I just finished a job using Hardox AR plate. It was a tumbler drum for some kind of abrasive cleaning system. The company formed and tacked everything and we just had to pour the wire to it. The company provided WPS did not call out any preheat for welding or tacking. The part arrived in our shop with cracks on almost every tack holding it together. I don't know how it even made it over in one piece. I called their EOR and questioned him about it and he stated "that's how we have always done it". So, we welded up some sections and ground out the cracked tacks, and welded it up with no problems. They speced out a specific manufacture 110-G metal core wire that sure did put out a LOT of spatter no matter where the set-up was in the WPS range. Again I called the EOR to inquire about the WPS, and he gave me the same response. Long story short, we put down 25 pounds of wire, wire wheeled the plates, stamped it, and shipped it.
What are any of your experiences with similar wires? Lots of spatter and smoke?