Spatter

[MM6CMC]

OK, so much as I solved my lap joint problem by using the Lorch 2040, and more volts, I was having a problem with excess spatter.

I tried experimenting with wire speed and fine volts, but no joy.

The (bigger) Miller machine I've used was much cleaner - does this vary from welder to welder, or are there any tips you can give me?

Advice much appreciated,

Chris

 

[Sparkey]

Can you post some pictures? it will be easier to give advise with pics!

 

[matt1978]

Spatter can usually be put down to too short arc length which is from too much wire or not enough voltage or, if you are in mixed arc, then it will be very spattery. This would happen on any machine, if the excess spatter is caused by welding in the mixed arc range, then you would need to change up or down wire diameter.

Is the Spatter, fine round balls, or is it coarse and ireggular shaped?

 

[YeeHa]

In work we use a Millers, at home I use an Olympus, both create spatter, in my experience all mig welders create spatter. If the spatter is easily scraped/chipped off its ok, however if it has fused/penetrated with the parent metal around the weld and is hard to remove your current and wire speed are to high, try turning these down.

 

[irondarren]

Buy a tin of anti spatter then it generally comes off with a wire brush. I never had much problem with spatter certainly no on the big portamig machine i have but, having said that i use 0.8mm wire for everything, so it generally produces much smaller balls of spatter than if we use 1mm wire. 9 time out of 10 its usually down to either wire speed doesnt match required voltage, or torch to far away from point of weld.

 

[Sparkey]

Yes, i usually get a lot of spatter (oerlikon citowave) if there's much cutting oil left on the parts that you are welding...

 

[MM6CMC]

I'll try lowering the wire speed, see if that helps - I'm definatley getting more spatter with the lorch than the other machines - I know beacuase I can feel it going down my neck, and pinging around inside my mask - which is a shame, cos apart from that, it's a great machine.

Matt - Lots and lots of round shaped spatter, fusing quite well to the steel (not brushing off, or chipping off easily)

Thanks again guys!

 

[Jake SS]

Are you using CO2? Worst shielding gas ever for welding !
Dont know machine but is the polarity correct, ie can you change the polarity from gas to gasless?.

Gas should be around 10LPM, too much is as bad as not enough.
Correct contact tip? Never use an oversized or drilled out tip unless absolutely necessary.

Bad batch of wire or gas.
.

 

[TechnicAl]

The wire can make a big difference. What brand are you using?

 

[matt1978]

I'll try lowering the wire speed, see if that helps - I'm definatley getting more spatter with the lorch than the other machines - I know beacuase I can feel it going down my neck, and pinging around inside my mask - which is a shame, cos apart from that, it's a great machine.

Matt - Lots and lots of round shaped spatter, fusing quite well to the steel (not brushing off, or chipping off easily)

Thanks again guys!

What size dia wire are you using? A M2040 is only 170 amp output, so really only suitable for 0.8mm wire.

The Voltage and wirespeed are automaitcally linked together, so turn voltage down to a low setting, put the wire control in the centre and then try and get a nice smooth stable setting in dip transfer, by adjusting the wire trim to suit. Then when you want to weld thicker material you should increase the voltage and the wire speed will be automatically increased accordingly and should require no or very little further adjustment.

Lots and lots of round spatters sound like too much wire, try backing it off a little.......but remember its only 170 amp output so it will struggle on 1.0mm wire.

 

[MM6CMC]

Thanks guys, I'll let you know how I get on this week.....

Might be some cutting fluid or general workshop grime or something on the steel?

I'll need to have a look and suss out what size of wire it is too.

Matt - I take it the M2040 should cope with 6mm steel OK?

 

[matt1978]

Yes mate, but use 0.8mm wire and get into spray arc, you shouldnt get any spatter then.

 

[Sparkey]

The wire can make a big difference. What brand are you using?

Lincoln....



Hehe, yes you will have neater welds in spray transfer!

 

[MM6CMC]

Spray Transfer? Thats over my head - but feel free to explain.......

 

[TechnicAl]

Lincoln....



Hehe, yes you will have neater welds in spray transfer!

must be the equipment then

 

[Sparkey]

Spray Transfer? Thats over my head - but feel free to explain.......

http://en.wikipedia.org/wiki/Gas_metal_arc_welding#Spray

On my kit i usually get into spray at around 200 amps and...mwoh...23 or 24 Volts...
You have to have a fairly high travelspeed tho! but once you've nailed it it works a treat!
Listen look and feel carefully untill you get a soft humming, sizzeling noise.
When you're welding you are using all senses!

edit: here's some pics of welds in spray transfer, post 9:
http://www.mig-welding.co.uk/forum/showthread.php?t=14039&highlight=art+spray