Understanding transfer modes for GMAW

Proper inductance and slope adjustments in short-circuit transfer mode help to ensure a flatter bead
appearance with less spatter.

The gas metal arc welding (GMAW) process uses four basic modes to transfer metal from the electrode to
the work piece. Each mode of transfer depends on the welding process, the welding power supply, and
the consumable, and each has its own distinct characteristics and applications.

Several variables dictate the type of transfer you use, including the amount and type of welding current,
the electrode chemistry, electrode surface, electrode diameter, shielding gas, and the contact tip-to-work
distance. Transfer mode also affects your choice of filler metal used.

Which mode is right for you? Choosing wisely can greatly affect your efficiencies and productivity.

Short-circuit Transfer

In short-circuit transfer; the electrode touches the work and short circuits, causing the metal to transfer
as a result of the short. This happens at a rate of 20 to more than 200 times per second.

The advantage of the short-circuit transfer is its low energy. This method is normally used on thin material
¼ inch or less, and for root passes on pipe with no backing. It can be used to weld in all positions.

This mode of transfer generally calls for smaller-diameter electrodes, such as 0.023 (0.58 mm), 0.030
(0.76 mm) , 0.035 (0.88 mm), 0.040 (1.0 mm), and 0.045 inch (1.14 mm).The welding current must be
sufficient to melt the electrode, but if it is excessive, it can cause a violent separation of the shorted
electrode, leading to excessive spatter.

Using adjustable slope and inductance controls can enhance the transfer to minimize spatter and
promote a flatter weld profile. Slope adjustment limits the short-circuit amperage, while inductance
adjustments control the time it takes to reach maximum amperage. Proper adjustment of these two
factors can produce excellent bead appearance and is essential for short-circuit transfer with stainless
steel electrodes.

The most predominant solid stainless steel electrodes are ER308L, ER309L, and ER316L. These electrodes
are also available in the Si type, such as 308LSi. The LSi types contain more silicon, which increases puddle
fluidity and helps the weld puddle to wet out better than the standard alloys. While minor power source
adjustments may be needed, both types can be used successfully as long as the specification for the
welding consumables permits.

For carbon steel electrodes, the electrode classification dictates the silicon level. ER70S-3 and ER70S-6
are the most widely used. For pipe applications, ER70S-2, ER70S-4, and ER70S-7 are sometimes used for
open-root work because they offer lower silicon levels.
The lower silicon produces a stiffer puddle and gives you more control of the back bead profile. In an
open-root weld, you may use an S-6 type electrode with less inductance than an S-2 type electrode
because the S-6 type has a higher level of silicon and the puddle is more fluid.

Maintaining a constant contact tip-to-work distance in short-circuit transfer is important to maintain a

smooth transfer.

The most common shielding gas for the short-circuit transfer mode for carbon steel electrodes is 75
percent argon/25 percent CO2. Numerous three-part shielding gas mixes are also available for carbon steel
and stainless steel for this mode of transfer.

Globular Transfer

Globular transfer means the weld metal transfers across the arc in large droplets, usually larger than the
diameter of the electrode being used. This mode of transfer generally is used on carbon steel only and uses
100 percent CO2 shielding gas. The method typically is used to weld in the flat and horizontal positions
because the droplet size is large and would be more difficult to control if used in the vertical and overhead
positions compared to the short-circuit arc transfer. This mode generates the most spatter; however,
when higher currents are used with CO2 shielding and a buried arc, spatter can be greatly reduced. You must
use caution with a buried arc because this can result in excessive reinforcement if travel speed isn't
controlled.

Stainless steel GMAW electrodes normally aren't used in this mode of transfer because their nickel and
chrome content (9 to 14 percent nickel and 19 to 23 percent chromium) creates a higher electrical
resistance than carbon steel electrodes. In addition to the electrical resistance differences, the use of 100
percent CO2 as a shielding gas could be detrimental to the corrosion resistance of the stainless steel
electrodes.

Carbon steel ER70S-3 and ER70S-6 generally are the electrodes of choice.

