spray welding

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oaky... so i've heard that Spray welding is good. what is the big hype all about? can my LE 100HD be set up to accomplish this? just curious...thanks,Later,Andy
Reply:I've only spray'ed on a few instances, anywhere I have worked that has the capability to spray doesnt allow it, but, all I have to say is, your beads look like glass, and it really reduces cleanup in most cases.
Reply:Originally Posted by SonyMobileI've only spray'ed on a few instances, anywhere I have worked that has the capability to spray doesnt allow it, but, all I have to say is, your beads look like glass, and it really reduces cleanup in most cases.
Reply:No, you won't even get close to spray transfer with that machine.
Reply: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.
Reply:MoonRise gives good info.  Spray welding makes a LOT of heat and takes more power than your machine has.  I was doing a small job today.  Gas 92% Argon, 8% Co2, 29.5 volts, .030 wire 400 ipm, just under 200 amps.  It makes a nice smooth penetrating weld.  98% argon, 2% Oxygen is the preferred gas, but I use 92/8 because you can spray or short circuit with it.  Almost of all of my work is short circuit.Your machine only goes to 20 give or take volts and 100 amps.  Not even close.  What I am trying to say is it takes a LOT of balls to spray weld.  It actually atomizes the wire.  Definition of spray weld is droplet transfer is smaller than the wire.  The arc is silent, the power is awesome.  When doing it, my helmet gets hot and it can burn your hands.  I did a demo for the snap on man one day. He called me the next day and told me he had a bad sun burn from it.If you want I can post some pics of the results.DavidLast edited by David R; 11-06-2007 at 06:10 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:The references I checked, like this one from Lincoln, http://content.lincolnelectric.com/p...ture/c4200.pdf, show 0.030" steel wire sprays at about 155 amps.  I did not find data on smaller wire, but 0.024" or whatever the next smaller size is, may spray at around 100 amps with the right gas.
Reply:What I meant by "it looks like glass" was, its just that smooth, you won't really see any ripples and your bead will not have any ridges like a regular weld.  It really gives a show quality appearence.  And yes, it requires a LOT of power to get a machine to spray, I've tripped many breakers, and fried a whip while spraying,  which is why most comapnies frown upon this method, while it does leave a nice finish, it can be hard on consumables..and... non consumables :P  If your going to spray, make sure you machine can give enough power, and make sure you check the cuty cycle beforehand.
Reply:Originally Posted by David R  I did a demo for the snap on man one day. He called me the next day and told me he had a bad sun burn from it.David
Reply:Originally Posted by MoonRiseAndy,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.
Reply:Originally Posted by Joe HHAHAHA!! It's about time someone burned the snap-on man! You gotta love the irony...
Reply:Originally Posted by weldgaultWhat do you call Pulse if not part of GMAW (MIG).  John
Reply:According to the lincoln hand book for arc welding, you can pulsed spray vertical up.  I would like to see that.  I can buy a pulse panel for my V350, but not until jan 1st.  Its mostly for Aluminum, but has settings for steel, stainless and nickel also.  Eight bills for the panel.  I WANT IT!DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by pulserThe references I checked, like this one from Lincoln, http://content.lincolnelectric.com/p...ture/c4200.pdf, show 0.030" steel wire sprays at about 155 amps.  I did not find data on smaller wire, but 0.024" or whatever the next smaller size is, may spray at around 100 amps with the right gas.
Reply:okay. that makes sense (everything that's been stated). i was just wondering. i knew it woudl take a lot of "OOMPF" to get the spray to work, but i wasn't sure if mine was too small or not. it has surprised me so far with the capabilities that it has. thanks again for all the input.later,Andy
Reply:no one even mentioned that spray transfer was a good way to get higher deposition rates. Pulsed spray is too a transfer mode in MIG. The wire is only transferred across amperage peak time. --Gol'
Reply:As stated be careful around high plasma arcs, in spray welding the radiance of the plasmatic metal is in a spectrum that produces Ozone gas, and severe sunburn, it would be advisable to wear most of a proximity suit mainly gloves forearm and neck protectors.
Reply: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!