Spray Welding Information

Spray Welding

- Requires Amperage at or above Transition Level (short circuit then globular then spray arc)

Transition - The point at which the weld pool changes. For example, if the voltage is too low for the ipm then the wire will strike the parent material, by raising the voltage to the transition level the arc length will be increased to the short circuit transition level.

- In spray arc mode the wire forms a point (funnel) at the electrode wire end

- very small droplets are formed and sprayed on the weld puddle

Strong points

- Smooth Weld Bead - High Penetration (used on metal 3/16" or greater) - High Weld Deposit rates - Minimal Spatter

Weak Points

- Requires welder training - Gas Cost can be greater due to higher argon levels ( > 85%) - Recommended for flat position and horizontal fillets only - High Heat can cause welder discomfort - Undercut can be caused, especially on the top edge of wleds


- High Voltages, (usually 26 volts To 37 volts ) - Wire Electrode Size: (usually 0.045 or larger required ) - High Amperages (usually 180 Amps To 440 Amps ) Shielding Gases: At least 85% argon remainder CO2. 92/8 is most commonly used.

See suggested settings for spray modes. Machine settings can greatly effect the weld.

High current/heat.

Small machines not capable of spray mode.

Machine duty cycle is an important factor.

When setting machine parameters (volts/ipm) start with the suggested setting then manipulate the voltage up or down until the sound is 1/2 “crackle” and 1/2 “whoosh”

More Spray Welding Information