What Causes Excessive Spatter in CO2 Welding?
2 Answers
The reasons for excessive spatter in CO2 welding are as follows: 1. Mismatched welding parameters: CO2 welding has a flat and hard output characteristic. When the current is too high, instantaneous short circuits often occur, forming small liquid metal bridges during the early stages of the short circuit, which frequently lead to significant electrical explosion spatter. 2. Excessive wire stick-out length and poor arc stability: The longer the wire stick-out length, the greater the welding spatter. Therefore, it is recommended to minimize the wire stick-out length as much as possible. 3. Presence of oil, rust, paint, moisture, or other contaminants on the workpiece surface: During welding, these contaminants burn, obstructing the normal transfer of the molten pool and resulting in larger spatter. 4. Improper control of the welding gun angle: When the welding gun is perpendicular to the workpiece, the amount of welding spatter produced is minimal. The greater the tilt angle, the more spatter occurs. During welding, the tilt angle of the welding gun should preferably not exceed 20º.
I've also encountered the issue of excessive spatter in MIG welding, which is quite a headache. It's usually due to improperly adjusted welding parameters, such as too high current or excessive voltage, causing sparks to fly everywhere. Sometimes, the gas isn't pure enough, and inadequate CO2 shielding allows air to mix in, increasing spatter. Incorrect torch angle or too fast welding speed can also cause splashing if the molten pool isn't stabilized. Additionally, if the material surface has oil, rust, or moisture, these impurities can explode when heated. When I used to repair car body panels, excessive spatter would weaken the welds, making them prone to rust and breakage, requiring repeated rework. I recommend beginners start with standard parameters for test welds, check for leaks in gas cylinders and lines, clean the workpiece thoroughly, and gradually gain control. Remember, patient adjustment is key.
