Materials & Welding: How can eliminate spatter inside pipe welding with STT (Surface Tension Trasfer) welding machine?

Saturday, May 6, 2017

How can eliminate spatter inside pipe welding with STT (Surface Tension Trasfer) welding machine?

I got problem with spatter inside pipe with the pipe welded by STT machine. Because spatter stuck inside and can not remove (cause can not access to inside to remove) whereas Spec required all spatter need to remove (attachment picture)

Could experts advise which medium we can coat inside pipe before welding to spatter can remove automatically after welding? Or other method to remove this one? Thank a lot!Show less

Bill ZHANG Try to optimize welding parameters…

Marcelo Ricci Bill, which gas did you use? How many welds do You need to weld? All joints are the same diameter?

Jean Philippe Simon Try with Alpha Q from EWM with the force arc modus

Michael Lang Quality filler metal, the right gas selection and the correct parameters. Great welding method but good choices are key.

Cody Keenan You have more problems than spatter in that picture

Nam Phung Could experts advise which medium we can coat inside pipe before welding to spatter can remove automatically after welding? Or other method to remove this one? Thank a lot!

Lori Kuiper Torch angle and travel speed.

Leon Wong use anti-spatter spray inside both pipe end before welding.
Or change your process to TIG or Tip-TIG welding for root weld., if allowable

Dr. Eng. Catalin Toma, IWE/EWE The weld in the picture has quite a few problems, so I would requalify the welder. On pipe welding with Miller RMD I never saw spatter so hot that it sticks to the metal inside the pipe, but even with STT you normally shouldn't have this problem.

Effendi Sitanggang Please use the grinder to remove the spatters to the welded pipe. No other option.

AGUS SETIJONO it looks not only spatters. if it is possible to change welding process for root. e.g. TIG

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Jørgen Sundt Mikkelsen You weld with solid wire and short arc go either for sync puls or a MCW

Faisal Alam you should use Anti Spatter gel,We are using in our Project..100% Satisfactory result.

Mohammed Siraj may I know the filler wire n base metal
STT is well known for low spatter process.

Tin Ha Minh very nice topic!

Philip Pugsley Train Welders to keep tip of wire farther back in the puddle away from leading edge of puddle. Slow down travel speed. From the looks of the bead they are getting a little bit of under fill on the root pass. Don't know what shielding gas you are using but would suggest an argon mix. 75 to 90 % argon.

Alan Cauchi Looks like the root is also a little concave at the bottom also, you can eliminate the concavity and also minimise any spatter issue using EWM Pipe solution, which was specifically developed for root pass in positional applications

Parveen Kumar Use anti spatters spray.Tool box meeting to fabricator/welders.or change welding process.

jorge carvalho i use the same process, and i don't have this probleme!

Michael Vaillancourt I would be more worried about that root pass. . .

Julio Herrera you shouldn't have this issue. can you provide me wich process parameters are using? gas? are you welding in downhill progresion?

Paul Bryant AWeldi,CertEd Not only is the root concave, there is a lack of side wall fusion.

Dave White They accepted that's root,but are worried about spatter?

Luke Griffith I'd tackle your root pass issues first.

Andy Spence If You pre cleaned the root side before welding it may help.

Mostafa Hanafy, MBA Short Arc Mig in the root such as STT/RMD/CMT tends to produce spatter as in the picture, you can reduce using antispatter gel in the inside before welding and antispatter spray as well to reduce much of it, you can also use metal cored wire instead of the solid wire, also you need to use mix gas with Argon co2 80/20 or even 85/15, then after doing all these you will reduce spatter to max 2 or 3 balls on 6 o'clock position, however i think if you are still not happy then you better go with TIG in root where you can enjoy a spatter free root

Grzegorz Dabrowski Spatter sticked

Carlo Cherubin Use Tig root or orbital welding

perry dhillon you have to practice on your welding please. try outside and get technique right

Ed Molloy Try a Fronius TPSi LSC Adv

jason van den bussche RSE Make sure fitters clean both pipe and fitting before tacked together what cfm of gas and use approved wire for procedure

jason van den bussche RSE Also in pic the welder should watch for lack of fusion to looks like he missed a bit

Jason Van Vlack First if you have a good route pass you should have no spatter and it doesn't look like you have a good route pass so def practice that because if you have a bad route pass then even if the rest of it is fine the route is what matters most maybe try to TIG the route pass first and then use 7018 rod to do the rest

Leroy Dyck You sound be getting little to no spatter with the stt short current. I I would look at the weld parameters your using

Mitchell Kooiman STT root should look better than that. Anti spatter will help.

