Spray Arc with the MM210

[HAWK]

To all,

I made mention of spray arc and explained it in the post "keeping things square". shane7207 is interested in the process and I believe he has a MM210. I recall a post or 2 regarding spray with this machine. Anybody out here want to tell us what gas mix you have found effective for spray transfer with this machine.

Please reply here and/or to the "keeping things square post" as this is where shane7207 originally posted.

Thank You

[Danny]

Hawk,

I ve tried 85 argon/ 15 Co2, 90 argon/ 10 co2, and 98 argon/ 2oxy. 98/2 by far produces the best results.

In spray transfer mode, the MM 210 is capable of producing single pass fillets on 1/4". To do this, I run the machine on tap #7 and around 62 to 65 on the wire speed. BTW, this is with an .035 E70S-6. With an .030 E70S-6 you still use tap #7 and about 80 to 82 on the wire speed. Ive had meters hooked up to my machine, and at these settings the machine is out putting around 205 amps and 24.5 to 25.2 volts. So, keep in mind that the MM 210 is a light duty spray transfer machine, because to produce spray you have to run the machine near its maximum output. So, a person needs to pace themselves so that duty cycle doesn t become an issue. Now, I realize that the duty cycle that Miller gives there machines is very conservative, because i ve done some pretty serious spray sessions with my machine, and the machine wasn t blowing warm air out of it. However, i am currently in the process of possibly stepping up to a MM 251 so that i am not so hard on my MM 210.I was just running a MM 251 yesterday with 90/10, and it had no problem producing a very high energy spray on 1/4" steel.

[HAWK]

Dan,

Thanks for the reply. Shane will be happy to hear that. Do you have any pictures of sprayed beads to post?

[Paul Seaman]

Seems that the hotter gasses are used for this, can it be done with the 75/25 mix on the mm210?

[HAWK]

pjseaman,

No. The MM210 maximum voltage output is arund 25 volts. It does not have enough voltage behind it to spray with 75/25. Also the 75/25 Ar/CO2 mix is not designed for spray. Add another 5% to 10% argon and it will be more suited to spray transfer. I have sprayed with 75/25, but your really must have the higher CV output to do it. It will start into the spray mode around 36-38 volts. One of the hotter gases is your best bet.

[KS2K]

Dan, what settings

What settings on your MM251 were you using to spray weld on the .250" stock ?

Thanks
Paul

[Danny]

Re: Dan, what settings

Originally posted by Paul
What settings on your MM251 were you using to spray weld on the .250" stock ?

Thanks
Paul

Paul, i wish i had a MM 251, I was just test driving one yseterday for a little bit. Anyway, to spray arc 1/4" steel with an .035 E70S-6 you need at least 400 to 420 IPM of wire- about 200 to 210 amps. The voltage requirement is going to depend on the spray gas mix that you choose to use. 98/2oxy will produce spray in the above IPM range at a load voltage of 24 to 25 volts. Now, the argon/co2 gas mixes are higher energy mixes so they require more voltage to produce a stable spray transfer- the more CO2 in the mix the higher the voltage.

Paul, I can t give you an exact answer to your question because I was just playing with machine, and was paying more attention to the arc quality then my actual weld results. About the only help that I can supply for now is with the wire speed meter reading about 420 , i had to set the voltage between 26 and 27 to produce a good spray with 90/10. Sorry i can t help more then this.

[Danny]

Originally posted by HAWK
Dan,

Thanks for the reply. Shane will be happy to hear that. Do you have any pictures of sprayed beads to post?

Hawk, here are a few example pictures of spray transfer welds with a MM 210.

[Danny]

example #2

[Danny]

final example.

[Paul Seaman]

Thanks all solid info I have done spray in school but with a lot more machine Invision 354mp Argon and Helium mix not sure what mix. I will be switching to a little hotter gas after this tank, it'll be nice to be able to push the mm210 if I need to, Don't do much heavy work mostly mild tube and Al tube and plate.

[shane7207]

thanks hawk and all others who replied to this post. as soon as i get a bottle of gas i'll give the spray arc method a try. i'll let you know how it goes. this forum is never short on good advice. once again, thanks for the help.

[cope]

Originally posted by HAWK
pjseaman,

No. The MM210 maximum voltage output is arund 25 volts. It does not have enough voltage behind it to spray with 75/25. Also the 75/25 Ar/CO2 mix is not designed for spray. Add another 5% to 10% argon and it will be more suited to spray transfer. I have sprayed with 75/25, but your really must have the higher CV output to do it. It will start into the spray mode around 36-38 volts. One of the hotter gases is your best bet.

Hawk-bang on. I tried to achieve spray using C25 in my PowCon and got really close but no cigar. I believe it will do spray at the top end but the Tweco #1 gun isn't going to hold up to the heat. I bought some 90/10 for spray and the gun will like it much better. I have toyed with the idea of switching to a Tweco #2 but I have lots of consumables; consumables for the #2 aren't as cheap or as easy to find on a Saturday. I will eventually make the change.

[JWELD]

Does my Vintage put out enough volts for a good spray??

[HAWK]

JWELD,

The Vintage is no longer a current offering for Miller. It is a pulsed GMAW all in one power source producing 200 amps at 60 percent and capable of welding 1/2" steel in a single pass. Yes, it will do spray arc just fine. I believe I would choose the 98% argon / 2% oxygen and that way you will have it if you decide to try a gas- shielded stainless wire. The Vintage will probably spray with 92% argon / 8% ccarbon dioxide, but the 98/2 will be hotter and a more versatile choice. My guess is your have access to roughly 28-30 volts with the Vintage power source.