Mig Welding - Excessive spatter

[Rishi]

Hello Experts
We are using Lincoln power sources and wire feeder for Mig welding
Before welding, we are using "'afra"' make Heavy duty silocone spray as anti spatter liquid and same is put on component. Despite that amount of spatter generation is more in the nozzle of welding torch.
We are operating between 280-330Amps and voltage between 28-32V, copper coated wire dia is 1.4mm
Ar+Co2 gas flow is 25 to 30 LPM
Request to advice on how to avoid/minimize spatter generation
Regards

 

[backpurge]

Don’t spray anti spatter into the actual weld joint, it needs to be on the plate where the spatter is landing
Tune the parameters in so that you are in spray transfer and you shouldn’t get any spatter
Your gas flow is way too high, provided you are working in an environment that is free from strong draughts of wind 20 l/min is plenty

 

[Rishi]

Thanks for your response

 

[Jack Ryan]

Hello Experts
We are using Lincoln power sources and wire feeder for Mig welding
Before welding, we are using "'afra"' make Heavy duty silocone spray as anti spatter liquid and same is put on component. Despite that amount of spatter generation is more in the nozzle of welding torch.
We are operating between 280-330Amps and voltage between 28-32V, copper coated wire dia is 1.4mm
Ar+Co2 gas flow is 25 to 30 LPM
Request to advice on how to avoid/minimize spatter generation
Regards

I assume you are using solid wire and not fluxcore.

Are you using pulse, spray or short circuit transfer?

Sorry, I don't know your level of expertise so you may have tried the usual torch angle and cleaning solutions. If you are using short circuit transfer, does changing the inductance help?

When you say "excessive", what is that compared to? What is the metal you are welding? New mild steel? Old (recycled) alloy steel?

Jack

 

[Rishi]

Thank you for your response
Yes we are using solid wire in the form of roll kept in a drum
We are welding new mild steel obtained through cold roll mill.
Are you using pulse, spray or short circuit transfer? - Sorry I am unclear about this
Solid wire passes thro nozzle of torch kept at 45 degrees on either side of component
There is little gap between nozzle of weld torch and component being welded due to this often weld torch gets bent due to spatter in between component being welded and nozzle of torch.
Shall share video of welding on Monday for your perusal
By excessive, I mean visually as these weld spatters need to be removed thro chisel
Regards

 

[henry Kadzielski]

Shall share video of welding on Monday for your perusal

A picture tells a thousand words, a video will tell us 10000

 

[zeppelin builder]

wrong polarity ?

 

[zeppelin builder]

is source set to constant voltage ?

 

[Munkul]

Anti spatter spray makes things worse not better, in my experience. A lot of the sprays are genuinely useless. Some are ok for protecting the tip/shroud, but only after its heated up.
As said, probably too much voltage, its always better to start volts low and crank it up to the point where it gives least spatter, ideal with an inverter machine.

 

[Rishi]

Hello as mentioned earlier, We are operating between 280-330Amps and voltage between 28-32V, copper coated wire dia is 1.4mm
Ar+Co2 gas flow is 25 to 30 LPM

 

[henry Kadzielski]

Where is the video!

 

[Rishi]

Apologies for delay

 

[Rishi]

Please refer to attached video, in weld off condition, to understand torch angle, gap between weld wire and component and entire weld operation

 

[Wozzaaah]

Please upload your video to a hosting site and add it as a media link.

 

[chrismac]

Hello as mentioned earlier, We are operating between 280-330Amps and voltage between 28-32V, copper coated wire dia is 1.4mm
Ar+Co2 gas flow is 25 to 30 LPM

What are the percentages of Ar and CO2 in your bottle, (bottlebank)
to think 6 months later you have still not managed to resolved the issue, thats not good,
Hopefully someone here will manage to help you out.

 

[Rishi]

Ar 80%, CO2 20%

 

[Rishi]

Please upload your video to a hosting site and add it as a media link.

Sorry how do I do that, is it via "Media"

 

[Wozzaaah]

Yes.
I doubt anyone will open that file, there's no knowing what it may contain.

 

[Erie Fred]

Sorry how do I do that, is it via "Media"

simply post it to you-tube, and then post the link here.

 

[OJCar]

A screen shot from the video attached above.

(I have access to VMs to open files like this at work in a safe environment.
There was nothing untoward in the zip file )