Spray Transfer Mode

Spray transfer is named for the spray of tiny molten droplets across the arc, similar to spray coming out of
a garden hose when the opening is restricted. Spray transfer usually is smaller than the diameter of the
wire and uses relatively high voltage and wire feed speeds or amperage. Unlike short-circuit transfer,
once the arc is established, it is on at all times. This method produces very little spatter and is most often
used on thick metals in the flat and horizontal positions .
 Shield Gas Transition Currents
Wire Diameter Shielding Gas Spray Arc Current (amps)
0.023 135
0.030 150
0.035 98% Ar/2% O2 165
0.045 220
0.062 275
0.035 155
0.045 95% Ar/5% O2 200
0.062 265
0.035 175
0.045 92% Ar/8% O2 225
0.062 290
0.035 180
0.045 85% Ar/15% CO2 240
0.062 295
0.035 (0.8 mm)
0.045 (0.8 mm) 195
80% Ar/20% CO2 255
0.062 (1.57 mm) 345

Spray transfer is achieved with high percentages of argon in the shielding gas, generally a minimum of 80
percent. Also called axial spray, this mode uses a current level above what is described as the transition
current. The transition current will vary depending on the electrode diameter, shielding gas mixture
percentages, and contact tip-to-work distance.

When the current level is higher than the transition current, the electrode transfers to the work in very
small droplets that can form and detach at the rate of several hundreds per second. Sufficient arc voltage
is required to ensure that these small droplets never touch the work, achieving a spatter-free weld. Spray
transfer also produces a fingerlike penetration profile.

This transfer mode is used mostly in the flat and horizontal positions because it produces a large weld
puddle. High deposition rates can be achieved compared to the other transfer modes. Because of the arc
length used, it is also more easily influenced by magnetic fields. If this is not controlled, penetration
profile, bead appearance, and spatter levels can be negatively affected.
The major factor in choosing a carbon steel electrode is sometimes the amount of silicate islands that
remain on the weld bead surface. This is especially the case if you need to minimize post weld cleaning
time or if the finished product will be painted.

For this reason, you might choose an ER70S-3, ER70S-4, or ER70S-7 electrode. With stainless steel
electrodes, there is little difference in the bead appearance in the Si types because of the higher energy
used in this mode of transfer.

The wetting action advantage of the Si types is not necessary, and if they are used it usually is a matter of
preference. The effect of the chemistry on the transition current is minimal, but a higher voltage may be
required with one alloy compared to another to achieve a true spray.

Pulse-Spray Transfer

In the pulse-spray transfer mode, the power supply cycles between a high spray transfer current and a
low background current. This allows for super cooling of the weld pool during the background cycle,
making it slightly different than a true spray transfer. Ideally, in each cycle one droplet transfers from the
electrode to the weld pool.

Because of the low background current, this mode of transfer can be used to weld out of position on thick
sections with higher energy than the short-circuit transfer, thus producing a higher average current and
improved side-wall fusion.

Additionally, it can be used to lower heat input and reduce distortion when high travel speeds are not
needed or cannot be achieved because of equipment or throughput limitations.

Generally, the same shielding gases used for spray transfer are also used for pulsed-spray mode.

The electrodes you can use include all the standard carbon steel and stainless steel types, along with
some of the specialty alloys such as INCONEL® (625), duplex (2209), and super duplex (2509). With a
programmable pulse power supply, most solid-wire alloys can be used with a customized pulse waveform.

With all modes of transfer, the wire type will have some effect on the machine settings. In addition, the
wire surface will affect the transfer. Manufacturers use different types of arc stabilizers on the wire
surface to enhance a smooth transfer. This is why small adjustments must be made when welding with
the same type of electrode from different manufacturers.

https://www.thefabricator.com/article/consumables/understanding-transfer-modes-for-gmaw
 Pulsed MIG Welding Improves Quality, Saves Money

Some of the latest technology power sources on the market today are those that provide pulsing
capabilities. Most likely, you have heard how these sophisticated machines make welding easier for the
operator and provide a high quality weld. But, did you know that these machines actually provide a cost
savings? Although you may pay a little more for these power sources initially, the advantages that they
provide will decrease overall welding costs and provide a payback of your investment in the long run.

