Welding is an age-old art of metal joining. It’s an effective and efficient way for metal fabrication for almost all industries; ranging from automobile manufacturing to aerospace engineering.
The process involves using an electric arc with an electrode to melt and join two pieces of metal. Whether hand welding or machine welding– spatter is an unavoidable byproduct of merging two pieces of metal. Spatter in welding is a result of an accumulation of small metal droplets on the spot of welding.
It can be anything from a minor frosted appearance to a buildup of large, painful balls of metal. Research has shown that up to 28% of welding time can be wasted with the removal of spatter and 16% of weld defects can be attributed to spatter. Hence, it is essential to have a good understanding of the topic: What is Spatter in Welding?
What is Spatter in Welding?Welding is a method of joining two metals together, allowing them to form a connection that will last far longer than a simple adhesive connection. When two pieces of metal are welded, the process can produce a variety of side effects and by-products, such as spatter.
What is Welding Spatter?Welding spatter is particles of molten metal that are expelled during the welding process and fall onto surfaces adjacent to the weld.
These particles are small in size, generally ranged between 0. 08-5mm (0.
003-0. 06 in) in size.
This spatter can travel to a variety of different surfaces so it is important that welders take the necessary steps to prevent the spatter from reaching the wrong places.
What Causes Welding Spatter?
Welding spatter is caused by a number of things. These include:
- The wrong gear ratio. If a welding machine has too much amperage, the weld can become too hot, which can cause spatter.
- Incorrect polarity. For MIG welding, if the polarity is not correct, spatter will be created.
- Incorrect gas pressure. Too much gas pressure can create spatter.
- Incorrect travel speed. If the welding gun is moving too fast, the weld will not join the metal properly and can cause spatter.
- Unsuitable electrode. Certain welding rods create more spatter than others so it is important to choose the right welding rod.
Prevention and Control of Welding Spatter
- Using the right gear ratio. Set the amperage to the correct setting for the welding job.
- Correctly setting up the polarity. For MIG welding, make sure the polarity is set correctly.
- Setting the correct gas pressure. The correct pressure will help to keep the spatter down.
- Maintaining an appropriate travel speed. Slower is almost always better to prevent spatter.
- Choosing the right electrode. Select an appropriate welding electrode to minimize spatter.
- Using a welding shield. A welding shield will help to keep the spatter away from the surrounding area.