Spray transfer is a GMAW mode in which fine metal droplets are transferred axially across the arc, producing deep penetration and clean, spatter-free welds. This article explains how spray transfer works, the variables that control it—such as shielding gas composition, electrode diameter, and amperage—and why it requires high heat input. While spray transfer offers high deposition rates and excellent weld quality on thicker materials, its use is limited to flat and horizontal positions due to the fluidity of the weld puddle. Understanding both the advantages and limitations of spray transfer is essential for selecting it appropriately and avoiding issues such as burn-through, undercut, or welder discomfort. When applied correctly, spray transfer is a powerful and productive welding mode.