Advantages provided by pulsing machines include:

Wire and gas savings

Pulsed MIG machines offer a wider operating range because they extend the low and high range of each
wire diameter. For instance, before the operator would have to stock .035”, .045” and .052” wire
diameters for varying applications, but with Pulsed MIG, .045” can be extended on the low end and top
end range so that it can be used for a variety of applications. What this means is that rather than having
two or three different sized wires, an operator would only require one. Having one wire type minimizes
inventory costs and reduces changeover times. The same is true with shielding gas – one gas can reach
both the low and high ranges of the application. In addition, the different types of spare parts (gun, gun
tips, liners, etc.) are decreased for additional cost savings.

Spatter and fume reduction

Compared to Conventional MIG, Pulsing offers reduced spatter and fume. Reduction in spatter
translates into significant cost savings because more of the melted wire is applied to the weld joint, not
as surface spatter on the product and surrounding fixtures. This also means less clean-up time. A
reduction in the welding fumes creates a safer and healthier environment for the entire plant or shop.

Heat reduction
Pulsing offers controlled heat input leading to less distortion and improved overall quality and
appearance which means fewer production problems. This is especially important with stainless, nickel
and other alloys that are sensitive to heat input.

Improved productivity
Pulsed MIG offers high deposition rates. In addition, since the new machines are simpler and adaptive,
it is easier to weld with pulsed MIG than other transfer methods, less time is spent training.

Better quality
All these advantages of Pulsed MIG outlined above result in overall better quality of the finished and a
more stable arc. In addition, operators are receiving a better quality working environment since they
are not dealing with fume, spatter and extra clean-up or grinding time. One more benefit is that
synergic power sources allow for these high quality welds to be achieved by those with relatively less
training.
What is Pulsed MIG?

In simple terms, pulsed MIG is a non-contact transfer method between the electrode and the weld
puddle. This means that at no time does the electrode ever touch the puddle. This is accomplished
through high-speed manipulation of the electrical output of the welding machine. It is designed to be a
spatterless process that will run at a lower heat input than spray or globular transfer methods.

The pulsed MIG process works by forming one droplet of molten metal at the end of the electrode per
pulse. Then, just the right amount of current is added to push that one droplet across the arc and into
the puddle. The transfer of these droplets occurs through the arc, one droplet per pulse.

To understand this process in detail, let’s take a look at a waveform. Unlike CV (constant voltage) where
current is represented by a straight line, pulsed MIG drops the current at times when extra power is not
needed, therefore cooling off the process. It is this “cooling off” period that allows pulsed MIG to weld
better on thin materials, control distortion and run at lower wire feed speeds.

During the process, the current rises to a peak when the droplet is formed. Then, in the background
current phase, the current is lowered to reduce the overall heat input. It is the height and the width of
the peak that is important for proper transfer.

Pulsed MIG Compared to Other Transfer Methods

How does pulsed MIG compare to other welding transfer modes? We will examine each with their
advantages and disadvantages.

Short Circuit
In short circuit, the wire touches the work piece and shorts to itself. This is the coldest form of welding
that still offers good fusion. Short circuit allows operators to weld on both thick and thin material in all
positions. It also has the benefit of a small, quickly solidifying puddle. Its disadvantages include limited
wire feed speed, and deposition rates. There is also a danger of “cold lapping” on thicker metals. This is
where there is not enough energy in the puddle to fuse properly. Short circuit also produces an
increased amount of spatter over the other transfer methods.

Globular
The globular transfer mode is basically uncontrolled short circuit. It is characterized by a large volume of
weld metal coming off the electrode. These large droplets are pinched at the arc and drop into the
puddle. This method of transfer produces a tremendous amount of spatter as well as high heat input.
Also, globular is limited to flat and horizontal fillet welds. Less fusion is often common because the
spatter disrupts the weld puddle. Also, because globular transfer uses more wire, it is generally
considered less efficient.

On the positive side, globular transfer runs at high wire feed speeds and amperages for good
penetration on thick metals. Also, it can be used with inexpensive, CO2 shielding gas. It is used mainly
when appearance is not an issue.
Spray Arc
Spray arc propels small molten droplet of the electrode to the work. It is a pure CV process that must
produce enough current to send a constant stream of metal off the electrode. Its advantages include
high deposition rates, good penetration, strong fusion, good weld appearance with little spatter.

Its disadvantages include high heat input, a limited range of welding positions and proneness to burn
through on thin materials.

