Spray Transfer Welding Settings Guide

Do you have loads of experience with spray transfer via a welder? If not, there is a high chance that you do not know the right way to handle the task. With this in mind, you might spend countless hours looking for the right settings that will get the job done.

One of the easiest ways of using spray transfer welding involves using a guide. So if even if you are a beginner welder, you should be able to use the instructions to whip out a decent weld within a short period.

In this post, we will be listing several spray transfer settings that can be used with welders. Luckily, these settings are comprehensive and can be used by anyone.

spray transfer welding settings

Spray Transfer Welding Settings Guide

Here are charts showing the wire speed and voltage speed settings required for spray transfer welding with a Miller welder. But before using these values, we suggest that you have a decent understanding of your preferred metal. Also, consider the amperage settings and the task at hand.

Spray Transfer Welding Settings Chart for Aluminium

Material Thickness Wire Size (mm) Volt Setting Amperage Range Wire Speed Shielding  Gas
3.2mm 0.035 21-22 110-130 350 – 400 Argon
4.8mm 0.035 23- 24 140-150 425 – 450 Argon
6 4mm 1.2 24 – 25 180-210 350-375 Argon
7.9mm 1.2 26-27 200 – 230 400 – 425 Argon
9.5mm 1.2 26-28 450-480 450 – 480 Argon
11.1mm 1.6 28~29 280 240 – 270 Argon
12.7mm 1.6 29-30 290-200 290 – 300 Argon
           

If you are working with different aluminum samples with varying thicknesses, you will have to use the right settings. For instance, a piece of aluminum with 3.2mm thickness is perfect with a volt setting of 21 – 22 while the wire speed stays on 350 – 400.

Spray Transfer Welding Settings Guide for Stainless Steel

Material Thickness Wire Size (mm) Volt Setting Amperage Range Wire Speed Shielding Gas
7.9mm 0.045  24-25 200 – 210 250-300 98% Argon/2% O2:
9.5mm 1.6 25-26 250-275 140 – 170 98% Argon/2% O2
11.1mm 1.6 26-27 275-300 170 – 200 98% Argon/2% O2
12.7mm 1.6 27-32 300-325 200 – 230 98% Argon/2% O2

Stainless steel is another metal that suits spray transfer welding. But instead of working with random figures, it would help if you selected a setting based on the thickness of the material. For example, 7.9mm thick stainless requires at least 25 volts and 250 wire speed.

Spray Transfer Settings Guide for Solid Wire Welding (Steel)

Material Thickness Wire Size (mm) Volt Setting Amperage Range Wire

Speed

Shielding Gas
3.2mm 0.9 23-24 160-170 320-340 98% Argon/2% O2
4.8mm 0.9 24-25 180 – 190 360 – 380 98% Argon/2% O2
1.1 24 – 25 180 – 190 185 – 195 98% Argon/2% O2
6.4mm 0.035 24 – 25 200-210 400- 420 98% Argon/2% O2
0.045 24-25 200 – 210 210 – 220 98% Argon/2% O2
7.9mm 0.035 25-26 220 420 – 450 98% Argon/2% O2
0.045 25-26 220 – 250 220 – 270 98% Argon/2% O2
9.5mm 0.045 23 – 24 300 375 98% Argon/2% O2
12.7mm 0.045 29 – 30 315 390 98% Argon/2% O2

As with most metals, you will have to spend a few minutes adjusting the settings on your welder, especially before the transfer. Supposing you are working with 12.7mm steel, you should leave the welder at 29 volts while the wire speed stays on 390. Then if you are using 9.5mm steel, then you should leave the welder at 375.

Spray Transfer Welding Settings Guide for Aluminium

  • 2mm material thickness: 21-22 volts, 350 – 400 (Wire Speed)
  • 8mm material thickness: 23 – 24 volts, 425-450 ( Wire Speed)
  • 4mm material thickness : 24 – 25 volts, 350 – 375 Wiire speed
  • 9mm material thickness: 26 – 27 volts, 425 Wire speed
  • 5 mm material thickness: 26 – 28 volts, 460 – 480 Wire Speed
  • 1 mm material thickness: 28~29 volts, 240 – 270 Wire Speed
  • 7 mm material thickness: 29-30 volts, 290-300 Wire Speed

Spray Transfer Welding Settings Guide for Stainless Steel

  • 9mm Material Thickness: 24-25 volts, 250 – 300 Wire Speed
  • 5mm Material Thickness: 25 – 26 volts, 140 – 170 Wire Speed
  • 1 Material Thickness: 26 – 27 volts, 170 – 200 Wire Speed
  • 7 Material Thickness: 27 – 32 volts, 200 – 230 Wire Speed

Spray Transfer Welding Settings Guide for Steel

  • 2mm Material Thickness: 23 – 24 volts, 320 – 340 Wire Speed
  • 8mm Material Thickness: 24 – 25 volts, 360 – 380 Wire Speed
  • 4mm Material Thickness: 24 – 25 volts, 400 – 420 Wire Speed or 220 – 270 Wire Speed
  • 9mm Material Thickness: 25 – 26 volts, 420 – 450 Wire Speed
  • 5mm Material Thickness: 23 – 24 volts, 375 Wire Speed
  • 7mm Material Thickness: 29 – 30 volts, 390 volts

What 3 conditions are required for the spray transfer process to occur?

Before you can get complete the spray transfer process, it would help if you completed the process under certain conditions. These three conditions include

  • DCEP Polarity
  • Argon Polarity
  • Current level above the transition level

What is the difference between spray transfer and globular transfer?

Spray Transfer involves the transfer of axial non-spatter droplets via argon-filled gas while globular transfer transfers globules of molten electrodes via gravity.

Spray Transfer Welding Gas

As you try spray transfer welding, make sure you use the right gas for the task. Normally, argon is the recommended gas for performing spray transfer welding. Even if it’s used in a mixture of gases, argon makes up for at least 80% of the mixture.

Disadvantages of Spray Transfer Welding

Spray Transfer welding might be a great idea. But due to the presence of a fluid weld puddle, you can only use this method in a flat position. Although this serves as a drawback, you might invest in machines that can handle the weld puddle.

Author

  • Danny Saunders

    Danny Saunders is a tech enthusiast. He enjoys getting his hands dirty with the features and settings of tech products and pushing them to their limits just to know how to get the best from them and how well they can endure "abuse" without breaking down. He shares his findings on this blog.