I think the sharp "pop" that occurs every so often during Bob's demonstration may be caused by an intermittent loss of grounding. Good grounding is extremely critical during spray transfer, wether it's welding with solid wire or cored wires. I deal with these issues constantly in the hard facing business, and I have found that the more contact points for grounding you can have between the lead and the work piece, the better off you will be. I use some old lead cable in between the ground clamp and the steel table when working on a table like Bob's, it really makes a big difference. Great video Bob keep them coming!!!
I'm just starting out with spray. I have 4 year experience (pretty much self taught) with globular and short circuit. I've found that I prefer spray transfer. It's quieter and cleaner. Less spatter. I also use that Esab hood.
I just landed my first job working with spray too, I did a lotta short circuit and gas shielded flux core, I passed a 2g certification with pulse, pulse is nice too!! Especially since you can run it out of position more..seems like it wants to cut into any type of bevel though:/
I have run a spray arc downhill. Using a small percentage of oxygen in the gas. a tri-mixture. We would run downhill with the gun angled up, traveling fast, continuous 60 inch long beads, customer wanted no stops. 1/8 inch sheet, had to learn to walk down a ladder while running the bead. Anyway love the channel.
Welding going down a ladder is what I have to do running finish welds on dump trucks. Long pretty downhills with no breaks. I love it. It really helps if you can run one handed. Makes going down the ladder easier when you have a free hand.
I had to weld half inch carbon sheets together recently and my foreman had me use this process. I had never used it before. Itâs hot hot hot. Gets bright after a couple hours. But itâs really quick and clean.
Cheers Bob from Aussie Land. I also have to maintain a slight oscillation in my welds to control my timing and weld pool size. Especially when I do a 10 -12 hr shift working in heavy Fabrication on large earth moving buckets, with all the heat coming off the job and the noise all around me I go into zombie mode. So the back / forth technique, which is automatic for me keeps everything under -control. (Duel shield Flux cored 1.6 mm in spray mode 28 - 30 Volts / 300 - 340 Amps multiple pass's). P.S. I found having about 20 mm stick out gives an excellent result ; it allows for any oil on the wire (from manufacture) to burn off, and not end up in the weld.
Mig sprayweld is just high voltage with its respective wire speed. If youre experienced you set this up by ear...and do the drag or zig forward zig backwards...kinda like welding fluxcore
I'm looking to go to school or join a union soon to start my welding career and this is like speaking another language. Didn't know there was so much involved with welding. Awesome channel. So much info!
I'm a total uneducated/self-taught welder, this is the setting that I've discovered I love! I use this doing even sheet metal rust repair and such. It helps tack stack technique make a nice really well penetrated weld that doesn't have a huge bead to grind off. I even used this to weld up a differential using my little 110v mig. I was able to just crank multiple passes into it no problem.
Think you could be talking about dip transfer, spray is used for heavy fabrication not thin sheet, having worked on 22gauge and 6" thick plate it's totally different.
So, thats what its called. Been doin it for decades and everyone said i was ding it wrong because it didnt sound ilke bacon, till i showed them the penetration! Lots of time in automotive sheet metal but when i had to do thick stuff i figured it out and practiced. Just didnt know i was "spray welding"! Love the videos, thanks.
Robert Dinicola you canât spray with C25 gas 75/25 you really need 90/10 or around there. So if you are using short circuit gas it wonât spray youâre setting are just off and you got good off it. Or maybe you are if you have the right gas
Welding Junkie 75 25 just slow wire and biggest amps and burn it in. Had good results and sounds the same. Usually break out the stick for it but for small non critical stuff just get it deep
Hi Bob could you do some technical non welding stuff such as setting up manifold systems for delivery of gases in various ratio's for mig and tig workshop/bench welding
We roll all our pipe in our shop and spray all the hot, filler and cover passes. We can spray down to 3" schedule 40 with 035. wire. We usually stay with the .035 wire for most pipe sizes unless we are getting into the bigger stuff like 24 or 30 inch pipe.
I remember when I first started 10 years ago I had a hobart Ironman 230 and every now and then it would go globular and with no experience I always thought I was doing something wrong. Very funny looking back now.
Sir. I ran across this video and I love spray transfer. I am also surprised at the amount of people that don't know about this prosses. If you would try something when I was in school we had a military trailer factory near us and they came and demonstrated a vertical up with spray. The trick is to trigger on counts, but not let the puddle cool completely before triggering you count again. I know that it works because I passed multiple 3/8 bend test with this technique. Thanks
I use to build roll away dumpsters and did 50 feet of overhead fillet welds on each can. It's easy after you're use to the spray. And I'd run a 4 foot weld on a vertical wall downhill in one pass.
