MIG Welding Spatters
The MIG/MAG welding method is the most widely used welding method. But along with its many advantages it is accompanied with a significant drawback – welding spatters. They stick on the gas nozzle and on the contact tip, wearing them out, reducing their lifetimes and limiting the welding gas flow.
Spatters also stick to the welded parts. Cleaning requires time, effort and resources. Companies spent huge amounts every year in preventing and cleaning spatters and compensating for the resulting lost production time.
For this reason, various manufacturers, as well as universities, are looking for ways to reduce the impact of this problem. Its resolution is generally difficult to attain, because of the large number of factors that play in spatter formation and spatter adhesion. Many, though not all, of these are listed below:
- Quality of welding wire
- Quality of base metal
- Chemical composition of welding wire
- Chemical composition of base metal
- Type of welding gas in use
- Type of welding process used (cv, pulse, cmt, etc.)
- Volt-ampere curve of the power source
- Welding wire diameter
- Base metal thickness
- Type of metal transfer process (short circuit, globular, spray transfer, etc.)
- The selection of welding parameters
- WSO (wire stick out)
- Angle and position of the welding gun
- Manual or automated (robotic) welding
- Deviations in the stability of arc burning
- Welding direction (left welding, right welding, vertical up, wertical down, etc.)
- Presence of platin
- Burn back problems
The above factors are interrelated and often influence one another jointly, they affect on:
Our MIG Anti Spatter Concept
An integrated unique anti spatter device called MIG Active Shield makes spatter protection an integral part of the MIG welding process.
What Offers This Concept?
- nonstop protection of MIG welding gun during welding
- self – acting protection – the protection is integrated into the welding
equipment and it is activated when the welding starts and deactivates when welding stops
- complex protection – simultaneous protection of the welding gun and positive effect on welded parts
- extremely low consumption of protective fluid
- extremely low emission in work environment
What Is The Effect?
On welding gun:
- nonstop protection of the welding gun during welding
- extending the service life of welding gun consumables several times
- considerably increasing the time between cleanings of welding torch – reduction of
- in many cases a self-cleaning process of the gas nozzle can be achieved – eliminates the need for cleaning
- programming the blowing of the welding gun after welding cycle eliminates in
many cases the need for cleaning
- the device, once installed is completely autonomous. It activates when
welding starts and deactivates when welding stops. No additional activities
are needed. This saves extra production time.
Soft start of welding:
- improves start parameters
- reduces spatters when welding starts
On welded parts:
- reducing spatters in many applications 40-70 %
- in many cases strong reducing spatter adhesion – the rest of spatters can be easily
removed with minimal effort using just small metal scraper
- the summary effect can reach 70-90 %
- when welding shot blasted or galvanized surfaces, also heated surfaces due to changes in surface conditions, the effect of using this method is limited. Other anti spatter methods may be added in these cases.
- more than 100 times lower emission in the environment compared to other methods
- the working fluid contains not less than 80 % of natural ingredients
Complementing and Combining, not Competition
This new MIG Anti Spatter Technology can be combined with other existing Anti Spatter methods. The goal is the same – to fight the spatters.
By the Inventor to Welding Engineer and Production Manager
Welding spatters are very big problem for the welding industry. This is one of the major problems for the Welding Engineer and Production Manager. The problem has its negative impact mainly in two directions:
- Spatters in welding gun. Spatters stick in front and inside of the gas nozzle and on the contact tip. Then the robot needs to move to the cleaning station for cleaning. In many cases the operator stops the robot to be cleaned by hand. The cleaning time is lost production time. Accumulated for a work shift this can be a lot of time.
- Spatters on welded details. Spatters stick on welded parts as well. Cleaning requires time, effort and resources and much labor.
The inventor says:
- Welding industry so passionately desires to completely get rid of weld spatter that easily rejects any solution that does not solve the issue of 100%.
- You should be aware that 100% solution of this problem does not exist.
- This invention does not eliminate the whole weld spatter problem but it’s a cheap and affordable solution to a large part of it.
- There are various anti spatter methods and , as well as very good technological solutions in welding equipment. They are all in competition each other.
- Maybe thinking, one problem – one solution, is not possible because more than 60 years MIG/MAG welding no solution yet.
Therefore, we have changed our vision:
- Complementing and combining, not competition because the goal is the same – to fight spatters.
- Our product can continuously protect the welding gun and ensures a lot of additional production time.
- Our product reduces spatters on welded details in many cases 40-70 % including strongly reduced spatter adhesion. There are limitations to the effect on shot blasted and galvanized surfaces,also on heated surfaces.
- Combining and complementing with other anti spatter methods will produce the desired maximum effect . That is the goal.
- More weapons are always better than one !
Impulse welding, which is increasingly entering the industry, can greatly reduce the spatters on welded product. In combination with the MIG Active Shield device, a successful solution to the spatter problem can be achieved simultaneously on welded product and on welding gun.
When welding galvanized or shot blasted surfaces: The combination of MIG Active Shield with any conventional anti spatter method can solve great part of the problem.
In many cases MIG Active Shield can bring high % reducing of welding spatters on welded details and on welding gun. In all of the cases it can be combined with the existing way of protection from spatters in every plant. This can lead to a complex elimination of the problem.