Name one major difference between short-circuit transfer and spray transfer in GMAW.

• A. Short-circuit uses higher current with droplets transferring by shorting to the weld; spray uses lower current with a continuous stream of droplets.
• B. Short-circuit uses no shielding gas; spray uses shielding gas.
• C. Short-circuit transfers by continuous spray; spray transfers by shorting to the weld.
• D. Short-circuit uses lower current with droplets transferring by shorting to the weld; spray uses higher current with a continuous spray of tiny droplets.

Answer: (D)

The difference lies in how metal is transferred and the current level used. In short-circuit transfer, the arc operates at a lower current and the electrode tip momentarily touches the weld pool, causing a short circuit that transfers each droplet as the wire shorts to the work. This results in a less aggressive heat input and is forgiving with gaps or thin materials. In spray transfer, the arc is sustained at a higher current, and metal is drawn from the wire as a rapid spray of many tiny droplets carried by shielding gas, providing a higher deposition rate and deeper penetration when conditions are stable. So the correct description is that short-circuit uses lower current with droplets transferring by shorting to the weld, while spray uses higher current with a continuous spray of tiny droplets.