*kek Making truck parts and truck accessory, I"d set a miller 350P to 666 wfs and 27.5v make some nice weaves and freak out the few hoodlums from Puerto Rico. would play with the pulse mode sometimes. you set the length and width of the arc, and the on/off time (off being a "still lit arc" but 50% less heat) fun to play with, but without any prior arc time, in a production shop, was hard to figure out the right setting for a range of thicknesses on A32 mild and 309 stainless .045 and .035 respectfully .
@@PaganiniPagani Iâd take that if you knew what you were talking about lol A fast, and easy google search would prove you wrong. Go get educated, bud
@@manmangaming407 Maybe for stainless, but for most mild steels, 80/20 or 85/15 would suffice, at a lesser cost than tri-mix. Not every tri-mix is good for carbon steel. Tri-mix 66/26.5/7.5 will do spray transfer on carbon, and low-alloy steels, and is good for dirty material. Spray can be achieved with more than just tri-mix, at a lower cost. A lot of shops opt for metal-core over solidwire because itâs can mimic spray-transfer to an extent, if settings are correct, and it still needs at least an 80/20 mix to support the heat required to achieve a spray-like transfer, even then metal-core can produce spatter.
Wanted to add this, even though it's a year later. In spray the arc *shouldn't* go out as it does in short-circuit. That's also one of the reasons it resembles tig, much like the tungsten always keeping that arc lit. Even when watching a welder run short circuit, if you look at the walls/surroundings around them you'll see a slight flicker. In spray it's a constant stream of light, just like TIG welding. I'm just pointing that out, I suspect you already know this!
Kindly note a minor mistske: on the 2nd run once the wire put into the center of puddle - there is a splash. Avoid it by keeping wire in the forward quarter of tbe puddle.
For those of us who went to public school, it really helps if you put those setups on the screen. It's a lot easier to take in if I can see it while you're talking.
Mr. Moffatt, What a great amount of information. I watch each video at least 10 times and take notes. This took two 5X8 cards front and back for future reference. I did purchase a 235 ic and one detail that I did not pick up was the CFH on the gas regulation for Spray process. Maybe someone can help with this. This was so much great information. I just registered for Fabteck Atlanta and paid for my room and flights. Excited. Let us know your schedule one day. It would be an honor take a minute of your time and meet you, sir.
You neglected to mention that you need a minimum of 80% Argon in your gas mixture to achieve spray transfer. I think that it's a very important tip to note. I can't count the amount of videos I have seen demonstrating "spray" transfer with 75/25 argon/CO2. If you don't have a minimum of 80% argon, then it's just globular transfer with very high settings.
We use 92/8 and you can start to get the spray transfer at around 23 to 24 volts. Our parameters allow 24-28 volts and 180-250 amps. Its pretty strict and honestly 90/10 may do better.
New to this. Could you explain why 80% minimum? Wondering whether the dark deposit on the weld was the CO2 dissociating, the O2 burning some metal and the C turning into the dark deposit?
Hello Bob, thanks for your time and effort! Could you please ask camera dude to share some more insides on his set up for filming the welding process. Please.
I run 85/15 - 300/525. I canât find anyone who runs as hot as we do when it comes to spray. We fabricate and weld out riggers for cranes. I also use .045
CAT does. Used to work for their work tools facility in KS and most guys ran about that if not slightly hotter. I personally liked it about that hot with less wire feed. The metals were so thick with so much rust that you basically had to run that hot.
working for eb and everything yall do is diffrent than whats accepitable there in terms of welds. been here 2 months idk how i feel about it. im gonna try my luck at the union
Good stuff there, Bob! I use almost the exact same consumable setup for my work. 92/08 gas, I run .035-.045 70 s-6 wire.... Same rough stickout. Difference is, I program robots to lay em down for me. (I do them manually as well.) Very happy to see I'm doing it right!
