Spray Transfer Welding Settings Guide

If you lack experience with spray transfer during welding, it’s likely that you’re unsure of the correct approach to take. This could result in a significant amount of time spent searching for the appropriate settings to successfully complete the task.

Spray transfer welding can be made simple by following a guide. Even as a novice welder, you can easily produce a satisfactory weld by following the instructions, allowing you to complete the task quickly and efficiently.

This post will provide a list of spray transfer settings that are suitable for use with various types of welders. Fortunately, these settings are inclusive and accessible to all individuals.

Spray Transfer Welding Settings Guide

Displayed below are charts that present the necessary wire speed and voltage settings for achieving successful spray transfer welding with a Miller welder. However, it is recommended that you possess a solid comprehension of your chosen metal and carefully consider both the amperage settings and the nature of the task before utilizing these values.

Spray Transfer Welding Settings Chart for Aluminium

Material ThicknessWire Size (mm)Volt SettingAmperage RangeWire SpeedShielding  Gas
3.2mm0.03521-22110-130350 – 400Argon
4.8mm0.03523- 24140-150425 – 450Argon
6 4mm1.224 – 25180-210350-375Argon
7.9mm1.226-27200 – 230400 – 425Argon
9.5mm1.226-28450-480450 – 480Argon
11.1mm1.628~29280240 – 270Argon
12.7mm1.629-30290-200290 – 300Argon
      

When handling diverse aluminum samples of differing thicknesses, it’s essential to utilize appropriate settings. For example, a 3.2mm thick aluminum piece pairs well with a volt setting of 21-22 and a wire speed of 350-400.

Spray Transfer Welding Settings Guide for Stainless Steel

Material ThicknessWire Size (mm)Volt SettingAmperage RangeWire SpeedShielding Gas
7.9mm0.045 24-25200 – 210250-30098% Argon/2% O2:
9.5mm1.625-26250-275140 – 17098% Argon/2% O2
11.1mm1.626-27275-300170 – 20098% Argon/2% O2
12.7mm1.627-32300-325200 – 23098% Argon/2% O2

Spray transfer welding is also applicable to stainless steel. However, instead of utilizing arbitrary values, it’s recommended to choose settings based on the material’s thickness. For instance, stainless steel with a thickness of 7.9mm necessitates a minimum of 25 volts and a wire speed of 250.

Spray Transfer Settings Guide for Solid Wire Welding (Steel)

Material ThicknessWire Size (mm)Volt SettingAmperage RangeWireSpeedShielding Gas
3.2mm0.923-24160-170320-34098% Argon/2% O2
4.8mm0.924-25180 – 190360 – 38098% Argon/2% O2
1.124 – 25180 – 190185 – 19598% Argon/2% O2
6.4mm0.03524 – 25200-210400- 42098% Argon/2% O2
0.04524-25200 – 210210 – 22098% Argon/2% O2
7.9mm0.03525-26220420 – 45098% Argon/2% O2
0.04525-26220 – 250220 – 27098% Argon/2% O2
9.5mm0.04523 – 2430037598% Argon/2% O2
12.7mm0.04529 – 3031539098% Argon/2% O2

Like with many other metals, it’s typically necessary to spend a few minutes fine-tuning your welder’s settings, particularly prior to initiating the transfer. For example, when working with 12.7mm steel, it’s advisable to maintain the welder at 29 volts with a wire speed of 390. Conversely, when using 9.5mm steel, a welder setting of 375 is recommended.

