Most farmers may not realize that adjusting the volts, amps, and wire speed on wire welders can produce transfer modes fine-tuned to thick metal.
The limiting factor with globular or spray modes is they can only be used on “metal ⅛ inch thick and thicker and only when making flat and horizontal fillet welds,” says Lincoln Electric’s Karl Hoes.
- Globular transfer: Voltage, amperage, and feed speed are higher than the standard short circuit mode. This results in large globs of wire expelling off the end of the wire to enter the weld puddle. This mode provides deep penetrating welds on thick material, but it produces a lot of spatter.
- Spray arc transfer: The volts, amps, and wire speed are higher than in globular mode. It produces a stream of tiny molten droplets that spray across the arc from wire to metal. For true spray transfer, you’ll need to use argon-rich gas. Spray arc allows the use of large-diameter wire, so a lot of metal is deposited, and you get a great-looking bead. It can only be used on flat or horizontal fillet welds; its puddle is very fluid. Be sure to change your gun’s nozzle to a unit that is about 3 inches long or longer.
(Source – http://www.agriculture.com/machinery/tools/welding/choose-right-wire-weld-trsfer-mode_245-ar49401)