i've been having such a hard time at work, for the past 2 weeks ive been trying to play with the settings, im using a miller cp302 with an older 60 series wire feeder, running providence .045 er70s6 and 90/10 gas. the only time ive been able to achieve a spray arc transfer is at 350 inches a minute and 32 volts with a 1'' stickout and it works good for 1/4'' and up but i work for a company called blueline manufacturing in washington and i manufacture agricultural equipment and sometimes we have gaps and each weld is different, every other weld is a different position from a open gap vertical down to a flat fillet to a vertical down fillet to a T joint to a butt joint to overhead to a vertical down butt weld. On 1/4'' square tube i have been able to do spray arc at 32 volts and 350'' a minute with ,045 er70s6 but for verticle down and overhead butt joints it drips too much, even at 24 volts and 315 inches per minute with short circuit it was too much and too runny, for verticle down, overhead and tight horizontal welds i have been running short circuit at 22.5 volts and 300 inches per minute and works great but for some vertical and flat positions i want to run very hot and for the 1/2'' to 1'' plate and 1-1/4'' plates i want to do spray and the only time ive been able to achieve it is at a minimum of 32 volts and 350'' per minute and higher, at 300'' per minute and 27 volts i can do globular transfer but its such a mess and im trying to achieve spray arc at 26 to 27 volts but im having a hard time trying to get my wire feed settings dialed in, my welder goes up to 450 amps and the wirefeed maxes at 700 inches a minute, at 350 wire feed speed and 32 to 33 volts i can achieve a spray arc, at 300 inches a minute and between 26.5 to 28 volts i can achieve a globular transfer, im wondering when i get to globular and i want to achieve a spray arc do i increase my voltage or do i decrease it??? at 300 inches a minute and 27 volts i am at globular transfer and if i increase it, it becomes a short arc tranfer, even at 375 inches per minute and at 27.5 volts and a 3/4'' to 1'' stickout even down to a 1/2'' stickout still is at a short circuit range, im having such a difficult time and its driving me insane and i am completely lost and have been getting extremely frustrated, i contacted miller 2 days ago and still havent recieved any answers and i would like to know at 300 inches per minute and at 27 volts i am at a globular transfer, i want to be at 27 volts and at a spray arc transfer, if i am at a globular transfer at 27 volts and 300'' per minute should i increase or decrease my wire feed speed to achieve a spray transfer?? im really lost, frustrated and i could really really really use some advice please please please, this is driving me absolutely crazy and im losing hours and hours of sleep each night over it and i stress so much throughout the day trying to figure it out, if anyone at all can help me please i beg of you for some advice, this has been an ongoing struggle and i dont know what to do next, i have a good ground by the way directly to the part and the material is nice, clean and no oil or contaminants or mill scale what so ever, perfectly clean metal with a good solid ground and am still having trouble
Bob, I am a TOTAL MIG beginner trying to learn to weld my project, joining 3/16 to 1/4 fillet welds with .035 5386 wire. I have a Lincoln mig pak 140 multi purpose 110 volt machine. Please do a video on small machines doing aluminum. I have a spool gun K4360-1. Regards Billy Graham
May I suggest calling it axial spray transfer? Just to avoid confusion with pulse spray. Not that I know as much as you do, just my understanding of nomenclature. Good video!
Iâve never been able to run it down. It just drops. But maybe you were running a lot cooler? When I use spray transfer it usually 28-350 or 29/30- 450
In the motion of your welding, is the arc momentarily short circuiting, as I can hear the crackle on the backward motion? Thanks. Man, I wish I had your demeanor when teaching, so practical, straight forward which reduces anxiety.
Running downhill passes arent bad, just cant tarry, let it dig, slight up angle on the wire, jam it in and szzzztt, downhill in a hurry, 95/5 at about 40cfh(worlkng in fan breezes). .035 on a miller 302.
This is a great series and great camera work. I've always had a tough time understanding the three phases of MiG welding and the transition points especially in the spray mode seeing that my machine is not powerful enough to do it. Watching this series is letting it really sink in for me. What would your minimum recommendation be for buying a new Mig welder that is capable of spray welding? Not talking about manufacturer brand just amperage and voltage requirements. Thank you
Please show more videos using the everlast pulse mig. I am very interested in the capabilities of those welders. They have some really great features. thanks.
I work for the military/government and I had to make a trip to Massachusetts and thats all they wanted someone to do was spray overhead! Gotta know what youre doing!
Yes I missed that and I know the sound real well I've spent many many hours under the hood spray arc One thing you didn't say is that I used a number 13 shield because when you spray Ark. It is Ho bright and it is hot For me with my eyesight the number 13 with a cheater lens I can actually see it spray The wire was 0 45 75 25 flux core 1" plate with multiple passes
Great video but would like to add to it here I weld spray everyday with my fronius synergetic 5000 and I weld fillet horizontal overhead vertical and down hill with no problems normally running 1.2mm 316 Lsi wire
I use 90/10 for my spray. My HTP Pro Pulse 200 will Weld it out nicely. I can decide if I want to pulse spray or just spray as well. It seems to really like that gas. Itâs synergic so the arc is amazing. Have you ever checked out the HTP machines made by Stel Bob?
Please do a video on MiG and all the different gasses. Co2 and 90/10. Is there a reason to use one over the other on heaver plate. 1/8 to 1/2 is normally what I use, with a 200 amp miller. Thank you in advance for straightening out my bad habits!
The start and stop popping for me on my 1976 Miller 200. What the tension was too tight on the spool of wire. It should be just enough to keep the spool of wire from unwinding.â
Hello Bob Question: is it possible to do spray transfer with 75/25 gas if the machine can dial up hot enough? Or is spray transfer only possible when using 95/5 gas for example. Just wondering how much the type of gas used effects if spray can be achieved or not? Thanks for your educational videos Bob, much appreciated.
I spray metal core using 85a/c15. The reason explained to me was c20 is the minimum amount where the transition from globular to spray occurs while still having the penetration profile of the higher c02.
