spray welding

[Iron man]

What can anyone here tell me about spray and pulse arc spray welding?
I understand that pulse arc is for thinner metal. but what is it in general and what if any special equipment do I need?

[JonnyTIG]

Spray welding offers the highest deposition rate of all GMAW process'. To spray weld, the voltage generally has to be around 30V or higher, for a solid wire. Steel vs. aluminum varries. Some gas mixtures help with the spray arc, but higher voltage can sometimes force the metal transfer into spray. Spray transfer is best suited for horizontal and flat welds, where high travel speeds and deposition can be used. Pulsed spray, allows the puddle to cool intermitantly and is used not only for controlling heat in thin sections but allows the use of the spray arc in the vertical and overhead positions. No special equipment is needed for regular spray, as long as the machine has the capacity to get up into the voltage range. Pulsed spray uses add-ons to existing equipment or equipment designed for pulsed MIG.

[Bert]

thanks Johnny,
someone said the MM251 isn't strong enough to spray. Do you know anyone that at least tried it?

[Danny]

thanks Johnny,
someone said the MM251 isn't strong enough to spray. Do you know anyone that at least tried it?

Bert Who ever told you that doesn't know what they're talking about. The MM 251 does real well in spray transfer mode with an .030 /.035 solid wire and 98/2 oxy or 90/10 CO² shielding gas.

Here's a sample with 98/2 and .035. Don't remember the settings anymore, I just remember I had unit turned way up beyond what it need to be for the 1/4" material the weld was being ran on. I was just messing around , checking out the level of power the unit was capable of outputting.

[fun4now]

FWIW;
the MM212/210 is also capable of getting into spray arc with the proper gas and setting it will also spray arc. so the MM251/252 is well into that area.

that shore is a nice looking bead.

[monte55]

Great weld!!!!!!!!

[Bert]

Danny,
THANK YOU SO MUCH!!! BEAUTIFUL!!!! I was a fool for not trying it for myself!!!!!!!!!!!!!!!!! GREAT JOB!!!!!!!!!!!!!!!!!!!

[Bert]

Also, I heard spray isn't just for thin stuff, it's also great for thicker material, as penetration is really good...comments?

[monte55]

I understand the 210 will spray also. Anybody here know? Also can you explain the gasses needed to spray other than just #'s......what is 98/2 etc.?

[dabar39]

monte55

98/2 is 98% argon and 2% co2

[monte55]

Post #4 is different than what you just said. Still confused.

[dabar39]

monte55

My bad! I started typing before I was done thinking. post 4 is correct argon/ oxygen mix. Sorry, Dave

[monte55]

Then is 90/10 correct being argon/co2 ?

[Danny]

I understand the 210 will spray also. Anybody here know? Also can you explain the gasses needed to spray other than just #'s......what is 98/2 etc.?

The MM 210 will spray arc an .030 solid wire real well, with a gas mixture of 98% argon / 2% oxygen, also known as 98/2. This is really about the only gas mixture worth try to use for spray transfer with a MM 210.


Understand though the 210 doesn't have the duty cycle to be a production unit in spray transfer mode. For home use, and farm repair work it works just fine.

[Danny]

Then is 90/10 correct being argon/co2 ?

Yeah, 90/10 is 90% argon / 10% CO²