What is Spray Arc Transfer in Welding?

Spray arc transfer is a mode of metal transfer across the arc where the molten metal droplets are smaller than the electrode diameter and are axially directed to the weld puddle. This mode of welding requires high voltage and amperage settings and a shielding gas of at least 80% argon. Spray arc transfer is used in welding applications where a high deposition rate is needed, such as in heavy equipment manufacturing.

While spray arc transfer has a higher deposition rate than other modes of welding, it is also more difficult to control. Because of the high heat input, spray arc transfer can cause distortion of the weld pool and lack of fusion if not done correctly.

Welders who are skilled in using spray arc transfer can produce high-quality welds that are strong and have a good appearance. However, it is important to note that this mode of welding is not suitable for all applications and should only be used by experienced welders.

How does spray transfer welding work?

In spray transfer welding, the electrode is held at a high voltage and amperage setting. This causes the arc to be unstable and results in a spray of small molten metal droplets. The shielding gas helps to direct the metal droplets towards the weld pool, where they will cool and solidify.

What are the advantages of spray transfer welding?

Spray transfer welding has a number of advantages over other modes of welding, including:

Higher deposition rate: Spray transfer welding can deposit metal at a rate of up to 10 times faster than other modes of welding. This makes it ideal for applications where a high deposition rate is needed, such as in heavy equipment manufacturing.
Stronger welds: The high heat input of spray transfer welding can result in stronger welds. – Good appearance: When done correctly, spray transfer welding can produce welds that have a good appearance.

What are the disadvantages of spray transfer welding?

There are also a few disadvantages to spray transfer welding, including:

Difficulty to control: The high heat input and unstable arc of spray transfer welding can make it difficult to control. This can result in welds that are of poor quality or lack fusion.
Not suitable for all applications: Because of the difficulty in control, spray transfer welding is not suitable for all applications. It should only be used by experienced welders in applications where a high deposition rate is needed.
High cost: The equipment needed for spray transfer welding can be expensive, and the process itself requires high voltage and amperage settings. This can make spray transfer welding a more costly option than other modes of welding.

Spray transfer welding voltage

The voltage and amperage settings for spray transfer welding are higher than for other modes of welding. The exact settings will depend on the materials being welded, the thickness of the materials, and the desired deposition rate.