Welding Tips and Tricks

Hi, I am starting to use Axial Spray transfer and have a couple questions that hopefully the good folks here can shed some light on. I am using a PowerMig 256 with .035 wire and 90/10 gas with 35-40CFH. When I look up the settings on Lincoln and Millers apps they point @ 400wfs and 25volts. In order for me to get Spray my settings are 370wfs and 27-28 volts. This seems like quite a bit higher in voltage. The material is 1/4 inch steel. Not sure if the voltage difference is because of the gas not being 98/2. But Lincoln's site specifies 90/10.

Thanks!!
John

Welcome to the forum John.

John,

When I do spray on stainless, it's usually 27V and 240 IPM for .035 wire. The gas is tri-mix [90%He, 7.5%Ar, 2.5%CO2].

Smooth as glass in a dead-flat position.

I'd expect similar from 90/10 on carbon.

Steve S

Thanks for the info Steve. looks like I am on the right track.

I have talked to a few gas suppliers in the past 90/10 they say is the breaking point for spray any lower and its really hard to transfer that being said they did say that 90/10 should transfer nice but the higher you go the easier it is to transfer such as 95/5 or a 98/2. How long have you had the bottle of 90/10? If you have had it to long one of the gas suppliers recommends unhooking it and putting the cap on and rolling it on its side across the floor to get the gas to mix back up, this was the case with a bottle of 75/25 I had, day and night difference.

Thanks Jason for the info. I just picked up the bottle few days back. Don't know how long it was sitting at LWS.
I will give it a try.

John,
Welcome to the forum! There are a few things that come to mind. First, those guides are recommended settings to get you started and in the correct current range not necessarily gospel. Also, I wouldn't be worried about 2 volt difference. Higher voltage will increase your arc length and make your bead profile wider and smoother and not necessarily increase your current or amps. Another thing is just because your machine says 27 volts does not mean that is what is actually coming out. I have seen quite a difference in what the display says and what is actually coming out of the machine, at leaset for current anyway.

I would also think that the diffenence you are seeing in voltage can in fact be that you are using 90/10 verses the 98/2 (oxygen). Again, nothing to worry about. It also can be just the way you prefer your arc to look like or weld bead appearance.

Point is, every machine is different and every welder likes his machine a little different as well.
-Jonathan

Thanks for the info Jonathan. It's greatly appecciated.

jpr4pitts wrote:Hi, I am starting to use Axial Spray transfer and have a couple questions that hopefully the good folks here can shed some light on. I am using a PowerMig 256 with .035 wire and 90/10 gas with 35-40CFH. When I look up the settings on Lincoln and Millers apps they point @ 400wfs and 25volts. In order for me to get Spray my settings are 370wfs and 27-28 volts. This seems like quite a bit higher in voltage. The material is 1/4 inch steel. Not sure if the voltage difference is because of the gas not being 98/2. But Lincoln's site specifies 90/10.

Thanks!!
John

Hi John, Welcome to the forum!
I'm confused by your OP....
Are you using 98/2 or 90/10?
Does Lincoln's data sheet specify 98/2 or 90/10 for the 400wfs/25volt setting?

regardless...."typically", the 98/2 will use a few volts less than 90/10 to get the same smooth(hissing sound not crackling bacon frying), spatter free, spray transfer.

and like Jonathon mentioned, the dial may not be reading the same voltage as the wire is seeing at the contact tip.(not many machines that I've checked have read dead on in both places due to the voltage loss in the length of the whip.)

CTWD has an effect on the voltage used also, so keep that in mind when using the datasheet for finding/setting the voltage.

CTWD is essentially the "R" in the math formula because the length of the stick out increases/decreases the amount of resistance..... (amps)I x (CTWD)R = E(volts)

Hi John,

Thanks, It’s been great getting all the feedback.
I am using 90/10 gas and looked up the settings on Lincoln & Miller’s welding calculators.
Miller’s showed .035 - 400-420wps - 24-25v. - 98/2 gas
Lincoln’s showed .035 - 390wps - 25v. - 90/10 gas
my CTWD is 3/4 inch.

So I understand now this is just a starting point and have to tweak to get that sweet spot.
Thanks again!

jpr4pitts wrote:Hi John,

Thanks, It’s been great getting all the feedback.
I am using 90/10 gas and looked up the settings on Lincoln & Miller’s welding calculators.
Miller’s showed .035 - 400-420wps - 24-25v. - 98/2 gas
Lincoln’s showed .035 - 390wps - 25v. - 90/10 gas
my CTWD is 3/4 inch.

So I understand now this is just a starting point and have to tweak to get that sweet spot.
Thanks again!

The starting point suggested by the electrode mfg is usually pretty close(at least in my experience) for their product.
If you are using Lincoln's product, use their data and visa versa. Believe it or not, but different electrodes from different mfgs, run slightly different from each other due to the mix of ingredients and the process of making the wire.

jwright650 wrote:

jpr4pitts wrote:Hi John,

Thanks, It’s been great getting all the feedback.
I am using 90/10 gas and looked up the settings on Lincoln & Miller’s welding calculators.
Miller’s showed .035 - 400-420wps - 24-25v. - 98/2 gas
Lincoln’s showed .035 - 390wps - 25v. - 90/10 gas
my CTWD is 3/4 inch.

So I understand now this is just a starting point and have to tweak to get that sweet spot.
Thanks again!

The starting point suggested by the electrode mfg is usually pretty close(at least in my experience) for their product.
If you are using Lincoln's product, use their data and visa versa. Believe it or not, but different electrodes from different mfgs, run slightly different from each other due to the mix of ingredients and the process of making the wire.

I can agree with that statement!
-Jonathan

Just wanted to give some follow up. Here are some picks of my spray transfer welds. Thanks for all the great feed back!!

Looks good. Soon you'll be ready to do miles and miles of it, down on your knees. I hate to think how far ive welded in the last 15 or so years.

Miles and miles, my friend.

Nice cut/etch examples.

Steve S