The OTC Welbee P400 II L offers a wide range of welding processes to help you target the best weld profile for your application utilizing the Cobot Welder. In this document we will be discussing what each process can help you achieve. We will also cover individual versus synergic welding parameter control.

Processes covered:

• CV (Constant Voltage)
• Short Transfer Arc
• DC Pulse
• DC Wave Pulse
• DC Low Spatter Mode

Constant Voltage (CV)

Best used when:

• A traditional waveform is sufficient
• No advanced arc manipulation is required
• Welding steel, stainless steel, or aluminum using standard transfer mods

Constant voltage is controlled through voltage and amperage adjustments. The CV process allows for a variation of welding transfer modes including short arc, globular and spray transfer. This is the straightforward welding process and is commonly used when no special waveform is required to achieve specific results.

CV can be used with:

• Gas Metal Arc Welding (GMAW)
• Flux Cored Arc Welding (FCAW)
• Metal Cored Arc Welding (MCAW)

Note: Transfer mode selection is dependent on your gas, wire type, and wire diameter. Always refer to your welding wire manufacturer’s data sheets to ensure proper setup.

Short Circuit Transfer (Short Arc)

Short Circuit Transfer occurs on the lower end of both amperage (wire feed speed) and voltage. Metal transfer happens only when the electrode contacts the weld pool, momentarily creating a short circuit. At that point, current rises to pinch off the molten droplet.

This transfer mode is well suited for:

• Open root welds
• Thin base materials
• Applications where heat input must be limited

Because the electrode repeatedly dips into the weld pool, spatter is common. Short Circuit Transfer is frequently used on steel and stainless steel, especially where higher-amperage transfer modes could cause distortion or burn-through.

Consider: Low amperage often results in shallow penetration. A weld that looks good on the surface may lack proper fusion internally.

Globular Transfer

Globular Transfer is generally considered an undesirable transfer mode. It occurs when low amperage (wire feed speed) is combined with high voltage, producing large spatter droplets that transfer erratically across the arc.

Characteristics include:

• High spatter generation
• Poor weld appearance is not desirable
• Limited use deposition

Consider: Many welders believe they are in spray transfer mode, when they are actually in globular transfer. This can be verified by measuring voltage and referencing the welding wire manufacturer’s data sheets.

See Also: Why Automated Weld Fixturing Reduces Rework

Spray Transfer

Spray Transfer represents the upper threshold of CV transfer modes. It is achieved through high amperage (wire feed speed) and high voltage and is characterized by a steady stream of fine droplets that are smaller than the wire diameter. This mode allows for the highest consumption of your welding wire.

Benefits include:

• Very low spatter generation
• Focused, stable arc
• High deposition rates
• Increased travel speed
• Maximum penetration potential

Spray transfer mode is typically targeted for thicker base materials and is applicable on steel, stainless steel and aluminum.

Consider: Spray transfer can often be identified by arc sound – typically a steady hiss and a very light crackle.

DC Pulse

Best used when:

• Lower heat input is needed without sacrificing penetration
• Spatter must be minimized
• Welding out of position or on heat-sensitive materials

DC Pulse welding is a variation of CV Spray Transfer that allows for deeper penetrartion with reduced overall heat input. In this process, amperage (wire feed speed) is pulsed while voltage follows, creating controlled droplet transfer similar to spray transfer but with significantly less heat.

Key advantages include:

• Minimal spatter with proper setup
• Improved weld puddle control
• Reduced distortion and burn-through
• Faster puddle cooling
• Capability to weld in all positions (flat, vertical, overhead)

Because of these characteristics, DC pulse is especially effective for aluminum, while also performing well on steel and stainless steel.

Consider: Shielding gas is critical for a stable pulse arc. Typically, a low CO₂ blend is required (less than 20% CO₂).

See Also: 15 Types of Welding Processes with Their Advantages and Limitations

DC Wave Pulse

Best used when:

• Advanced arc control is required
• Welding thin materials at high travel speeds
• Improved puddle wetting and bead appearance are desired

DC Wave Pulse is OTC’s proprietary waveform technology. It builds on standard DC Pulse by mechanically manipulating the welding wire through the wire feeder in synchronization with specific pulse frequencies. This coordination produces a distinctiverippled weld appearance while maintaining excellent arc stability.

Controlled parameters include:

• Amperage (or wire feed speed)
• Voltage
• Pulse frequency (measured in Hertz,Hz.

Originally developed for aluminum welding, DC Wave Pulse has proven effective across a wider range of applications.

Increased pulse frequency can assist with:

• Degassing zinc oxides when welding galvanneal
• High-speed welding of very thin steel or stainless steel materials

By combining low amperage transfer with high pulse frequency,DC Wave Pulse allows for fast travel speeds while minimizing distortion.

Consider: In DC Wave Pulse, travel speed can be often be increased simply by raising pulse frequency without increasing amperage (wire feed speed).

Low Spatter Mode

Best used when:

• Precision puddle control is required
• Excessive penetration must be avoided
• Open root joints are being welded

Low Spatter Mode is a modified version of short circuit transfer designed to reduce spatter and improve control. This process requires lower amperage and voltage, producing a softer short circuit transfer that allows for precise manipulation of the weld puddle.

A critical requirement for this mode is proper connection of the volt sense lead between the power source and the work surface. This enables faster arc feedback than the standard sensing methods, which is necessary for stable operation.

Consider: When high amperage welding is not required, Low Spatter Mode can offer an effective solution for controlled, low-distortion welds.