When the flames splatter, the welding spatter on the workpiece is usually not far away. Once splashing occurs, it must be removed - resulting in time and financial costs. Prevention is better than cleaning, we need to prevent welding spatter as much as possible - or at least minimize it. But how to do it? Every welder has the ability to help combat splashing, whether it is through the use of optimal welding equipment, correct preparation of materials, correct handling of welding guns, or minimal modifications to the workplace. With these 8 techniques, you can also declare war on welding spatter!

Preventing welding spatter--Why is it so important?

Welding spatter refers to small metal droplets sprayed from the welding area by the force of an arc - usually falling on the workpiece, weld seam, or welding gun. In addition to time-consuming and expensive cleaning, welding spatter can also cause the following problems:

-Reduce weld quality

-Unclean and unsafe workplace

-Production downtime

Therefore, it is necessary to prevent welding spatter as much as possible. With our quick prompts, you will be prepared for everything. Let's start with the best welding equipment！

Frist: Ensure stable current

A stable current is crucial for preventing welding spatter. Therefore, the welding gun and return cable must be securely connected to the power supply. This also applies to the grounding of the workpiece: the fastening points and grounding clamps must be exposed and have high conductivity to allow current flow.

Second: 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:

-Ensure that the welding gun is installed correctly (wire feeding tube (diameter and length), conductive nozzle, etc.).

-Ensure that the bending of the trunk line is minimized as much as possible.

-Adjust the contact pressure of the wire feeding roller to adapt to the welding wire used.

Too little pressure can cause the welding wire to slip over, leading to wire feeding problems and quickly developing into splashing problems, "explained professional welder Josef Sider.

Third: Choose the correct protective gas with the correct flow rate

Insufficient protective gas protection can lead to unstable arcs, leading to welding spatter. There are two key factors here: gas flow rate (rule of thumb: wire diameter x 10=gas flow rate in liters per minute) and dry elongation (wire end extending out of the conductive nozzle), which need to be kept short enough to ensure effective gas protection. Low splatter welding also depends on selecting the correct gas, as welding in normal CO2 gas will generate more splatter in the higher power range. Our suggestion: Use a mixed gas instead of 100% carbon dioxide to reduce the chance of welding spatter!

Forth: Select suitable vulnerable parts

When it comes to vulnerable parts and welding spatter, there are several things you need to consider. Firstly, vulnerable parts such as welding wire trays, wire feeding tubes, or conductive nozzles need to be made of suitable materials and diameters for the welding wire. Secondly, the degree of wear has an impact on the formation of splashes. Severely worn parts can lead to unstable welding processes, resulting in more welding spatter.

Fifth: Apply correct welding parameters

Choosing the correct welding parameters is crucial for preventing welding spatter as much as possible, especially when setting the power range of the intermediate arc. According to the situation at hand, power should be increased or reduced to transition to droplet transfer arc or jet arc.

Sixth: Clean materials

Thoroughly cleaned materials are another decisive factor. Before starting welding, all dirt, rust, oil, scale, or zinc layers must be removed from the welding position.

Seventh: Correct welding gun operation

It is equally important to pay attention to the correct position and guidance of the welding gun. The welding gun should be maintained at an angle of 15 ° and move along the weld seam at a stable speed. It is absolutely not recommended to use obvious' push 'welding techniques, as this position will cause a corresponding large amount of splashing spray, "added Josef Sider. The distance from the workpiece should also remain unchanged. If the distance is too large, the protection and penetration depth of the protective gas are affected, resulting in more spatter during welding.

Eighth: Avoid ambient airflow

A commonly overlooked practical technique is to avoid ambient airflow. If you weld in a garage with strong airflow, you will soon encounter issues with shielding gas, "Sider explained. Of course, there is also welding spatter. When welding outdoors, it is not always possible to shield the welding position, but fortunately, Sider has a top-level technique: increase the shielding gas flow rate by approximately 2-3 liters/minute to keep the ambient airflow away from the welding position.