Hello Bob, I enjoy your presentations on mig welding. I have owned a 180A. Lincoln buzz box for over fifty years that has been used for farm repair and fabrication with 6013 rod for most jobs. A couple years ago I picked up an SP-250 to build a round bale trailer. I have been able to get decent looking beads that lay on top with no penetration to speak of. Back to the buzz box. The machine has .045 wire. I believe the gas is 25/75. Most of the work is A36. Should I sell or trade it for a stick/tig ac-dc machine. There have been times that it is close to getting adjusted with a sledgehammer. Any ideas? Thank you for listening to my frustrations. Do you have a couch Doc?
Bob thanks for the videos, I'm learning to weld on my own, can't afford or have the time for a course, I'm not very good but I'm getting better. I'm using Hobart 140 with gas. Sometimes when I start the weld the wire hits the metal and pushes back slightly and then the arc starts. I've tried many things to rectify this issue but have had no success. Sometimes the start is perfect and sometimes it's terrible, why?
Could be a non-conductive deposit on the end of the wire? Does it happen when you start with a clipped-off wire end? Loose connection somewhere? Check all your connections.
It might be possible, basically for each wire diameter, there is an amperage threshold that must be exceeded, and you must supply enough arc voltage as well. Not to mention you still need an argon-rich mixture like 90/10, or better yet 92/8.
I'm a Rocker and it's not liked on a lot of jobs/tests, trouble is I've been doing it 36 years so I'm not stopping.
I think the sharp "pop" that occurs every so often during Bob's demonstration may be caused by an intermittent loss of grounding. Good grounding is extremely critical during spray transfer, wether it's welding with solid wire or cored wires. I deal with these issues constantly in the hard facing business, and I have found that the more contact points for grounding you can have between the lead and the work piece, the better off you will be. I use some old lead cable in between the ground clamp and the steel table when working on a table like Bob's, it really makes a big difference. Great video Bob keep them coming!!!
The kind of oscillating he is doing makes the wire almost touch the puddle, hence the "pops". Watch from 11:10
I do agree with you, when he does the rocking back motion, the wire does hang out in the puddle a little too long, which will create some disturbance.
To get rid of the "Pops," use a Rosebud & heat the work up first. Dry, clean steel makes for awesome looking welds.
Rick Reiff. uou are so right....I have been using the lead cable trick for many years and it really makes a difference.....
Would you recommend I hit my ground clamp at work with an abrasive and move clamp closer to my work piece to mitigate spatter?
I'm just starting out with spray. I have 4 year experience (pretty much self taught) with globular and short circuit. I've found that I prefer spray transfer. It's quieter and cleaner. Less spatter. I also use that Esab hood.
I just landed my first job working with spray too, I did a lotta short circuit and gas shielded flux core, I passed a 2g certification with pulse, pulse is nice too!! Especially since you can run it out of position more..seems like it wants to cut into any type of bevel though:/
This is the best welding channel I have seen on CZcams
I have run a spray arc downhill. Using a small percentage of oxygen in the gas. a tri-mixture. We would run downhill with the gun angled up, traveling fast, continuous 60 inch long beads, customer wanted no stops. 1/8 inch sheet, had to learn to walk down a ladder while running the bead. Anyway love the channel.
Welding going down a ladder is what I have to do running finish welds on dump trucks. Long pretty downhills with no breaks. I love it. It really helps if you can run one handed. Makes going down the ladder easier when you have a free hand.
New lenses are nice but I still tilt my head to drop my huntsman haha. Old submarine welder here, tx for the memories and good job!
I had to weld half inch carbon sheets together recently and my foreman had me use this process. I had never used it before. Itâs hot hot hot. Gets bright after a couple hours. But itâs really quick and clean.
Cheers Bob from Aussie Land. I also have to maintain a slight oscillation in my welds to control my timing and weld pool size. Especially when I do a 10 -12 hr shift working in heavy Fabrication on large earth moving buckets, with all the heat coming off the job and the noise all around me I go into zombie mode. So the back / forth technique, which is automatic for me keeps everything under -control. (Duel shield Flux cored 1.6 mm in spray mode 28 - 30 Volts / 300 - 340 Amps multiple pass's). P.S. I found having about 20 mm stick out gives an excellent result ; it allows for any oil on the wire (from manufacture) to burn off, and not end up in the weld.
Mig sprayweld is just high voltage with its respective wire speed. If youre experienced you set this up by ear...and do the drag or zig forward zig backwards...kinda like welding fluxcore
I love those tweco and Bernard mig guns,they don't feel like a toy gun mig guns.
I'm looking to go to school or join a union soon to start my welding career and this is like speaking another language. Didn't know there was so much involved with welding. Awesome channel. So much info!
Hey man. It's been 4 years. What are you up to?
I'm a total uneducated/self-taught welder, this is the setting that I've discovered I love! I use this doing even sheet metal rust repair and such. It helps tack stack technique make a nice really well penetrated weld that doesn't have a huge bead to grind off. I even used this to weld up a differential using my little 110v mig. I was able to just crank multiple passes into it no problem.