Philip Behzadi One solution is to use electrode with less spatter depositing for root pass. Sometimes welders use reverse pole in order to having minimum level of spatter but this is ended to having low mechanical properties specially In toughness. You must be careful about this.

Kevin Bohne STT should give no spatter problems. It is most important to get the joint preparations correct in correlation with your wire diameter used.
Best results for carbon steel ate 0.9 wire diameter with vertical down root pass using feather edge prep ( no Landing ) 60deg included angle and 2.5 to 3mm gap.
Remainder of passes in the vertical up direction.
The key is to get the root pass parameters low enough to just fuse the ID of the pipe with a small weave motion. There should be no spatter produced if set correctly. Be careful with the use of coatings on the inside and try to avoid this

David Holcomb CWI/CWS/CWE Use the Ultima Arc in the negative range. This helps quite a bit. Also make sure that the weld wire is entering into the puddle about 1mm or 1/32" from the edge of the puddle. This along with cleaning the inside before welding should fix the spatter problem.

Ekim Tepe The best is using GTAW (TIG) welding method at root pass if you want to avoid spatters inside. Or you can run a brushy-pig in the piping to remove existing spatters later on.

Mark Dinnes IEng CQP Voltage setting will usually control spatter if I recall.

Einar R. Solberg Bestsolution is to USE Tiptig process 👍🏻😃 www.epotiptig.no you will then reduce also the Production cost 30 to 50 %

Mohamed Ali reduse arc volt, and length.

Navin Kothari Nam - In STT, transfer of metal is controlled by an auto set current to weld arc resulting in less heat input, and overall effect of this is little or no spatter and smoke. Thus try to control current using waveform control technology developed by Lincoln. Also by optimizing arc parameters in continuous manner, metal from electrode is transferred in orderly flow during the root pass reducing the spatter to nil. Make sure to use the right size of electrode with right root gap. STT machines are made from the patented process by Lincoln Electric and thus contact them if you are still having problems with spatter and smoke. Need more, let me know.

servto p.xavier fernandes the best option is to make root pas with TIG welding than filling and capping by stt process - quality should not be compromise ( Quality is free what cost money is not doing the job right for the first time)

Abdul Muneer M STT itself developed for reducing spatter in root pass. so i think it may be the trouble of your STT welding machine. approach your welding machine service person.

stephane mahe Hello , maybe you can try with a metal cored wire , normally you will have low spatter .

Cristian Bratan The quality of that weld is very low, I bet the parameters are messed up. maybe that's where the spatters came from too.

Mehmet Talha Bozkurt You can use copper-free wire. I heard that it reduces spatter

Alister Taylor (Brangis) Get professional welder to Tig root and hot pass end of internal spatter .

Erry Bondan Setiawan however STT machine produces more spatter than other welding process,it cannot eliminate spatter if you use it for root,you should use another process based on your approved WPS. and as like its name STT have more characteristic to shrinkage your welding area,so you can try to maximize the welding sequence to avoid pipe shrinkage and misalignment pipe.

Alan Copleston Welding parameters need some tweeking including speed. The root is inconsistent which shows travel speed is not maintained.

Nitin Raheja You can try Fronius LSC Adv. absolutely zero spatters. Also you can do fill and cap with same synergic line. No spatters there too.

Odd Buschmann Recommend to change welding process for the root pass(GTAW).
The quality on root pass weld itself show not accepted quality(no matter spatter or not), and can be weld preparation or welder cause.

Corey Philpott Looks like you need a procedure change to GTAW and a new operator.

Hans Lommerde STT process is exelent for rootpass welding in Pipe and Plate. It is developed in 1996 by Lincoln Electric for reduced 50% less spatter and 50% less welding fume. If all parameters are set correct you can weld a perfect rootpass with zero spatters inside pipe or behind plate. The right parameters for 1.0 mm solid steel wire are: Peak current 265 and background current 65. Wire feed speed: 4,15 M/Min. Use a tapered gas nozzle 10-12 mm. This is for steel welding. STT Pocess is exelent usefull for Stainless steel and Duplex steel as well. So what I can see on your picture ther something realy wrong. Check your parameters on your welding machine. Good Luck !

