When it is all wrong, ( like with lots of spatter etc.) it usually needs a little more voltage or current. Some smaller machines do not have the output capability to achieve spray transfer, but if you want to try a different gas mixture 95% Argon/ 5% O2 operates in spray transfer at around 155-160amps and 23-24V with an 0.035" wire. I think 85/15 may have too much CO2 for the machine you indicated. Good Luck!

@@nathanfarquharson9307 very valuable information! *high fives* 😊👍🏾

Nice video! I would like to see some videos on mig pulse like some of the newer everlast mig welders have. I'd love to use spray arc out of position or on thinner material. Would mig pulse help?

Yes James Johnson you can do multiple passes as well. I run 27 volts at 425 ipm. Which the company I work for doesn't want anything under 27 volts. But the answer is yes you can. Just make sure you run your bead at a good steady pace so you don't burn through or have any undercut on your previous welds.

Try a little back step with a slight pause after your forward movement. Also dont hold a 45° angle on the fillet. Relax to about 35°

You are correct technically it won't spray transfer with an 0.035" wire and 75/25. You were probably experiencing a controlled globular transfer. The way to tell is look at the size of the droplets as they are being transferred across the arc. In the conditions that you described the droplet is likely larger than the diameter o the wire. The AWS definition says something along the lines that spray transfer occurs when the droplet is equal to or less than the diameter of the wire. So when welding in spray transfer and you have reached the transition current the wire will start to become pointed and the droplets will be forced across the arc and not transferred by gravity. With all of that said, yes you can get a clean smooth weld with 75/25 in a "spray-like" transfer but it is typically too hot for most applications...and it isn't truly spray. That is how i understand it anyways.

@@nathanfarquharson9307 it took me a while but i managed to finally get a true spray on my machine a rebel 235 (EU version) on 0.8mm 0.030 wire on 26v and 12.8m wire feed.. its a fine balancing act as i found out lol but i have now to try get spray going correctly on 1.0mm/0.040 wire on 26v as that is my max.. gas played a huge part in my progress as i went from a 83 mix to 93 and that changed everything as far as spray stabilty goes

Max power to start, set wire speed from there. Bless the work piece with the cutting torch before hand.

You don’t need meters per minute, not being a prick but you need to pay attention to the silica that is deposited on the bead surface…… the colour ranges from very light caramel to dark brown and all the way to black….. you don’t want black, you want to be getting a caramel colour, more towards the light end of the range, that goes for both dip transfer (shirt circuit) and spray transfer… the colour gives you your temperature. As for voltage, you can’t get spray below 25 volt’s so just crank your machine to 3/4 of its maximum wire feed speed then set the bolts to around 30 volts, from there you can fine tune depending on the results…. The tip of the wire should be pointed, and the arc will be conical with an arc length, measured from the tip of the wire to the weld pool, of about 5mm….If that gap is say 10mm then you either need to increase wire speed or decrease the volts….. I jump from dip to spray depending on which weld I’m doing and I think I spray at around 13-14 meters a minute, .09 dis wire, argoshield gas and the volts are about 30-31 and that’s just a light bead….. play with the settings and have fun, try setting your machine up for dip just by listening to the sound it makes, should sound like bacon frying….. I shouldn’t have smoked that joint earlier!!!🤣🤣🤣🤣

..No...you need at least 80% Argon....90% is better...

Bulllshit....been there done that on a bet made in the shop yes you can !....but welding with 100% CO2 sucks. In any case you can spray transfer with any gas when you are running .045-.052 wire with a quality wire feed and Constant Voltage 400 amp or bigger machine running over 32 volts

@@dougankrum3328 What if I use flux cored wire instead of solid wire?

Nope it won’t spray it will run super hot short circuit. The argon gives the arc the ability to maintain spray.

@@Migman2020 I've run many rolls of wire in Spray-transfer....Miller-Matic 200...no actual voltmeter on that one, but 24-26+ volts and you need close to 175 amps with .035" solid wire...a little lower current with .030". I used 90% Argon, 8% C02, 2% Oxygen usually called "98-2" it is 90/8/2.......there is also 92/8 Argon-C02...and most every gas supplier has their own 'secret' mixes.. You will not get spray transfer with less than 80%+ argon...