Dear Mr. Sachin,
The following info. required to get a solution for your problem.
1. Type of power source used,
2. Filler wire size, welding position,
3. Ampere, Voltage, Stick out used during welding,
4. Type of shielding gas and flow rate,
5. Nozzle opening diameter and travel angle,
6. Brand of the filler wire.
6. Type of process used - Semi-auto or, SPM or Robotic.
Also, follow the below given 15 ways to reduce the Spatter level:
a. Do not use higher voltage for the ampere selected,
b. If it is 100% CO2, change it to mixed gas like 80 A+20 CO2, 90A+10CO2, 90A+8CO2 + 2O2,
86A+12CO2+2O2 or likewise,
c. Globular mode of transfer generates more spatters even on clean metal. Change over to Spray or
Pulsed Spray transfer,
d. Too much or too less a gas flow rate may induce high spatters or porosity,
e. Not all welding wires are created equal. Low-cost consumables have poor quality control including the
chemistry. Excessive copper coating or wire feeding results in increased spatter level.
f. Travel angles beyond 5 to 15 deg. may induce spatters on the higher side.
g. Excessive electrode stick-out beyond recommended as per transfer mode may increase
arc voltage and create more spatters.
h. Poor equipment maintenance may create wire feed issues (erratic wire feeding) and may create spatters.
i. Poor ground connection clamping may create a loss in Voltage and may increase spatter level.
j. More moisture in shielding gas may increase the spatter level.
k. Poor nozzle cleaning may restrict gas flow rate and induce more spatters.
l. Undersized or poorly connected cables may create Voltage losses and increase spatters.
m. Over-sized contact tip may cause an erratic wire feed and an inconsistent arc may create more spatters.
n. Further poor joint cleaning, excessive fit-up gap, and part orientation may also create more spatters.
o. Change your power source to Inverter, Synergic, Puled Inverter type from Diode or Thirstier controlled type
if they are in use presently.
Hope the above info. will help you to get spatter-free welds with a uniform bead profile.
Sridhar.
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On Saturday, 17 September, 2022 at 04:40:52 pm IST, Sachin Gonjare <sachinsgonjare@gmail.com> wrote:
Dear Profesionals
-- Please guide me how we can avoid/reduce welding spaters in GMAW process.
Regards
Sachin
https://materials-welding.blogspot.com/
https://www.linkedin.com/groups/122787
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