What is Pulsed Spray Welding?

Pulsed spray welding is a variation of the arc welding process in which the current is pulsed to achieve spray metal transfer at average currents equal to or less than the globular to spray transition current.

Pulsed spray welding can be performed using either DC or AC power sources. When using a DC power source, the electrode is typically positive and the workpiece is negative. This reversal of polarity results in a more stable arc and improved weld quality. When using an AC power source, the electrode and workpiece are usually connected to opposite sides of the power source, resulting in a more unstable arc. However, AC power sources are often preferred for pulsed spray welding because they allow for higher welding currents and can be used with a wider range of electrode materials.

Pulsed spray welding is typically performed using a constant voltage power source. This provides good arc stability and helps to prevent weld defects such as porosity and slag inclusion. The welding current is typically set between 10-100 amps, depending on the thickness of the material being welded. The welding speed is typically kept low to minimize the heat input into the workpiece and prevent warping or distortion.

Pulsed spray welding can be used to weld a variety of metals, including carbon steel, stainless steel, aluminum, and copper. This process is frequently used in the automotive and aerospace industries for welding thin materials such as sheet metal and tubing. Pulsed spray welding can also be used for surfacing applications, such as hard-facing or build-up welding.

What is one of the main advantages of pulsed spray welding?

Pulsed spray welding is often used for welding thin materials, as it provides good weld penetration while minimizing the heat input into the workpiece.

What are the advantages of pulsed spray transfer?

Pulsed spray transfer provides good weld penetration while minimizing the heat input into the workpiece. This process is often used for welding thin materials.

What are the disadvantages of pulsed spray welding?

Pulsed spray welding can be more difficult to perform than other arc welding processes, and it may not be suitable for all applications. Additionally, this process is typically only used for welding metals that have a low melting point, such as:

aluminum
copper

Is Pulse MIG spray transfer?

Pulse MIG is a variation of the arc welding process in which the current is pulsed to achieve spray metal transfer at average currents equal to or less than the globular to spray transition current.