Spray Transfer Welding Settings Guide for Aluminium

  • 2mm material thickness: 21-22 volts, 350 – 400 (Wire Speed)
  • 8mm material thickness: 23 – 24 volts, 425-450 ( Wire Speed)
  • 4mm material thickness : 24 – 25 volts, 350 – 375 Wiire speed
  • 9mm material thickness: 26 – 27 volts, 425 Wire speed
  • 5 mm material thickness: 26 – 28 volts, 460 – 480 Wire Speed
  • 1 mm material thickness: 28~29 volts, 240 – 270 Wire Speed
  • 7 mm material thickness: 29-30 volts, 290-300 Wire Speed

Spray Transfer Welding Settings Guide for Stainless Steel

  • 9mm Material Thickness: 24-25 volts, 250 – 300 Wire Speed
  • 5mm Material Thickness: 25 – 26 volts, 140 – 170 Wire Speed
  • 1 Material Thickness: 26 – 27 volts, 170 – 200 Wire Speed
  • 7 Material Thickness: 27 – 32 volts, 200 – 230 Wire Speed

Spray Transfer Welding Settings Guide for Steel

  • 2mm Material Thickness: 23 – 24 volts, 320 – 340 Wire Speed
  • 8mm Material Thickness: 24 – 25 volts, 360 – 380 Wire Speed
  • 4mm Material Thickness: 24 – 25 volts, 400 – 420 Wire Speed or 220 – 270 Wire Speed
  • 9mm Material Thickness: 25 – 26 volts, 420 – 450 Wire Speed
  • 5mm Material Thickness: 23 – 24 volts, 375 Wire Speed
  • 7mm Material Thickness: 29 – 30 volts, 390 volts

What 3 conditions are required for the spray transfer process to occur?

In order to successfully complete the spray transfer process, it’s crucial to ensure that specific conditions are met. These conditions typically include the following three factors:

  • DCEP Polarity
  • Argon Polarity
  • Current level above the transition level

What is the difference between spray transfer and globular transfer?

Spray transfer welding refers to the transfer of axial non-spatter droplets facilitated by argon-filled gas. In contrast, globular transfer welding entails the transfer of molten electrode globules via gravity.

Spray Transfer Welding Gas

It’s crucial to utilize the appropriate gas when performing spray transfer welding. Typically, argon is the recommended gas for this process. Even if it’s combined with other gases, argon should constitute a minimum of 80% of the gas mixture.

Disadvantages of Spray Transfer Welding

While spray transfer welding can be an advantageous method, it does have some limitations. Due to the presence of a fluid weld puddle, this method can only be utilized in a flat position. However, you could consider investing in machines that are capable of managing the weld puddle.

Frequently Asked Questions

No, spray transfer welding can only be used in the flat position due to the presence of a fluid weld puddle.

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The settings for spray transfer welding depend on the type and thickness of the metal being welded. Charts are available that show recommended voltage and wire speed settings for various metals.

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You will need a welding machine with the ability to perform spray transfer welding, a wire feeder, a gun, and the appropriate welding wire and shielding gas. It’s also recommended to invest in a machine that can handle the fluid weld puddle if you plan to work with spray transfer welding.

Meadows, a seasoned tech enthusiast, shares expert insights on optimizing settings for peak performance on our platform. With a knack for simplifying complex concepts, Meadows delivers user-friendly guides to enhance your digital experience. Trust Meadows to demystify settings and empower you with the knowledge needed to optimize your devices effortlessly, ensuring a smoother and more efficient user experience.
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Spray transfer welding is a welding method that involves the transfer of small, droplet-sized molten metal from a wire electrode to the workpiece, through a stream of shielding gas.

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Argon is the recommended gas for spray transfer welding. It can be used in combination with other gases, but it should make up at least 80% of the mixture.

Meadows, a seasoned tech enthusiast, shares expert insights on optimizing settings for peak performance on our platform. With a knack for simplifying complex concepts, Meadows delivers user-friendly guides to enhance your digital experience. Trust Meadows to demystify settings and empower you with the knowledge needed to optimize your devices effortlessly, ensuring a smoother and more efficient user experience.
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Conclusion

In conclusion, spray transfer welding is a highly effective method for welding various types of metals, including aluminum and stainless steel. However, achieving successful spray transfer welding requires precise adjustment of your welder’s settings, based on the thickness and nature of the metal being welded. It’s also essential to utilize the appropriate gas, with argon being the recommended gas for this process. While there are limitations to this method, such as the need for a flat position due to the presence of a fluid weld puddle, it can still be an excellent option with the right equipment and settings.

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