Metal Transfer in MIG/MAG: Short-Circuit, Globular and Spray

Introduction

Metal transfer is the mechanism by which molten metal passes from the consumable electrode to the workpiece in the MIG/MAG process (process 131/135 per EN ISO 4063). Understanding the three main modes — short-circuit, globular and spray — is essential for selecting the correct parameters and achieving quality welds.

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Short-Circuit Transfer (Dip Transfer)

In this mode, the electrode physically touches the weld pool, creating a short-circuit that extinguishes the arc. Current rises rapidly, metal is transferred by electromagnetic and surface tension forces, and the arc re-ignites.

Applications: thin sheet (0.5–3 mm), positional welding (vertical, overhead), pipe root passes.

Gases: Pure CO₂ or Ar/CO₂ mixtures (M21 — EN ISO 14175).

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Globular Transfer

In globular mode, metal droplets larger than the wire diameter form at the wire tip and fall into the pool by gravity. The arc remains continuously lit.

Limitation: Produces significant spatter. Transition zone — generally avoided in practice.

Gases: Pure CO₂ or mixtures with low argon content.

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Spray Transfer

With voltage and current above the transition current, droplets become smaller than the wire diameter and are projected axially into the pool. The arc is stable with virtually no spatter.

Condition: Requires mixtures with ≥ 80% Ar (group M21/M12 — EN ISO 14175). True spray cannot be achieved with pure CO₂.

Applications: Thicknesses ≥ 4 mm, flat and horizontal position, high productivity.

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Transition Current

*Source: IIW — MIG/MAG E/IWE Module 1.8*

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Choosing the Mode by Application

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