When you have welding in your production line, one of the worst problems to deal with is determining how to reduce spatter. Caused by metal thrown free from the welding point to land on nearby surfaces, reducing spatter improves efficiency and reduces overhead in your assembly line, as less time is spent cleaning up the weld and in wasted material. Why would you spend time and money removing part of what you worked so hard to apply? But how do you reach a point of having minimal spatter in your welds? Here are three tips for reducing spatter from your production line welds.
Three ways to reduce spatter
- Adjust the arc Voltage. If it's not set correctly, your voltage setting can significantly increase spatter. Low voltage settings will cause spatter because the wire is repeatedly short-circuiting in the weld pool causing small explosions at the tip of the wire. This short circuiting is normal for “short arc MIG” welding, but if arc voltage is set correctly you can typically control the expelled spatter to a small size and avoid it sticking to your work piece or surrounding fixtures. On the other hand, high voltage can also produce excessive spatter due to extreme arc force.
- Change the Stick-Out. The amperage of the arc is determined partially by the length of the stick-out, or the amount of wire that is beyond the contact tip that creates the weld. If the stick-out is too long, it can reduce amperage, throwing spatter out of the weld because it's not penetrating deeply enough into the weld. If it's too short, it increases amperage, throwing material out of the weld due to the force of the arc.
- Consider welding machines with special features to minimize or virtually eliminate spatter. With the advent of ultra-high speed electronics, some of today’s welding power sources focus on spatter reduction because of its costly impact. They also offer other benefits that improve total weld quality and they easily justify the investment. Check out the OTC Welbee Series of GMAW and Pulse GMAW power sources and related equipment. Several models offer our CBT-EX (Controlled Bridge Transfer) low spatter mode, and unique pulse GMAW modes to drastically reduce weld spatter to save you big money.
By keeping these three tips in mind, you'll be able to reduce spatter in your welds in no time, improving productivity and reducing overhead. Please feel free to contact us today to find out more about our Welbee Series welding power supplies features and benefits. At OTC Daihen, we've been working since 1919 to provide you with the best in cutting edge welding technology.