How to Prevent Welding Spatter

Welding | April 20, 2023

Welding spatter can be a frustrating nuisance for welders, as the tiny bits of molten metal fly off during welding and stick to adjacent surfaces. These droplets can cause a rough finish and even lead to corrosion over time. Fortunately, there are several ways to prevent welding spatter from occurring. As a leading provider of fabrication and welding services, LWS Manufacturing & Welding understands the importance of delivering high-quality work that meets the client’s expectations. That is why we have compiled some information on how to prevent welding spatter, regardless of the materials we work with or the equipment we use.

Learn our 5 welding safety tips.

3 Tips to Prevent Welding Spatter

Here are three tips that help to prevent welding spatter:

1. Adjust the Voltage

Make sure your welding machine is set up correctly. Voltage is the amount of electrical energy flowing through your machine during welding. If your voltage is too high, it can lead to excessive heat, leading to more spatter. On the other hand, if your voltage is too low, you may be unable to create a strong enough arc for effective welding. Adjust the voltage and wire speed according to the thickness of the metal being welded to ensure that they are optimized for the thickness of the welded material. This will help ensure you control your weld pool well and reduce the likelihood of excess spatter.

2. Use Anti-Spatter Spray or Gel

An anti-spatter spray or gel is one effective way to stop welding spatter. This product creates a protective barrier between the welding surface and any stray droplets that may come off during work. An inappropriate filler wire can cause excess spatter due to improper melting or chemical reactions between the wire and base metal. Similarly, using an electrode with too high of an amperage setting can result in increased spatter because of overheating. Applying a thin layer of anti-spatter solution on your tool before starting will prevent adhesion, making cleaning easy after use. They also help protect your welding gun nozzle from build-up and extend its lifespan.

3. Clean Your Workpiece

Clean your workpiece thoroughly before starting to weld. Oil or grease residues on metal surfaces can cause excessive spatter by creating an unstable arc. Make sure there is no oil or grease on the surface before welding. This can be done by heat cleaning, power brushing, or wiping the metal with solvents such as acetone or alcohol. Let the workpiece dry entirely before starting your weld; otherwise, any residual moisture could cause additional spatter.

To learn more about how to prevent welding spatter, there is no better team to turn to than LWS Manufacturing & Welding. If you want to learn more about our services and how we can assist you, reach out through our online contact form. We will be happy to answer any questions you may have and provide additional details regarding your project.