Welding Modes | Short Circuit vs Spray vs Globular

Introduction

Welding is a process that involves joining two or more metal parts to form a permanent bond. A key factor in achieving a successful weld is the choice of welding transfer mode, which determines the way in which the filler metal is transferred from the welding wire to the workpiece. There are three main welding transfer modes: spray transfer, global transfer, and short-circuiting transfer. Each of these transfer modes has specific advantages and disadvantages and is best suited for certain welding applications.

Spray transfer is characterized by a high-energy arc that produces a spray of droplets that are transferred to the workpiece to form a stable weld pool. Global transfer involves the formation of large droplets that transfer to the workpiece to form the weld pool. Short-circuiting transfer is characterized by brief contact between the welding wire and the workpiece, causing a short circuit that forms droplets that transfer to the workpiece to form the weld pool.

Welding Transfer Modes

Spray Transfer Mode

How It Works

Spray transfer is like turning your welder into a high-speed metal mist machine. Instead of the wire touching the puddle, it heats up to the point that it sprays tiny droplets across the arc in a continuous stream. This provides deep penetration and a smooth, steady arc.

Spray Arc Characteristics

• Smooth and hissing arc sound
• High travel speed
• Little to no spatter
• Deep fusion into the base metal

Ideal Settings

• Voltage: High (24–30V or more)
• Wire Feed Speed: High
• Gas: 90–98% Argon with 2–10% CO₂ or O₂

Best Use Cases

• Thick steel or aluminum
• Flat and horizontal welds
• Industrial and structural welding

Pros

• Very clean welds
• Deep penetration
• Minimal spatter
• Ideal for automation

Cons

• Requires high voltage and good equipment
• Not suitable for vertical or overhead
• Needs argon-rich gas (costlier)

Globular Transfer Mode

How It Works

Globular transfer forms larger droplets than spray and sends them across the arc by gravity, not arc force. That makes them unpredictable—they often fall into the puddle off-center, causing spatter and irregular welds.

Key Traits

• Larger droplet size
• Irregular arc sound
• High spatter levels

Common Settings and Shielding Gases

• Voltage: Mid (20–24V)
• Wire Feed Speed: Medium to high
• Shielding Gas: Straight CO₂ or low-argon mix

Where It’s Used

• Heavy materials when cost is a concern
• Limited-budget fabrication shops

Pros

• Higher deposition than short circuit
• Works with cheap shielding gas

Cons

• Very spattery
• Not ideal for critical welds
• Limited positional capabilities

Short Circuit Transfer Mode

How It Works

In Short Circuit transfer, the wire physically touches the weld puddle. This causes a short circuit (literally), which makes the tip of the wire heat up and melt. Once it melts, the arc reignites and the cycle starts again. This happens up to 200 times per second, making it appear like a steady arc to the eye.

Ideal Settings

• Voltage: Low (typically 16–21V)
• Wire Feed Speed: Medium to high depending on the metal
• Shielding Gas: 75% Argon / 25% CO₂ (a common mix)

Best Applications

• Thin sheet metal
• Bodywork and fabrication
• Repair jobs
• Vertical and overhead welding

Advantages

• Low heat input, so it’s good for thin materials
• Allows out-of-position welding
• Easy to control, great for beginners
• Economical to run

Limitations

• Not much penetration on thicker materials
• Produces some spatter
• Can be slower than other modes

FAQs

What transfer modes can be used in all positions?

All three transfer modes (spray transfer, global transfer, and short-circuiting transfer) can be used in all welding positions, but each mode may be better suited for certain positions depending on the desired weld quality and the specific requirements of the welding project.

What method of transfer is best for all position welding?

For all-position welding, short-circuiting transfer is often considered the best method as it requires a low heat input and produces minimal spatter, making it ideal for welding thin metal sections and low-alloy steels.

Which method is used for mode of transfer?

The choice of transfer mode will depend on the specific requirements of the welding project, such as the thickness of the metal sections, the type of metal, and the desired weld quality.

Can you spray transfer in all positions?

Yes, spray transfer can be used in all welding positions, but it may not be the best option for all welding applications.

What gas is used for spray transfer?

A mixture of Argon and CO2 is commonly used for spray transfer welding.

What gas is best for spray transfer?

Argon is considered the best gas for spray transfer welding, as it provides a stable arc and reduces the risk of contamination.

How hot is spray transfer welding?

Spray transfer welding typically requires a high heat input and can result in a weld pool temperature of around 6,500°F.

Which modes of transfer should not be used when welding aluminum?

Short-circuiting transfer and global transfer should not be used when welding aluminum, as they can result in porosity and cracking in the weld.

What is the difference between spray transfer and globular transfer?

The main difference between spray transfer and globular transfer is the droplet size and energy input. Spray transfer produces smaller, more consistent droplets and requires a higher energy input, while globular transfer produces larger droplets and requires a lower energy input.

Conclusion

Conclusion Welding transfer modes are an important aspect of the welding process, as they determine the type of arc and the resulting droplet formation. Spray transfer, global transfer, and short-circuiting transfer are three commonly used welding transfer modes, each with its own unique advantages and disadvantages. Spray transfer is best suited for welding thicker metal sections, as it offers high deposition rates and a stable arc. Global transfer is ideal for welding thinner metal sections and low-alloy steels, as it requires a lower heat input and reduces the risk of defects. Short-circuiting transfer is well suited for welding thinner metal sections and low-alloy steels, as it requires a low heat input and produces minimal spatter.