May 28, 2021 6:30:00 AM | Written by AMPCO METAL

Weld spatters are a welders biggest enemy and have a massive negative influence on the productivity as they may force major downtimes. But there are ways to reduce weld spatters and therefore significantly decrease cleanup time as well as increase productivity.

The saying goes: “You can’t make an omelet without breaking eggs” meaning that it is impossible to achieve something desirable without there being some bad effects as well. For example, in welding you can’t make a welded joint without causing some weld spatters. Even if there is no way of avoiding weld spatters, there are possibilities to reduce them. Furthermore, certain materials are more prone to weld spatter, which leads to excessive downtime for cleanup.

Read more in the free «AMPCO METAL guide for resistance welding and anti spatter»

What is weld spatter?

Weld spatters are annoying to deal with as they can damage the body resting units and therefore add to the fixture downtime. The formation of such small metal spatters is clearly audible during welding. When it really crackles and pops during welding, small metal droplets are released from the weld pool, are flung away and finally land on the workpiece surface, the weld seam, the clamping jaws or even the torch consumables.

Certain welding processes tend to form more weld spatters than others. Especially the MIG / MAG welding process causes a lot of weld spatters, clearly visible along the weld seam. The reason for that is an electrodynamic phenomenon called pinch effect/force. Arc welding makes use of this effect/force by applying high currents to the lower end of the wire, which causes a drop to be cut off. This drop is additionally accelerated. The force is difficult to control and can lead to weld spatter if the molten metal burst due to the strong impact.

What are the reasons for weld spatter?

In order to minimize weld spatter, you first need to understand what causes weld spatter. And there are a lot of factors that have an influence on the amount of weld spatter. For example:

  • Material to be welded

Lower quality materials lead to a significantly higher amount of weld spatter. Furthermore, metal coatings are a problem as well when welding. Whether intentional coating (such as a paint finish) or contamination (such as dirt or rust): Both lead to a significantly higher amount of weld spatter.

  • Material of the filler metal

In addition to the material of the workpiece, the material of the filler metal also plays a huge role. Here too, low-grade filler as well as contaminated filler lead to more weld spatters.

  • Welding setting

Even the most expensive and highest quality material is of no use if the welding parameters are set incorrectly. Also you may need to adapt the welding setting depending on the chosen welding method.

  • Shielding gas

When using shielding gas, the wrong type of gas can also have a huge influence on the amount of weld spatters.

Tips to reduce weld spatter

1. Set your parameters right

Before welding, always set your machine parameters accordingly to ensure the least possible amount of weld spatter. There are multiple settings to check, here are the most important ones: amperage, voltage, polarity and stick-out.

2. Use high quality filler metal

In order to reduce weld spatter even more, ensure that you use a high quality filler metal that fits the tasks. If you need help with choosing the correct filler metal, please consider our welding wire selection guide.

3. Clean the surfaces

Coatings can lead to sever weld spatter. Therefore, always clean the surface of the workpiece as well as the welding wire before welding. The right preparation can greatly reduce weld spatters.

4. Chose the right shielding gas

When using a shielding gas, make sure to use an appropriate one. Most commonly argon and CO2 are used. Depending on the material to be welded, either pure CO2, pure argon or a mix between the both of them should be used.

AMPCO METAL and weld spatter

The tips above will help you reduce weld spatter in general. However, there will be weld spatter nonetheless. The correct choice of material for your welding equipment is therefore crucial as well. Otherwise you are quite vulnerable to excessive downtimes for cleanup or need to frequently exchange the equipment.

For instance, a roller on a spot welding gun made of AMPCOLOY® 940 can drastically increase the life span of the roller. A case study conducted at a reputed Indian Auto OEM shows, that a roller made of AMPCOLOY® 940 ensures a life span of more than 7 month, whereas the roller made of Brass had a life span of maximum 15 days.

Another case study conducted at a reputed Indian 2 Wheeler OEM compared an ordinary resting block to one made of AMPCOLOY® Mylar. The conclusions showed 100 % reduction in cleaning activities which resulted in 70 minutes saved time per shift and a 20 % productivity increase per shift.

For further information about electrical resistance welding, please download our free «AMPCO METAL guide for resistance welding and anti spatter»

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Expert team AMPCO METAL