Spray transfer? On sheet metal?
Yeah of course you are lol
Think you could be talking about dip transfer, spray is used for heavy fabrication not thin sheet, having worked on 22gauge and 6" thick plate it's totally different.
At my work we have 75/25 argon,co2 and we spray all the time production is so fast ! I love it . Great vid bob!
I dont think you can actually move into spray transfer with 75/25. It may honestly just be globular with high settings.
@@justinhall8318 Crank up the voltage 5 or 6 volts on C25 and try it again ;)
So, thats what its called. Been doin it for decades and everyone said i was ding it wrong because it didnt sound ilke bacon, till i showed them the penetration! Lots of time in automotive sheet metal but when i had to do thick stuff i figured it out and practiced. Just didnt know i was "spray welding"! Love the videos, thanks.
Robert Dinicola you canât spray with C25 gas 75/25 you really need 90/10 or around there. So if you are using short circuit gas it wonât spray youâre setting are just off and you got good off it. Or maybe you are if you have the right gas
Welding Junkie 75 25 just slow wire and biggest amps and burn it in. Had good results and sounds the same. Usually break out the stick for it but for small non critical stuff just get it deep
Hi Bob could you do some technical non welding stuff such as setting up manifold systems for delivery of gases in various ratio's for mig and tig workshop/bench welding
We roll all our pipe in our shop and spray all the hot, filler and cover passes. We can spray down to 3" schedule 40 with 035. wire.
We usually stay with the .035 wire for most pipe sizes unless we are getting into the bigger stuff like 24 or 30 inch pipe.
Spray welding sounds interesting. I might try this with my Everlast welder.
Thumbs up to the "camera guy", even though he catches hell for breathing, or beats you playing golf.
Only way the camera guy wins at golf is if he edits the film of us playing...... Which he is very good at.
I remember when I first started 10 years ago I had a hobart Ironman 230 and every now and then it would go globular and with no experience I always thought I was doing something wrong. Very funny looking back now.
I75
I absolutely love the sound of a MIG torch.
Sir. I ran across this video and I love spray transfer. I am also surprised at the amount of people that don't know about this prosses. If you would try something when I was in school we had a military trailer factory near us and they came and demonstrated a vertical up with spray. The trick is to trigger on counts, but not let the puddle cool completely before triggering you count again. I know that it works because I passed multiple 3/8 bend test with this technique. Thanks
That's awesome. I do the rocking thing. I agree with you. Plus it makes it look a little better.
I've done spray transfer overhead, if you weld right into a bevel it sucks it right in and looks just as good as if you did it flat.
Now THIS is welding. Looks easy, but it's being done by a pro. Thank you...
Spray and pulse are easy just point and shoot fast
I use to build roll away dumpsters and did 50 feet of overhead fillet welds on each can. It's easy after you're use to the spray. And I'd run a 4 foot weld on a vertical wall downhill in one pass.
*kek Making truck parts and truck accessory, I"d set a miller 350P to 666 wfs and 27.5v make some nice weaves and freak out the few hoodlums from Puerto Rico. would play with the pulse mode sometimes. you set the length and width of the arc, and the on/off time (off being a "still lit arc" but 50% less heat) fun to play with, but without any prior arc time, in a production shop, was hard to figure out the right setting for a range of thicknesses on A32 mild and 309 stainless .045 and .035 respectfully .
As long as you use .045 solidwire, and an argon rich mix of at least 80/20, you'll be able to achieve spray arc with proper settings.
Bullcrap home boy. Threemixed gas only for spray welding.
@@PaganiniPagani Iâd take that if you knew what you were talking about lol
A fast, and easy google search would prove you wrong. Go get educated, bud
In school my teachers always said a tri mix is best but argon rich gas will work too.
@@evanp9146 and I did it with 0.35 solid core wire at 25 volts and 430 ipm
@@manmangaming407 Maybe for stainless, but for most mild steels, 80/20 or 85/15 would suffice, at a lesser cost than tri-mix. Not every tri-mix is good for carbon steel. Tri-mix 66/26.5/7.5 will do spray transfer on carbon, and low-alloy steels, and is good for dirty material.
Spray can be achieved with more than just tri-mix, at a lower cost.
A lot of shops opt for metal-core over solidwire because itâs can mimic spray-transfer to an extent, if settings are correct, and it still needs at least an 80/20 mix to support the heat required to achieve a spray-like transfer, even then metal-core can produce spatter.
Bob, the arc shots looked like TIG. The sharp wire, the flame front. All reminded me of TIG on steroids.
SATAMAN Schmidt I thought the same exact thing. The puddle looks really similar
Wanted to add this, even though it's a year later. In spray the arc *shouldn't* go out as it does in short-circuit. That's also one of the reasons it resembles tig, much like the tungsten always keeping that arc lit. Even when watching a welder run short circuit, if you look at the walls/surroundings around them you'll see a slight flicker. In spray it's a constant stream of light, just like TIG welding.
