Welding spatter is an inevitable part of a welder’s life. At best, it looks unsightly. But at worst, it can introduce contaminants or inclusions to the weld. it can also cause damage to other parts around it or to the welder themselves, so it’s important correct PPE is always worn to avoid burns.
Plus, there’s all the issues with damage and wear and tear to your welding torch. So coming up with practical, cost effective solution is key to producing the best possible weld, and maintain the lifespan of your welding torch and consumables.
Excess spatter costs – both in the time spent removing it, and the cost of replacing consumables more regularly.
Removal of minimal spatter might be as easy as a quick pass over with a wire brush, but for heavier coverage a chipping hammer or grinder is necessary, quickly increasing the time and effort required.
If not done carefully, these methods can scratch or gouge the surface of the workpiece, as well as the welding torch and consumables. Anti-spatter spray is an option, reducing spatter adherence by forming a coating on the welding nozzle and workpiece to prevent spatter adhesion, however there are inherit risks of weld contamination associated with excessive or incorrect use, so it is important to apply carefully following the manufacturers instructions to avoid any transfer to the weld pool.
So How Can You Reduce The Impact Of Spatter On Your Welding?
Perfect your Welding Set-up
Welding Machine Parameters
Weld with the correct voltage and amperage settings for your job. Refer to your welding machine’s manual and experiment to find the optimal balance for your material thickness and wire type.
Travel Speed
Moving the torch too slowly allows molten metal to transfer erratically, leading to spatter. Conversely, traveling too fast can cause incomplete fusion and spatter.
Torch Angle
Maintain a proper angle (typically 5-15 degrees) between the torch and workpiece to ensure proper shielding gas flow, therefore reducing spatter.
Maintaining a Clean Work Surface
Thoroughly clean the joint before welding to remove dirt, oil, rust, and oxide layers using a wire brush, degreaser, or if necessary, a grinder.
Anti-Spatter
Apply a light, even coat of anti-spatter spray to the welding nozzle and surrounding workpiece. Follow the manufacturer’s instructions for application and allow the spray to dry completely before welding.
Utilise the Right Consumables
Filler Metal
Use wire with the proper composition and diameter for your application.
Contact tip Selection
The size and condition of the contact tip directly affects arc stability. A worn or dirty tip can cause spatter. Regularly inspect and replace tips as needed.
Shielding Gas
The right shielding gas composition protects the weld pool from contamination. Consult your welding machine manual or a welding supply specialist for the ideal gas choice.
Nozzles
Spatter build-up on the nozzle disrupts the flow of shielding gas essential for a clean weld, shortens the nozzle’s lifespan due to overheating, and adds to cleaning time. Luckily, Arc’s innovative SIC Technology prevents this.
This unique design incorporates a “well” which accumulates the molten metal particles. This well functions in conjunction with the nozzle retention system, allowing for trouble-free removal of both the nozzle and the accumulated spatter ring.
Benefits of SIC Technology
Reduced Downtime
Significantly reduces buildup on the nozzle, minimising cleaning time and keeping you actually welding for longer.
Extended Consumable Life
Less spatter on the nozzle translates to less wear and tear, extending the lifespan of contact tips and nozzles.
Improved Weld Quality
Minimising contamination results in cleaner, more consistent welds.
Enhanced Efficiency
Faster cleaning and reduced consumable replacement leads to a more streamlined welding process.
Welding spatter might seem unavoidable, focussing on prevention utilising good technique and the right equipment can significantly reduce its presence, saving time, money, and extending the life of your Mig welding torch and consumables, and most importantly, ensuring a good weld every time.