Pulsed MIG
Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while
minimizing or eliminating their disadvantages. Unlike short circuit, pulsed MIG does not create spatter
or run the risk of cold lapping. The welding positions in pulsed MIG are not limited as they are with
globular or spray and its wire use is definitely more efficient. By cooling off the spray arc process, pulsed
MIG is able to expand its welding range and its lower heat input does not make burnthrough on thin
metals a problem. Pulsed MIG is one of the best welding processes for a wide variety of applications
and metal types.

Customization of the Waveform

To take the pulsed MIG process a step further, Lincoln Electric offers complete customization of the
welding waveform through its state-of-the-art Waveform Control Technology®. This technology allows
the power source to be finely tailored to the wire and process. The power source rapidly adjusts the
pulse waveform for superior welding performance. It does this by providing a fast or slow front edge on
the pulse to transfer the droplet at the proper rate, the back edge then falls at a controlled rate to add
the heat needed to wet the droplet to the puddle. With Waveform Control Technology®, built-in
templates are set up in the power source for standard usage on a variety of materials. Variables such as
ramp rate, peak time, tailout, step off, among others are controlled in a precise manner so that when
there is a process set-up change, there is a corresponding change in waveform configuration.

Equipment Selection
Pulsed MIG welding has evolved quite a bit since it was first introduced to the marketplace. In the
1980s, it was a highly complex process that could only be performed by the most skilled welders. That
was because the operator would have to know exactly how to set the machine for the correct wire feed
speed to perform this type of welding. Today, this is all done for him or her as part of the synergic
control. When the operator adjusts wire feed speed, the synergic operation adjusts the waveshape and
frequency automatically.

The synergic operation of the machine makes it easy to use, even for the beginning welder, with a single
knob that controls all operations. In addition, its sophisticated internal electronics are even “adaptive”
to adjust for variations in stickout, gap or the torch angle.
Here are some tips to help operators choose which equipment to use for Pulsed MIG:

1. Choose equipment capable of operating over the new expanded range of welding processes
If an operator was previously welding with a 300 amp CV machine, it shouldn’t necessarily be assumed
that he must select a 300 amp Pulsed MIG machine. Because of the wider range of operating
capabilities with Pulsed MIG, an operator may be able to jump to a 400 amp machine that has the
higher amperage capabilities to handle the expanded wire feed speed ranges.

2. Look for advanced synergic controls

As was stated before, advanced synergic machines offer simple user interfaces that will result in less
training time for new users.

3. Consider investing in dual procedure guns

Because Pulsed MIG affords a wider operating range, it might make sense to invest in dual procedure
guns. These are guns that easily allow the operator to flip between procedure pre-sets on the machine.
Make sure though that the wire feeder is capable of running this dual procedure gun.

4. Carefully choose welding gun size

Because the Pulsed MIG process can go out to higher ranges and have high current pulses, it may run
“hotter” than previously used MIG processes. For this reason, an operator should choose a larger,
possibly water-cooled welding gun that is sized for the appropriate current.

5. Look for work voltage sensing if welding far from the power source
Some power sources have a work voltage sensing option that improves pulsing performance as distance
is placed between the work site and the power source. Normally the machine senses the voltage at the
output studs – one at the work and the other at the wire feeder. With this option an operator can run a
separate lead out to the work.

Set-Up Tips
Set-up for Pulsed MIG machines is a little different than Conventional MIG machines. Take care to
ensure that the appropriate guidelines are followed for safe operation.

1. Higher pulse currents require a better ground

The user must make sure that he or she has a good electrical path before welding.

2. Cable lengths should be minimized to reduce inductance

Cable lengths should be kept under 50 ft. as a general rule. Wherever possible, only use the length of
cable you need – coiling up the extra creates inductance. Inductance smoothes out the pulses and
reduce their effectiveness. Also, care should be taken to keep cables together without big loops or
looping around conductive objects. These factors will result in better performance specifically in Pulsed
MIG.
Conclusion
Cost savings, better quality, improved productivity and easier operation…all these factors make Pulsed
MIG an option that should not be overlooked. Although the high price tag may scare you, carefully
weigh the initial investment with the benefits that will be derived over the long term. Take advantage of
the new technological advantages provided by Pulsed MIG – one machine to handle virtually any
application, flawlessly.

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