Weld Process Training Cheat Sheet

Keep this in your tool box for future reference.

Spray Transfer
Open arc Requires a minimum current, voltage and specific gas mixture.
Greater than 220 amps Greater than 24 volts Greater than 80% Argon

Short Circuit Transfer

An Arc On, Arc Off Cycle Low current (Less than 220 amps) Low voltage (Less than 23 volts) 1 to 3 mm material Open arc

Globular Transfer
But short circuits erratically occur

Found between the high end of short circuit and the low end of spray.
With 0.035 wire, 175-220 amps, 22-25 volts. With 0.045 wire, 220-260 amps, 22-25 volts.

The most important thing to learn about this transfer mode is HOW TO AVOID IT.

Spray Transfer When should I use it?

Material 3mm or more Flat and Horizontal only
except vertical down on material under 5mm.

Short Circuit When should I use it?

Low current, Low voltage
Use on material 3 mm or less Use for welding Vertical up or Vertical down Use on gaps and open roots

Globular Transfer When should I use it?

Beneficial in bridging gaps on heavy material. Evident when the ball that forms on the tip of the wire is larger than the wire.
This large ball creates poor arc starts.

Caution - Poor fusion can result from

Horizontal fillet welds greater than 6mm. Manual welders using whipping or weaving techniques.

Never use on material over 5 mm (except vertical up).

Poor side wall fusion can occur.

Weld Spatter is the primary negative affect. AVOID GLOBULAR TRANSFER!

Limit single pass, horizontal welds to 8mm.

Mig Welding Parameters

The 2 primary welding controls
Voltage Control Wire Feed Speed (amp) Control

Mig Welding Parameters Weld Voltage Control

Short Circuit Transfer
16 to 21 volts

Mig Welding Parameters Wire Feed Speed Control

Short Circuit Transfer
0.030 dia. wire 35 to 410 ipm (Best - 240 ipm) 0.035 dia. wire35 to 450 ipm (Best - 210 ipm) 0.045 dia. wire 70 to 280 ipm (Best - 190 ipm

Spray Transfer
25 to 32 volts

Globular Transfer
22 to 25 volts Globular Transfer Generates Spatter!

Spray Transfer
0.035 dia. wire 450 to 650 ipm (Best - 575 ipm) 0.045 dia. wire 350 to 550 ipm (Best - 480 ipm) 0.052 dia. wire 250 to 450 ipm (Best - 300 ipm)

Mig Welding Parameters The Clock Method

View a traditional wire feed control like a clock with ten settings

Mig Welding Parameters The Clock Method

On average, Wire Feeders deliver 700 ipm
Traditional Feeders deliver 600 to 800 ipm

Mig Welding Parameters A Simple Check

Double check your Wire Feed Speed
Set your feeder at its highest speed setting. Pull the trigger for 6 seconds.
Insure the wire wont come in contact with the work.

Feeders usually operate within ten setting.

between 7 and 5 oclock 700 ipm 10 = 70 ipm each

12 oclock = the 5th setting

5 x 70 ipm = 350 ipm

Measure the amount of wire that came out in 6 seconds. Each clock position will increase Wire Feed Speed by the amount you measured.

Mig Welding Parameters

Dont just play-around with the buttons. Know your Voltage and Wire Feed Speed. Know your transfer mode, and why.

Mig Welding Parameters Remember The Clock Method

View a traditional wire feed control like a clock with ten settings Open arc

Globular Transfer
But short circuits erratically occur

Found between the high end of short circuit and the low end of spray.
With 0.035 wire, 175-220 amps, 22-25 volts. With 0.045 wire, 220-260 amps, 22-25 volts.

The most important thing to learn about this transfer mode is HOW TO AVOID IT.

To view this slide presentation and video in its entirety contact Paul W. Cameron Weld Engineer at 6163 or pcameron@crenlo.com This training is estimated to be 2 to 2 hrs in length.