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How to Mig Using Spray Transfer – Mig Welding Settings for Spray and Short Circuit
Want to learn how to migrate using a spray transfer? Maybe you’re not even sure what a spray transfer is. Do not worry. I’m about to explain how to spray using fluff and dirty smooth talk.
Spraying is the type of mig welding that is performed in harsh production environments. For example, railway box cars, heavy earthmoving machines, etc. to build…
It’s called “spray transfer” because that’s how the molten metal goes from the arc to the puddle. Fine droplets of molten metal spray into the puddle and that’s what makes the buzzing sound so unique.
Spray mig welding requires a different shielding gas than what is usually used in short circuit mig welding, (I will explain short circuit mig later) 90/10 argon/co2, 95/5 argon/co2 and 98/2 gas mixtures. Argon/o2 is used for spraying, along with much higher voltage settings.
A typical setting for welding 1/4″ (0.250″ or 6mm) steel with 035″ ER70s6 wire (like the Lincoln L56) is about 25 volts and 350 ipm wire speed.
So what does short circuit mig welding mean?
The term “short” means that the wire is actually touching the weld pool. It short-circuits as it melts into the puddle, heating up all the way until it finally melts like a fuse. When this happens, it creates an arc that produces heat. This arcing and shorting happens so many times in a single second that the arc sounds like bacon sizzling in a pan.
The short circuit mig uses a much lower voltage than the spray transfer, but is much more versatile for welding thinner metals and welding in all positions.
So for general fabrication, short circuit mig is the way to go because general fabrication requires welding steel in all positions and thicknesses… from thin sheet thickness to 1/2″ thick and thicker. .
A good tip for you:
If you want to use atomization in your shop but don’t want a separate gas mixture, get an 85/15 argon/co2 cylinder. This mix works well for both, so if you have a mig welder big enough to handle the high welding current used in a spray mig, all you have to do is adjust the voltage and wire speed and you’ll be spraying like a champ.
6 things to remember when learning how to migrate with spray:
- push the puddle
- only with flat and horizontal welding
- the outage will be longer than in the case of a short circuit
- 0.045″ wire is probably better than 0.035″ for most spray applications
- you need a high-performance, high-performance, high-performance, in-production sprayer
- use an argon mixture containing at least 85% argon
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