Spray welding

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I was wondering what is spray welding and how do you do it? Thanks
Reply:http://weldingweb.com/vbb/showthread.php?t=13218It's a transfer method in mig welding.  The arc is cone shaped.  In general it has a high deposition rate compared to short-arc with the same wire, deeper penetration than short-arc or globular, and spatter free when dialed in.  It's limited to flat and horizontal fillets only, the puddle is far to fluid to go out of position.  You're going to need a higher argon gas mix, 95-98% Ar , balance O is common.  Somewhere in the 85-90% Ar, balance CO2, up to 98% Ar, 2% CO2 mixes are also capable of spray, needing higher voltage than the Ar-O mixes.  With .045 wire and 95Ar/5O gas mix I would have the machine set to 26ish volts, 350ish ipm (if I'm recalling correctly I was getting somewhere in the 300 amp neighborhood).  Dial it in from there.  I used to do a lot of .052 spray.  95Ar/5O 28.5v 350ipm 400a.  The arc was partially burried with these settings.  I have done .035 wire too, been a while.  25v 400ipm 220a?
Reply:Have you expeirenced too much oxidizing using 5% of 02?
Reply:http://www.praxair.com/praxair.nsf/0...ILE/P-8126.pdfNice little breakdownEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by stiv9Have you expeirenced too much oxidizing using 5% of 02?
Reply:Essentially, spray is when the droplets of metal within the arc are so small, that it is like a mist.  You cannot see individual droplets of metal.
Reply:Originally Posted by stiv9Have you expeirenced too much oxidizing using 5% of 02?
Reply:Have you ever done any mild steel with 98/2 (oxygen)?  It works great on thicker plate, and can pass xray, PT, VT, UT, or whatever else you want to do do test it.
Reply:I have never done spray with Ar/O2 blends. For spray, I Always used Ar+8%CO2 and in shortage of it I used SCT mix Ar+18%CO2.I still wonder, what one could reach with Ar+2%O2 (or Ar+5%O2) and cannot reach with Ar+8%CO2 at mild steel with ER 70S-6.To be fair, I have never experimented, just followed the recommendations...And always passed X-rays and UT tests...I know about less heat input using Ar/O2 blends, maybe more stable arc due to lower V needed for spray, but I am still afraid of too oxidizing, and just have read about finger penetration profile, about danger of trapping porosity in that finger profile ...etcI see, you insist on top quality, so I am temped and will catch the opportunity to make some trials in the future...Regards to all!
Reply:Originally Posted by stiv9I have never done spray with Ar/O2 blends. For spray, I Always used Ar+8%CO2 and in shortage of it I used SCT mix Ar+18%CO2.I still wonder, what one could reach with Ar+2%O2 (or Ar+5%O2) and cannot reach with Ar+8%CO2 at mild steel with ER 70S-6.To be fair, I have never experimented, just followed the recommendations...And always passed X-rays and UT tests...I know about less heat input using Ar/O2 blends, maybe more stable arc due to lower V needed for spray, but I am still afraid of too oxidizing, and just have read about finger penetration profile, about danger of trapping porosity in that finger profile ...etcI see, you insist on top quality, so I am temped and will catch the opportunity to make some trials in the future...Regards to all!
Reply:i just got a WPS passed for carbon steel spray transfer useing 95/5%argon /oxy i have been doing this for 12 years and neved had any problemsfor stainless steel i use 98/2% argon/co2ChuckASME Pressure Vessel welder
Reply:Ok, I will ask it, how about 100% argon?Me!
Reply:for aluminum yesChuckASME Pressure Vessel welder