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The 'dual shield' electrodes do produce excellent weld penetration Brad. Due to the polarity settings of the gas shielded core wires, the spatter is most likely more pronounced when compared to an 'axial spray transfer' mode. If current levels are sufficient to raise the current above the critical value referred to as the 'transition current', the result will be a high velocity stream of very tiny molten droplets that will defy gravity so to speak. This can be utilized to achieve all position welding in the spray transfer mode. Where problems arise in using this mode out of position it can be attributed to heavy molten deposits arising from the high deposition rates. Your dual shield electrode will be better suited for filling gaps, for welding thinner material, and will be less affected by magnetic fields. There are some in the gas industry who believe that the spray transfer mode can be achieved using the proper CO2/Ar mix. Voltage in the range of 32 to 36 using an .045" diameter wire produces a droplet stream smaller than the electrode diameter. This is also said to be possible with .035" diameter wire at less than 20% C02 mix. In closing, please allow me to add this. Production and fabrication is not my field of expertise. My field of expertise revolves around repair and salvage. I have not personally tried to experiment with spray transfer from a Ar/CO2 mix.
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