST
Everlast PowerTIG 255EXT
Whats the smallest wire gauge you can use .35?I am looking in my Acklands catolog and all they have is .45?
Last edited by wagin; 03-26-2009 at 04:43 AM. Reason: stupid coment
Miller TrailBlazer 251
Miller HF-250-1
Miller MaxStar 150 STL
HyperTherm PowerMax 380 plasma
Lincoln PowerMig 180
Millermatic 252
Miller Diversion 180
Miller TrailBlazer 251
Miller HF-250-1
Miller MaxStar 150 STL
HyperTherm PowerMax 380 plasma
Lincoln PowerMig 180
Millermatic 252
Miller Diversion 180
Wagin,
You are not spray welding. C/25 may look like its spraying but its not. This has been discussed here a lot. If you had true spray, the gun would melt down. Try some 98/2 and see the difference. .030 wire is as big as that machine will spray, it doesn't have enough balls.
I have tried it with c/25 and with 30+ volts I can get something like spray, but I have no control of the arc. 155 amps is the minimum with 98/2. When it goes from globular to true spray the arc makes a loud crack. If its just on the edge, it will continue to crackle as you weld telling you not enough volts or amps. Hook a wire feed to your trailblazer and use 98/2. It should do it.
David
Real world weldin.
When I grow up I want to be a tig weldor.
MM350P/Python/Q300
MM175/Q300
DialarcHF
HTP MIG200
PowCon300SM
Hypertherm380
ThermalArc185
Purox oa
F350CrewCab4x4
LoadNGo utilitybed
Bobcat250
XMT304/Optima/Spoolmatic
Suitcase12RC/Q300
Suitcase8RC/Q400
Passport/Q300
Smith op