Let's see your welds...

   / Let's see your welds... #41  
What is spray mig?
Here you go.
Mig Welding - Short Arc and Spray Transfer - Welding Resources and Tips


Man you guys are rough on ZTFab. Yes the subject always comes down to strength. But you have to consider the simple heading of this thread and ZTFab fit in. You also have to consider what different people do for a living as welders. As a pipe welder it is all based on strength and integrity. But as a fabricator it is also important to have knoledge of many things more that welding.
The thread is "Lets see your welds" thats all.

Chris
Sure didn't mean to be, he is very good! I do understand that is some cases, like automotive work people go for that look. I'd really like to hear a CWI opinion of his welds.



As I understand the MIG process difference between short circuit (globular transfer)and spray is more or less, you just keep cranking the amps till the wire no longer pulses. By pulses, I mean that this is where it contacts the weldment, melts the short wire section between the weldment and contact tip which turns to a molten globule that then transfer into the weld puddle due to polar attraction. In spray arc, the amps are so high that the wire becomes a constant arc and vaporizes into a spray that is transferred to the weld puddle which pretty much eliminates any possibility of cold lap and makes for a very smooth weld with very, very small ripples. Unfortunately, this is too many amps to run root passes with on open butt and without rolling it like a subarc, it is too hot to fill with. This then lead to the pulsed arc that can use higher current but still allow it to cool between pulses similar to the short circuit method (supposedly if you believe the hype from Miller and Lincoln)

Gary I think it's more of really cranking the volts up. I used C10, I understand with 98% Argon and 2% oxygen you don't need as many volts to hit spray arc.
 
   / Let's see your welds... #42  
What do you have to be moving, like 2" per second?
 
   / Let's see your welds... #43  
Well yes the settings on the machine is voltage adjustment, cranking it up make the machine run hotter which in reality it cranks up the amperage. You really only have about 30-60 volts with DC to play with and voltage really doesnt equate to melting wire, amperage does. One can carry 4000 volts on a hair thin wire if the amperage is low enough. I never did really understand the wiring of a mig where you increased the wire speed with amperage and amperage with voltage adjustment.
I dont claim to be really knowledgeable about wire feeders, although I have ran them a bit and like them for massive structural fill when you can crank them up to Max and let the smoke fly but for me welding is Stick and TIG. I will leave the MIG/FWAW/ SAW to the production shops and MIG to the beginner hobbist who likes to open the box the welder come in, plug it in, pull the trigger and claim to be a welder.
MIG machines that arent at least 220 volt cant put out the power to provide proper fusion on anything more than thin sheet metal. The welds may look good, BUT
 
   / Let's see your welds... #44  
What do you have to be moving, like 2" per second?
Yes spray is fast, but I'm not sure it is worth it for the long haul! I'd like to see a study on a 40-hour work week between spray, and flux core gas shielded wire.



The welds may look good, BUT
Yeah it's that BUT that bites people in the beeehind!;)
 
   / Let's see your welds... #45  
I never tried it with FCAW just cranking it up, but I suspect that it would be similar to to hot on a stickrod, just get a truckload of buckshot coming off it if ran too hot.
 
   / Let's see your welds... #46  
I recall hearing on weldingweb that that 3/16 or 1/4 inch 7024 will actually outweld 1/16 fluxcore, so it seems stick is still great for high production work.
 
   / Let's see your welds... #47  
I never tried it with FCAW just cranking it up, but I suspect that it would be similar to to hot on a stickrod, just get a truckload of buckshot coming off it if ran too hot.
Where I was going with the comparison between spray arc and flux core gas shielded was not spry with flux core, just plain old flux core. The spray arc is kind of a PITA. The metal has to be bright clean, and all the heat is hard on the contact tip, and even the gun. I'm sure you'll agree, just because something is fast, but if it is hard on the equipment, or the operator is always messing around with something, is it really worth it? Kind of like the tortuous and the hare.






I recall hearing on weldingweb that that 3/16 or 1/4 inch 7024 will actually outweld 1/16 fluxcore, so it seems stick is still great for high production work.

In certain situations I can see where 7024 will give flux core a run for it's money. Changing rods every few seconds can slow a man down, but on the other hand changing a roll of wire can really slow a man down. To get real production, it's all up to the man, the longer you can keep him under the hood, the better the production. If you have guys who can think of a million reasons not to be under the hood, then production is going to drop off.
 
   / Let's see your welds... #48  
Figured id try to keep the post going was expecting more pics guys. After checking out ZTs mig like tig welds, I was playing around a little tonight.

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   / Let's see your welds... #49  
I will try to post some more this weekend If I can. I like seeing the welds too.

James K0UA
 
   / Let's see your welds... #50  
As for pictures, I am afraid I dont have a long enough camera lens to reach my welding shop or the satellite surveillance permissives to access those who do. It is a little inconvenient to be 7000+ miles away and 2 days by commercial jet travel just to get home. Maybe I could get the CIA to zoom in on my shop for me and take a few photos and send them to me so I wond be so shop sick. I hope to be home in about 3 more weeks and then start looking at some projects.
 

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