Trouble getting a spray transfer with anything but a 90 degree angle...

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I've ran into a problem getting a spray transfer.I am using Select-Arc 720 wire.  It is a dual-shield wire.  I am using .052" diameter with a 75/25 gas mix, and about 210-230imp.  Voltage is around 24.5-26v.I have never had any issues with getting a good spray transfer from this wire when using the 1/16".  In fact, this specific dual-shield wire is designed to spray (although 99% of the guys at my work use globular or SC transfer because they don't know the difference).Anyways, I am only able to achieve a spray flat and overhead at a 90 degree angle to the workpiece aiming DIRECTLY at the root.  Or about a 45 degree angle with vertical up.  And even then it is iffy, it sputters between a spray and a SC/globular transfer.  I ran into the problem over the past couple weeks when the boss took our 1/16" wire away since the max thickness of the steel we were welding on was 1/4" for this section of the boat we're building.  Most of it 3/16" or less.I tried recessing my contact tip, I tried even sticking it out just to see.  Nope.  I messed with my voltage, wirespeed, and even switched the welder to CC and switched the feeder to CC to see if that would fix it.  I tried off the Miller 6-pack welders, and I tried off the Miller XMT and Phoenix inverters.  Nothing.It isn't a probem for 90% of the work I am doing, but when I am in a tight spot I can't achieve a spray and end up burning the living hell out of myself with the molten drops.  (I have the blisters to prove this)  Plus, my welds weren't tying in properly and all the welds I am doing are 100% visible to the public and need to be PERFECT.  Anything less than perfect gets cut out and redone, no matter how long it takes.I was thinking it was the gas flow.  Our gas splitters in our yard don't have flow adjustment, it has to be adjusted from the bottles/mixer only.  The other yard has dials on the splitter so each welder can fine tune the gas.  I was thinking I may need to turn it up or down.  I checked the ratio and it was still at 75/25 and the flow rates were the same as they always are.I got so sick of it that everytime I got into a tight spot i'd walk to the stairs, down the stairs, to the rod oven, grab some 3/32" 7018, walk to my welder, set it to CC, bust out my stinger, stick weld it, then repeat the process in reverse to run wire.  (We are short on leads & welders on my job, so I couldn't setup stick and wire at the same time)  Then we ran out of 3/32" 7018 and the 1/8" was too thick for the material I was welding on.Any suggestions guys?  I talked to the boss, he said "Ask soandso".  Well, soandso is a steel fitter, not a welder.  He had no idea.  All the best of the best welders on my job are down the street at our other yard.I can usually get a spray at up to a 15 degree drag or push flat/horiz or 90 degrees with up to a 45 degree push vertical up with the bigger wire.So I am stuck...Last edited by WelderBoy; 09-04-2007 at 10:19 PM.
Reply:270 - 300 ipm and whatever volts you need to carry that speed, all the machines are different, find it's sweet spot. It'll be hot and fast, probably why the others don't bother with it. As for the gas, there could be several types of restrictions between you and the manifold. The Inspectors should have access to a small flow meter they can check it with at your connection.Anything worth doing is worth doing RIGHT
Reply:just curious but I didn't think 75/25 would go into a spray at that voltage.  I know on my powermig  If I run those settings it will be in a Globular rather than a spray...I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:AFAIK, you can't get spray transfer with C25.  Short-circuit and globular, but not spray.Turn the CO2 down to 20% or less and you can get spray.  C12, C8, C15, C18, 98-2 Ar-O2 can all do spray (with the right machine, etc).But spray and C25??Last edited by MoonRise; 09-04-2007 at 11:22 PM.
Reply:If there's no way with C25 then that would explain why the others don't.Anything worth doing is worth doing RIGHT
Reply:He is using dualshield wire.  I use AG8 (C8) at the lower voltages.  Dualshield 7100 ultra recommends Co2 for welding, but the LWS told me AG8 would spray at lower voltages and it does.  Once I get into the higher voltages, I need Co2 or I get "worms" in the weld.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by MoonRiseAFAIK, you can't get spray transfer with C25.  Short-circuit and globular, but not spray.But spray and C25??
Reply:how low have you gone with your wire speed...the first suggestion that I would have would be to go lower with the wirespeed and/or higher with the voltage...maybe up to 26 or 27.  That should improve your spray transfer.
Reply:weldrwomn, I tried both of those.I also checked all my gas lines, checked my gas filter, diffuser, replaced my contact tip, cleaned my nozzle, checked the drive wheel tension.I burned through that roll today and the new roll seemed to work a bit better.  Still not as smooth as the 1/16" wire.  IIRC that last roll was a partial roll sitting on the shelf for who knows how long.
Reply:Red wine gets better with age....welding wire, not so much
Reply:Hmm, update.I was using a Miller S-32P feeder.  I read the manual and it said that on "low" wire output it goes up to like 300/350imp or something.  Well, I was on low setting but for the past few days i've been using the Miller 12vs feeder and it only has one output and it ranges up to 700imp and actually displays the IMP on the wire speed dial.  After tinkering with it I realized that I was actually running anywhere from 350-450imp which leads me to believe that the other feeder was actually broken and only outputted on the "high" wire output setting.So I was actually running a LOT faster wire speed.  Up to twice as fast as I listed.
Reply:DCRP, CV power, gas shilded with ER 71T-1, c-25 will work.  Solid wire will not go into a true spray with c-25. nothin over 15% co2 will allow true spray.