Breaking Free from Anti-Spatter Welding Spray and Gels

Posted by OTC DAIHEN on April 7, 2024

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The welding world has long been acquainted with anti-spatter sprays and gels, which many consider necessary evils in achieving clean welds. OTC DAIHEN USA is challenging this status quo with a revolutionary approach that aims to make anti-spatter agents a thing of the past.

In this article, we delve into the challenges posed by these traditional solutions, the reasons behind their existence and how OTC DAIHEN USA is paving the way for virtually non-existent spatter in welding processes.

The Essence of Spatter and Anti-Spatter Woes

Factors such as incorrect welding parameters (e.g., voltage, current and wire feed speed), the choice of shielding gas and the condition of the welding equipment can all contribute to the occurrence of weld spatter.

Spatter consists of droplets of molten metal or non-metallic material that are scattered during welding, which can adhere to the workpiece surface, reducing the quality of the weld and increasing the need for post-weld cleanup and finishing. 

Manufacturers and welders have been battling this issue through various means, including the use of anti-spatter sprays and gels. These agents' primary goal is to prevent spatter from adhering to workpieces and equipment. While they serve a purpose, many welders view them as a necessary evil due to various downsides. These traditional solutions can be overused, contribute to a messy work environment, and even react negatively to the metal being welded.

Enter Ultra Low Spatter Welding TechnologySynchro-feed welding

Synchro Feed Evolution, an ultra low spatter welding technology developed by OTC DAIHEN, achieves welds with virtually no spatter, so there is no need for anti-spatter sprays and gels.

The technology's foundation is a revolutionary wire retraction system in the torch combined with a high-speed processor in the welding power source. Together, they create minimal spatter and a stable arc, which is optimal for robotic MIG, MAG and CO2 welding. 

The technology also includes Push Arc Mode, which combines the ultra low spatter capability with the desirable bead width and penetration depth of pulse welding. This enables ultra low spatter on simultaneous welds of multiple units. It achieves this by predicting the timing of arc generation and controlling droplet transfer without the need to rely on voltage feedback.Low-spatter welding on steel plate

Materials that benefit from Synchro Feed Evolution include sheet metal, thick steel plate, aluminum, stainless and galvanized steel plate and zinc-plated steel.

Find more material examples here of results when welding with Synchro Feed Evolution.

Furthermore, OTC DAIHEN's welding systems are designed to be user-friendly, allowing welders to achieve optimal results without the need for extensive adjustments or specialized knowledge.

Say Goodbye to Anti-Spatter Sprays

With OTC DAIHEN USA's innovative approach, welders can look forward to a future where spatter and spatter sprays and gels are virtually non-existent. This not only simplifies the welding process but also contributes to a cleaner and more efficient work environment. By reducing spatter and the reliance on anti-spatter agents, manufacturers can experience improved productivity and cost-effectiveness.

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Topics: Robotic Welding, Manual Welding


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