Mig welding splatter?

[greyshirtguy]

If after you've tried "everything" and it still "spatters" and, based on the knowledge that the welder used to "work much better" but has recently started spattering lots more...

That kinda suggests a step change - perhaps a sudden failure of a component.

I wonder if your output inductor (choke) has shorted??? (it's perhaps something worth checking in the end)

Where fitted they help to stabilise the current see: Inductor related post

Inductors have been known to fail - they usually short somewhere in the windings which would lead to a drop in inductance and perhaps lots more spatter....

You could open the box and take a peek at it - which would reveal if there were any failure (burn-out etc) visible on the outside of it. Mind you, even if it looked ok on the outside, it is possible to have shorted in the layers of windings below.

Having said all of that....it may be just fine too!

I don't know of any easy method to test them without a special meter.

(perhaps trying a weld without it in the ciruit to see if it is contributing much difference to the performance of the weld? Although, now that I think about it - that is probably bad advice given the chances of damaging the ciruit during the re-wireing of it)

(disclaimer: dont' even open the box if you unsure about dangerously high voltage electronics)

 

[greyshirtguy]

Oh, and if you do decide to look at the inductor.....
FYI: Here is a photo of my MIG internals - showing the output Inductor/Choke highlighted. They look a lot like a smaller version of the transformer (albeit with a single winding)



Photo Tip: If your camera has a "macro" of "close up" mode (often symbolised with an image of a flower) - use that for clearer focus on close-up shots......Otherwise, try moveing the camera back away from the object being photographed (30-60cm) and use the zoom to get closer in - this also can help with focus. (good lighting and steadying the camera by resting hand/arms/etc against something whenever using zoom helps too)

 

[one-eyed welder]

splatter

How much splatter is produced ? I think that the weld spray stops it sticking, but if excessive splatter, this could be due to too much power, or too low a wire speed? try to reduce power setting and see if splatter is reduced?( the splatter is due to uneven metal deposition)

 

[3Rs]

When your welding (do you weld with both hands) if this is the case, try welding with one hand. If the gun bounces about while arcing up then its a pretty good sign your wire speed is too high.

If your wire speed is too high = heavy self welded splatter. Looking at the picture you have heavy fume deposit don't hold the tip to close to the metal,
"AND SNIP YOUR WIRE BEFORE WELDING"

I would guess you have a big ball of metal at the end of your wire.