I'm just pointing that out, I suspect you already know this!
Kindly note a minor mistske: on the 2nd run once the wire put into the center of puddle - there is a splash. Avoid it by keeping wire in the forward quarter of tbe puddle.
it was a grounding issue
For those of us who went to public school, it really helps if you put those setups on the screen. It's a lot easier to take in if I can see it while you're talking.
try 500 amps 28 V and 50 induction very smooth weld
i run a Fronius welding system, it operates a bit differently than a CV unit, however it is a fantastic machine.
Mr. Moffatt, What a great amount of information. I watch each video at least 10 times and take notes. This took two 5X8 cards front and back for future reference. I did purchase a 235 ic and one detail that I did not pick up was the CFH on the gas regulation for Spray process. Maybe someone can help with this. This was so much great information. I just registered for Fabteck Atlanta and paid for my room and flights. Excited. Let us know your schedule one day. It would be an honor take a minute of your time and meet you, sir.
I like to run about 30-35 CFH for spray. It kind of depends on nozzle diameter.
Bob Moffatt thank you sir for taking your valuable time to answer me.
You neglected to mention that you need a minimum of 80% Argon in your gas mixture to achieve spray transfer. I think that it's a very important tip to note. I can't count the amount of videos I have seen demonstrating "spray" transfer with 75/25 argon/CO2. If you don't have a minimum of 80% argon, then it's just globular transfer with very high settings.
Iain Scott even 80% is very difficult only in high amps 90/10 works best
Thank you Soo much for that info. Basically the major reason I was watching this video was for which gas helps the transfer go into spray
Can I use 100% Argon ?
We use 92/8 and you can start to get the spray transfer at around 23 to 24 volts. Our parameters allow 24-28 volts and 180-250 amps. Its pretty strict and honestly 90/10 may do better.
New to this. Could you explain why 80% minimum?
Wondering whether the dark deposit on the weld was the CO2 dissociating, the O2 burning some metal and the C turning into the dark deposit?
Welding is an art form
Hello Bob, thanks for your time and effort! Could you please ask camera dude to share some more insides on his set up for filming the welding process. Please.
We're using it in a clean water tank to reduce hexchrome. Our ss is too thin to run it effectively tho i think. Great info boss.đđ
Miss you Bob hope all is well đ
I run 85/15 - 300/525. I canât find anyone who runs as hot as we do when it comes to spray. We fabricate and weld out riggers for cranes.
I also use .045
CAT does. Used to work for their work tools facility in KS and most guys ran about that if not slightly hotter. I personally liked it about that hot with less wire feed. The metals were so thick with so much rust that you basically had to run that hot.
working for eb and everything yall do is diffrent than whats accepitable there in terms of welds. been here 2 months idk how i feel about it. im gonna try my luck at the union
I love MiG spray transfer đ
Damn, Bob, I could listen to you talk about this stuff all day. Thanks for making the videos.
Gabriel Schleder we almost have the same last name
Bob you make me want the Rebel. Great advertisment. Good to see you budd.
Good stuff there, Bob! I use almost the exact same consumable setup for my work. 92/08 gas, I run .035-.045 70 s-6 wire.... Same rough stickout. Difference is, I program robots to lay em down for me. (I do them manually as well.) Very happy to see I'm doing it right!
Try spray arc vertical downhill on thin gauge mild steal
i've been having such a hard time at work, for the past 2 weeks ive been trying to play with the settings, im using a miller cp302 with an older 60 series wire feeder, running providence .045 er70s6 and 90/10 gas. the only time ive been able to achieve a spray arc transfer is at 350 inches a minute and 32 volts with a 1'' stickout and it works good for 1/4'' and up but i work for a company called blueline manufacturing in washington and i manufacture agricultural equipment and sometimes we have gaps and each weld is different, every other weld is a different position from a open gap vertical down to a flat fillet to a vertical down fillet to a T joint to a butt joint to overhead to a vertical down butt weld. On 1/4'' square tube i have been able to do spray arc at 32 volts and 350'' a minute with ,045 er70s6 but for verticle down and overhead butt joints it drips too much, even at 24 volts and 315 inches per minute with short circuit it was too much and too runny, for verticle down, overhead and tight horizontal welds i have been running short circuit at 22.5 volts and 300 inches per minute and works great but for some vertical and flat positions i want to run very hot and for the 1/2'' to 1'' plate and 1-1/4'' plates i want to do spray and the only time ive been able to achieve it is at a minimum of 32 volts and 350'' per minute and higher, at 300'' per minute and 27 volts i can do globular transfer but its such a mess and im trying to achieve spray arc at 26 to 27 volts but im having a hard time trying to get my wire feed settings dialed in, my welder goes up to 450 amps and the wirefeed maxes at 700 inches a minute, at 350 wire feed speed and 32 to 33 volts i can achieve a spray arc, at 300 inches a minute and between 26.5 to 28 volts i can achieve a globular transfer, im wondering when i get to globular and i want to achieve a spray arc do i increase my voltage or do i decrease it??? at 300 inches a minute and 27 volts i am at globular transfer and if i increase it, it becomes a short arc tranfer, even at 375 inches per minute and at 27.5 volts and a 3/4'' to 1'' stickout even down to a 1/2'' stickout still is at a short circuit range, im having such a difficult time and its driving me insane and i am completely lost and have been getting extremely frustrated, i contacted miller 2 days ago and still havent recieved any answers and i would like to know at 300 inches per minute and at 27 volts i am at a globular transfer, i want to be at 27 volts and at a spray arc transfer, if i am at a globular transfer at 27 volts and 300'' per minute should i increase or decrease my wire feed speed to achieve a spray transfer?? im really lost, frustrated and i could really really really use some advice please please please, this is driving me absolutely crazy and im losing hours and hours of sleep each night over it and i stress so much throughout the day trying to figure it out, if anyone at all can help me please i beg of you for some advice, this has been an ongoing struggle and i dont know what to do next, i have a good ground by the way directly to the part and the material is nice, clean and no oil or contaminants or mill scale what so ever, perfectly clean metal with a good solid ground and am still having trouble
You need to turn your heat up. Spray takes more heat than globular. When practicing I would be running 28v with 035 wire.
