What is the most dependable method for welding aluminum with a GMAW machine?
Spray transfer is the desired mode of metal transfer for welding aluminum. Spray transfer offers a smooth transfer of molten metal droplets from the end of the electrode to the molten pool. The droplets crossing the arc are smaller in diameter than the electrode. There is no short circuiting. The deposition rate and efficiency are relatively high and the arc is smooth, stable, and stiff. The weld bead has a nice appearance and a good wash into the sides. In spray transfer mode, a large amount of heat is involved, which creates a large weld pool with good penetration that can be difficult to control and cannot be used on materials thinner than 14 gauge. This transfer will produce a hissing sound and no spatter.
