8 Tips to Reduce Welding Spatter

When the flame is splashed, the welding spatter on the workpiece is usually not far away.

Once a splash occurs, it must be removed – which incurs a cost of time and money.

Prevention is better than cleaning, and we need to prevent weld spatter as much as possible – or at least minimize it.

But how?

Every welder has the ability to help fight spatter, whether by using the best welding equipment, properly preparing materials, properly handling welding guns, or making minimal changes to the workplace.

With the following 8 skills, you can also declare war on welding spatter!

8 Tips to Reduce Welding Spatter 1

Prevent welding spatter

Why is it so important?

Welding spatter refers to small metal droplets sprayed from the welding area by the power of the arc – usually falling on the workpiece, weld or welding gun.

In addition to time-consuming and costly cleaning, welding spatter can cause the following problems:

  • Reduce weld quality
  • Unclean and unsafe workplaces
  • Production downtime

Therefore, it is necessary to prevent welding spatter as much as possible.

With our quick tips, you’ll be ready for anything.

Let’s start with the best welding equipment!

1. Ensure current stability

Stable current is essential to prevent welding spatter.

Therefore, the welding gun and return cable must be firmly connected to the power supply.

This also applies to the grounding of the workpiece: the fastening point and grounding clamp must be exposed and have high conductivity to allow the current to flow.

8 Tips to Reduce Welding Spatter 2

2. Ensure continuous wire feeding

In order to minimize welding spatter, the arc must be stable.

In order to obtain a stable arc, you need a stable wire feed.

To ensure this, three things are important:

  • Make sure that the welding gun is installed correctly (wire feed tube (diameter and length), contact tip, etc.).
  • Ensure that the trunk line bends as little as possible.
  • Adjust the contact pressure of the wire feeding roller to adapt to the welding wire used.

“Too little pressure will make the welding wire slip, which will lead to wire feeding problems and quickly develop into splash problems,” explained professional welder Josef Sider.

8 Tips to Reduce Welding Spatter 3

Excessive bending of trunk line will lead to poor wire feeding, resulting in splash problem

8 Tips to Reduce Welding Spatter 4

Correct practice: reduce the bending of trunk line as much as possible

3. Select the correct shielding gas with the correct flow

Inadequate shielding gas will lead to unstable arc and welding spatter.

There are two key factors: gas flow (rule of thumb: wire diameter x 10=gas flow, in liters/minute) and dry elongation (wire end extending from the contact tip), which need to be kept short enough to ensure effective gas protection.

Low spatter welding also depends on selecting the right gas, because welding in normal CO2 gas will generate more spatter in the higher power range.

Our suggestion: use mixed gas instead of 100% carbon dioxide to reduce the chance of welding spatter!

4. Select appropriate wearing parts

When it comes to wearing parts and welding spatter, you need to consider several things.

First of all, vulnerable parts such as wire reel, wire feed tube or contact nozzle need materials and diameters suitable for welding wires.

Secondly, the degree of wear has an effect on the formation of spatter.

The severely worn parts will lead to unstable welding process, which will result in more welding spatter.

5. Apply correct welding parameters

It is very important to select correct welding parameters to prevent welding spatter as much as possible, especially when setting the power range of intermediate arc.

Depending on the situation at hand, power should be increased or decreased to transition to droplet transfer arc or jet arc.

6. Clean materials

Thoroughly cleaned materials are another determinant.

Before welding, all dirt, rust, oil, scale or zinc must be removed from the welding position.

7. Correct welding gun operation

It is also important to pay attention to the correct position and guidance of the welding gun.

The welding gun shall be kept at an angle of 15 °and moved along the weld at a steady speed.

“It is absolutely not recommended to use obvious’ push ‘welding technology, because this position will lead to a corresponding large amount of splash jet,” Josef Sider added.

The distance from the workpiece shall also remain unchanged.

If the distance is too large, the shielding gas and penetration will be affected, resulting in more spatter during welding.

8. Avoid ambient airflow

A practical technique that is often overlooked is to avoid ambient airflow.

“If you are welding in a garage with strong airflow, you will soon encounter the problem of shielding gas,” Sider explained.

And, of course, welding spatter.

When welding outdoors, it is not always possible to shield the welding position, but fortunately, Sider has a top tip: increase the shielding gas flow rate by about 2-3 liters/minute to keep the ambient air flow away from the welding position.

Or is there too much welding spatter?

Welding process can be changed.

Once all these techniques are considered, you will get an extremely stable arc, which can counteract the spatter during welding.

However, if you need higher stability and further reduce the amount of spatter generated, you can consider using innovative welding processes.

The improved LSC (low spatter control) droplet transfer arc – also known as the “low spatter” welding process, which can be used on the Fronius TPS/i platform – is very suitable for such needs, because it provides a particularly high level of arc performance, which can bring you high-quality welds with little spatter.

8 Tips to Reduce Welding Spatter 5

Very little spatter during welding – use LSC welding process

You can take various measures to prevent or at least reduce welding spatter, and you should do so.

After all, low spatter welding can save you time and money, improve welding quality and ensure a safe working environment.

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