Rene Strijbos I agree with hans

Juan Manuel Vrcic Portillo is it lack of fusion in the root pass? If so, I wouldn't concern about that little spatter.

marok hakim The right parameters for 1.0 mm solid steel wire are: Peak current 265 and background current 65. Wire feed speed: 4,15 M/Min. Use a tapered gas nozzle 10-12 mm. This is for steel welding. STT Pocess is exelent usefull for Stainless steel and Duplex steel as well. So what I can see on your picture ther something realy wrong. Check your parameters on your welding machine

marok hakim The revolutionary STT II generator combines high-frequency inverter technology with Waveform Control Technology (TM) technology to ensure performance and reliability in the face of traditional MIG MAG short-arc (short-circuit) technologies. The STT process combines speed of execution and reactivity of parameters in the arc of welding on the order of microsecond, thus reducing by 50% the emissions of smoke and by 90% the rates of projections. Low temperature welding can be carried out and the deformations are greatly reduced.

Controlled penetration and excellent control of the heat provided -Ideal for the welding of the root passes with clearance, or for the welding of materials of thin thicknesses.
Reduction of spatter and smoke - Tension is controlled to ensure perfect transfer of metal.
Various protective gas mixed gas or gas 100% CO2.
Beautiful appearance of the cord and good control of the speed of welding. Can replace TIG welding in many applications.
Tailout

Richard Lane is this carbon steel or stainless?

if stainless: use purging or if doing no backing gas use a higher % He mix

for carbon steel, stay in the middle of the puddle. being on the front of the puddle pushes the weld metal through and creates the spatter

parameter optimisation will also help.

Bermardino Rodríguez Espínola Dear Mr. Phung.
I recommend you use "ceramic anti spatter" spray, such as: https://www.google.es/search?q=ceramic+anti+spatter+spray&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiL89f1-oXTAhVlBMAKHSiMDqcQ_AUICSgC&biw=1242&bih=570
Good luck.

fidae amekran you should control your weld preparation first, max 1 mm talent and 3 mm of joint opening.
2nd step is to verify your weld parameters : 1st parameter is wire speed, few cm/m more can be the cause of problem, pay attention of the tall out also...
the gaz can also be the problem, normally this process is used with CO2 100 % but few pourcentage of argon could solve the problem...
if you give more details of wire used, gas, base metal in comment, expert her can give u the solution...

Mark Swinton go hotter change gas

John Grasso Try changing your parameters.

Nam Phung Thank you all!

Devendra Gope you can try Fronius TPS/I Power source with Low Spatter Control Process easily solve your Spattering Problem.

Felipe Monteiro de Castro Conti Nam, what is the base metal? are you using any purging technique?

Willem Mourits Correct Hans, we use also STT fot plate and tube

Rod Clarke Looking at your penetration in the picture there is a either a prep design or settings issues as mentioned. What shielding gas mixture are you using?

Tansu OZCELEBI tansu@kreamakina.com Apply Argon shielding gas from inside of the pipe and TIG weld the root. You will have better penetration and minimum splatter

Douglas Powell There are a number of anti-spatter sprays that I would try first. Another question I would ask is -what is the service for this pipe? I am a big fan of a manual GTAW root and although it takes a bit longer and requires perhaps higher skill level will (should) eliminate some potential under fill that I believe I might be seeing in the photographs . And IMO gives the highest purity rate

Patrick van Weert Spatter is the least of your problem. Your root looks awful.
When set correctly STT does not produce any spatter of importance.

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Jim Petts Comes down to prep and correct settings. STT is a very capable process and done correctly should work very well with NO spatter.

Lyn Evans What position is the application (overhead?) & what is the root-gap & face? Looks like a lot of suck-backs.

Carlos Roda Rouñada This root is a complete disaster. You must weld the two first layers with TIG and continue with the electrodes. I understand that that material is simple steel (P265GH or 16Mo3) no?. I hope yes. You must change the welder at first, the colour and the aspect of the weld is very bad, penetration also...

Arijoy Roy A simple chalk solution applied by a painting brush, in the area adjacent to the weld groove will not allow spatters to stick. Be careful about using anti spatters. It usually leads to welding defects, if not used by experienced and skill full welders.

Pierre Simard Carlos, quality is basically meeting the client request.
It seems to me you are able to extrapolate lots of stuff for the little input we have on this problem (base mtl, parameters, filler mtl, position, prep. gas...).

"...change the welder at first,.." A chance for you to be a hero???

olaf kyrre monrad use tig welding in the root, problem solved

JAPHETH MASANDA 1) Try anti-spatter spray where you can access the inside of the pipe.
2) Check polarity if necessary.
3) Check parameter settings
4) Have a clean surface free of foreign matters, e.g. Grease, paint, surface oxides etc.
Good luck.

Leonid Tune Possible factors:
1 Incorrect welding parameters
2 Improper gas shielding and possibly gas or gas mixture type.
STT is basically modified short circuiting. DCRP polarity shall be used.
3 Incorrect welding technique.
4 leaking gas shielding (?)