that welding jacket is really cool
Brilliant! That last fillet weld sounded so smooth, great tutorial again........Thanks Bob!
I learned something today! Spray MIG huh. Seems comparable to a stick pipe weld, maybe even better.
It will be nice if include the explanation of purpose for each process & the setting for each type of gas. Good video.
Bob, I am a TOTAL MIG beginner trying to learn to weld my project, joining 3/16 to 1/4 fillet welds with .035 5386 wire. I have a Lincoln mig pak 140 multi purpose 110 volt machine. Please do a video on small machines doing aluminum. I have a spool gun K4360-1. Regards Billy Graham
I love spray arc welding!
Love the sound
I need more practice with my everlast welder and spray transfer. Good video.
May I suggest calling it axial spray transfer? Just to avoid confusion with pulse spray. Not that I know as much as you do, just my understanding of nomenclature. Good video!
Pulse Spray is definitely different! Its fun though!
I run this vertical down, and it turns out good, you have to keep your angle up a little, but it's possible.
Iâve never been able to run it down. It just drops. But maybe you were running a lot cooler? When I use spray transfer it usually 28-350 or 29/30- 450
Yes, you can do OH welds.
In the motion of your welding, is the arc momentarily short circuiting, as I can hear the crackle on the backward motion? Thanks. Man, I wish I had your demeanor when teaching, so practical, straight forward which reduces anxiety.
I love welding with this process, great video
Sure wish I could weld like that! Great video!
Running downhill passes arent bad, just cant tarry, let it dig, slight up angle on the wire, jam it in and szzzztt, downhill in a hurry, 95/5 at about 40cfh(worlkng in fan breezes). .035 on a miller 302.
True class act Bob! Great work to both you and camera guy!!
I want to do some aluminum welding with my Everlast welder. I've already got the spoolgun on order. I can't wait to try spray welding.
Excellent video!!
I really like the look of that rebel 235.
That looks like fun. I'm gonna attempt spray welding with my power imig.
This is a great series and great camera work. I've always had a tough time understanding the three phases of MiG welding and the transition points especially in the spray mode seeing that my machine is not powerful enough to do it. Watching this series is letting it really sink in for me. What would your minimum recommendation be for buying a new Mig welder that is capable of spray welding? Not talking about manufacturer brand just amperage and voltage requirements. Thank you
well if you still need an answer(doubtful) id go with something around 600 ipm and 30-28 volts, voltage is a more important factor here though.
Thanks for the reply. Went with the Millermatic 350P W/spool gun.
@@edwardkawecki8101 awesome, figured I'd say something if the question was still open, but glad nobody had to wait 3 years for an answer
Love your vids and its good to know you still get "frisky" great welds down under.
Iv done spray with metal core going downhill. Not ideal but its doable as long as it's not a structural weld
Please show more videos using the everlast pulse mig. I am very interested in the capabilities of those welders. They have some really great features. thanks.
Just really love your videos fella. Very informative and totally right on and correct. VF
That was cool, even though it was too hot for up hill, it was cool! Why was it popping like it was? Thank you for another excellent presentation.
Sparky Welder he said he had "lazy finger" i believe he inadvertently let off the trigger
Probably due to his rocking motion he shortens up the stick out n drops the wire into the puddle causing a brief second of short circuit
I bought a rebel 215ic because of you
Iâm sheet metal stainless. Thanks for the refresher broski.
They call the gas C-8 in our area. 92-8 argon /Co2.
