How to Reduce Weld Spatter – 5 Quick ways and prevention

How to reduce weld spatter

Welding spatter leads to many problems when welding. Controlling welding spatter is a key factor in producing a quality weld, part or project. In order to reduce weld spatters, it’s important to know why exactly it happens in the first place. 

This blog will give a brief overview of five different factors that cause spatter to form on a weld, along with some tips on how to prevent it from happening.

1. What Is Weld Spatter?

Weld spatter is small, brittle, crystalline deposits that are extruded from a metal object during the welding process or by heating the metal with an open flame. Spatter is generated either internally or externally on the surface of the metal. It is typically composed of oxides, nitrides, carbides, and silicides. 

Externally formed weld spatter occurs when the heat capacity of the welding arc contacts the base material and melts the surface layer. 

Internally formed weld spatter occurs when intense heat from the arc or flame softens and melts thin surfaces of the metal. The spatter then moves to the outer surface. An internal source of spatter is a common problem in welding high-nickel or high-copper alloys.

2. Common causes of weld spatter

The most common causes of weld spatter are: Improper filler wire ( High carbon content filler wire), Use of improper filler wire ( Using the wrong type and/or size of filler wire), incorrect gas mixture, improper equipment set up, use of incorrect face shield, poor manipulation skills, High arc force.

Some of the most common causes of weld spatter

  • If you observe the weld spatter occurring frequently, it is a good practice to inspect the electrode for any damage, such as pitting or consumption.
  • If you detect the weld spatter occurring in the middle of the weld, it could be caused by contamination from the filler wire.
  • Choice of welding position, arc length and travel speed.
  • Welding current and voltage balance.
  • Welding equipment.
  • Welding technique.
  • Welding environment.
  • Lastly, if you observe a weld spatter occurring at the end of the weld, it is often caused by contamination from the improper filler rod selection.

3 Welder’s Techniques

For the most part, the punch has a standard tip size that is acceptable for the design and job. However, there are other concerns or requirements that must be looked at. The type of metal, the part, location, and welding process may help determine the tip size you should use.

Mig Welder

You should do two things. First, you need to have a good mig welder to do the job. You need to consider the power of the mig welder, and what kind of purpose you need it for. Second, you need to know some mig welder’s welding techniques if you want it to go smoothly. Here are some mig welder’s welding techniques for you.

Tig Welder

Tig welding is often preferred to other types of welding because of its excellent control, high-quality welds, and it produces almost no spatter. Tig welding is a kind of welding which uses tungsten inert gas (TIG) instead of conventional electrodes. Tig welding is very versatile, and the process can be used on a wide variety of materials including carbon steels, stainless steels, aluminum and copper alloys, nickel and titanium. With all of the above materials, different filler materials are used.

4. How to prevent spatter?

To prevent weld spatter, use a shield gas, neutral gas or pulse arc to shield the molten metal from the atmosphere. Shielding gas is a mixture of argon and oxygen, which suppresses oxidation and keeps the weld bead clean.

Spatter is usually caused by poor torch angle, excessive shielding gas, dirty electrodes or a combination of these. Poor torch angle can cause excessive heat on the root bead, which can cause the gases to release. Excessive shielding gas will blanket the weld puddle and cause excessive spatter.

All of these problems can be solved by improving the process for cleaning the electrodes and torch angle. You should try to keep the torch angle near 90 degrees and the electrode wire should be perpendicular to the root bead. You should also try to keep the shielding gas at a minimum and precisely monitor it.

Steps to follow for prevention

  • Keep the work area clean and clear of debris
  • Use a welding helmet (to prevent damage to eyesight)
  • Don’t use flammable materials (gas or oil) for welding
  • Use a welding gloves and other protective clothing
  • Use an oxyacetylene torch (instead of a welding machine)
  • Use a welding machine (instead of a torch)

Note: Use these tools to prevent spatter.

1. Welding Hoods 

Welding hoods are an essential part of a welder’s clothing. They are also known as safety helmets or protective face masks. The purpose of these hoods is to protect the welder from the dangerous rays of the welding arc.

Welding hoods protect eyes from flying harmful infrared rays and also prevent shield welding from being exposed to harmful UV rays. They are designed in such a manner as to protect the welder’s eyes from arc and splash.

2. Welding Gloves  

When you work with things that are burning hot, you must always use gloves to protect yourself. For a welder, gloves are an essential part of his attire.  Welder’s gloves are usually made of leather or cotton. While cotton makes the gloves inexpensive, these gloves are flammable. Leather makes a good glove as it is heat resistant and fireproof.

3. Welding Aprons

A welding apron is a form of protection designed to protect the welder’s body from exposure to harmful radiation and particles associated with welding. Welding aprons are typically made out of a heavy cotton material and offer a very effective protective barrier for any welder. Welding aprons are usually a traditional style and usually offer extra protection in the area of the neck and chest. Welding aprons are an essential tool for any welder and are considered a standard part of their tool supply.

5. How to protect from spatter?

There are many ways to prevent weld spatter. The following are some of the most common methods: – Make sure your machine is grounded to prevent static electricity, which can lead to weld spatter. – Use the safety shield on your machine to protect yourself from splatter. – Make sure to check your shield for holes or weak spots before starting a job. – Make sure your shield is clean, since weld spatter can build up inside the shield. – Make sure your machine is set to the correct voltage, since too low of voltage can cause weld spatter. – When wrapping your filler rod, make sure to cover the electrode. – Make sure the electrode is tightly secured to the filler rod, since a loose connection will cause weld spatter.

Conclusion

Always wear the proper welding gear and keep your work area clean and safe from molten metal droplets. Spatter is an annoying and frustrating byproduct of welding. When it is not controlled, it can cause defects in the weld, which can lead to problems with the finished project or part. But when you know how to control it, you can get a cleaner, more consistent weld every time.

Brayden Author

Brayden has been a welding enthusiast and expert for the past 7 years. He always loves to help others by guiding them as a welder expert. That’s the reason he found writing on a site “welderexpert.com” to guide other new and beginner welders.