You can def overhead spray!!!! Cause i do it all the time!!! No arguing with that comment bob!!!! Keep it up!!! Love these videos!!!
I work for the military/government and I had to make a trip to Massachusetts and thats all they wanted someone to do was spray overhead! Gotta know what youre doing!
What about vertical?
@@formeitwastuesday.1515 Runny liquid steel on a vertical surface... Well, it was there briefly...
Thanks Bob, I have yet to try this technique but have been wanting to try for some time. i think maybe, hope, you can teach an OLD DOG a new trick!
Pretty nice video itâs very informational and answered most my questions
Sweet welding jacket Bob!!
At my school they teach us only how to do a smooth weld with no motions loops or whips. I guess if you can do that well you can do anything.
Hello, great Video. Greetings from Austria đ
Hello Austria, Greetings from California!
Yes I missed that and I know the sound real well I've spent many many hours under the hood spray arc One thing you didn't say is that I used a number 13 shield because when you spray Ark. It is Ho bright and it is hot For me with my eyesight the number 13 with a cheater lens I can actually see it spray The wire was 0 45 75 25 flux core 1" plate with multiple passes
Bob you are an absolute rock star! Thank you for all your knowledge đ€
Great video but would like to add to it here I weld spray everyday with my fronius synergetic 5000 and I weld fillet horizontal overhead vertical and down hill with no problems normally running 1.2mm 316 Lsi wire
Is that a Transpulse Synergic 5000? If so, they're great machines aren't they!
Thank you, Bob. I always enjoy your videos, learn a lot.
I use 90/10 for my spray. My HTP Pro Pulse 200 will Weld it out nicely. I can decide if I want to pulse spray or just spray as well. It seems to really like that gas. Itâs synergic so the arc is amazing. Have you ever checked out the HTP machines made by Stel Bob?
Welding junket I have done spray welding and many other processes spray welding shou!of never undercut if monipulatin and travel speed is correct
Please do a video on MiG and all the different gasses. Co2 and 90/10. Is there a reason to use one over the other on heaver plate. 1/8 to 1/2 is normally what I use, with a 200 amp miller. Thank you in advance for straightening out my bad habits!
The start and stop popping for me on my 1976 Miller 200. What the tension was too tight on the spool of wire. It should be just enough to keep the spool of wire from unwinding.â
Thanks for all your videos Mr Moffatt. Thi
S has been very informative to choosing the Rebel...đȘđŒđȘđŒđđŒ
Thank you sir it's help me a lot spray arc is cool
Hello Bob
Question: is it possible to do spray transfer with 75/25 gas if the machine can dial up hot enough? Or is spray transfer only possible when using 95/5 gas for example. Just wondering how much the type of gas used effects if spray can be achieved or not? Thanks for your educational videos Bob, much appreciated.
I spray metal core using 85a/c15. The reason explained to me was c20 is the minimum amount where the transition from globular to spray occurs while still having the penetration profile of the higher c02.
Thank you so much you helped me to pass a test with your instructions keep it up
Could you do a video on vertical up spray arc?
Nothing better than spray mig in 4F!
Very good your explacation
Hello Bob,
I enjoy your presentations on mig welding. I have owned a 180A. Lincoln buzz box for over fifty years that has been used for farm repair and fabrication with 6013 rod for most jobs.
A couple years ago I picked up an SP-250 to build a round bale trailer. I have been able to get decent looking beads that lay on top with no penetration to speak of. Back to the buzz box. The machine has .045 wire. I believe the gas is 25/75. Most of the work is A36. Should I sell or trade it for a stick/tig ac-dc machine. There have been times that it is close to getting adjusted with a sledgehammer. Any ideas? Thank you for listening to my frustrations. Do you have a couch Doc?
thank you
Bob thanks for the videos, I'm learning to weld on my own, can't afford or have the time for a course, I'm not very good but I'm getting better. I'm using Hobart 140 with gas. Sometimes when I start the weld the wire hits the metal and pushes back slightly and then the arc starts. I've tried many things to rectify this issue but have had no success. Sometimes the start is perfect and sometimes it's terrible, why?
Greg austin ground problem, too much stick out, and itâs just like that some times lol
Could be a non-conductive deposit on the end of the wire? Does it happen when you start with a clipped-off wire end?
Loose connection somewhere? Check all your connections.
Bob Moffat goin' huntin' huntin' with his weldin' gun.
Is the ESAB rebel capable of pulsed spray .....canât find much info here in the uk
Could you approximate the spray process by using very small wire and maxing out the amperage and wire feed speed in a regular MIG welder?
It might be possible, basically for each wire diameter, there is an amperage threshold that must be exceeded, and you must supply enough arc voltage as well. Not to mention you still need an argon-rich mixture like 90/10, or better yet 92/8.
It's like the hardwire cousin to E7025 SMAW.
Thank you so much for this video and have a merry Christmas!!!