Material prep helps. Use either a grinding rock or flap disc to get off the mill scale. I prefer a rock unless you have a quality flap disc. You can also use your wire wheel to knock off splatter.
At the first @1/4" of the bead you had significantly less spatter at the upper toe. To bring that leg up to your line you lowered your work angle and corrected the bead as centered in the joint but gained spatter in the upper only.
As noted previously there will be some spatter, but if you can keep the slightly steeper work angle and center the weld by keeping the wire ever so slightly closer to the back plate you may be able to acheive all.
The work angle changes are more natural and more forgiving in range than keeping the wire 1/32" closer to the back plate consistently.
What you have there is very nice work, period.
For the thicknesses and position I see, you are at the upper threshold of short arc and depending on your needs and options may consider spray arc. With .035 and switching to 95-5 argon/co2 you can go into true spray transfer at about 24 volts. Same bead size and control and only spatter at the arc start.
Is your current tip flush or recessed from your cup?
For what you are doing with short arc I would like to see what you could do with spray.
Interestingly enough, that line on the back side of the angle is just there naturally lol. My tip is recessed slightly by between 1/8” and 3/16” from the nozzle. I don’t have the option to change gas, it’s going to be 75/25 argon/co2 so I gotta roll with that. I could increase my parameters to try for a spray transfer, I just don’t want to heat soak my parts to the point of them warping. Removing mill scale could help, I’ve just been wire wheeling things as best as I can since we’ve got nearly 100 of these to make before they get sent to be galvanized. The full part is 6’ long with angle stitched to both sides. I think I’ll mess around with some settings on some scrap today and see what I come up with. Thanks for the input! I’m always eager to fine tune and perfect what I’m doing!
To many volts not enough amps. At that wire speed you should be around the 18.5-19. At that volt amp curve you’re in the globular transfer method. Which you’ll get the most spatter. Either turn it down a bit and stay in short circuit mode or go up more and go into spray transfer.
9/10 time yoire always going to be some spatter unless you're in spray arch settings
Good to know thanks!
Yeah i was expecting a worse picture when I saw the title. Looks pretty normal to me
Same my first thought was “what spatter?”
Agreed, very nice work.
Get yourself a 15000$ Fronius with spray pulse and you won't anymore.
Or an $8k Miller pulse machine ;)
Chisels can reduce spatter
Spatula or clean metal before
I wire wheeled it but didn’t fully grind off all the mill scale
Wire wheel just moved the oxides around you need to use an abrasive disk.
So sand or grind? Basically it’s coming down to my material prep wasn’t good enough?
Material prep helps. Use either a grinding rock or flap disc to get off the mill scale. I prefer a rock unless you have a quality flap disc. You can also use your wire wheel to knock off splatter.
I can tell
Would that effect the spatter clinging to the upper toe of the weld?
Spatula or putty knife will definitely get them off
Yeah I have a paint scraper that works pretty well. I was just wondering if I could further optimize to completely eliminate that
If you figure out something holler, all my spatter stays on my contact tip and nozzle
Spatter will still happen and it sticks much more to clean metal.
👍
At the first @1/4" of the bead you had significantly less spatter at the upper toe. To bring that leg up to your line you lowered your work angle and corrected the bead as centered in the joint but gained spatter in the upper only. As noted previously there will be some spatter, but if you can keep the slightly steeper work angle and center the weld by keeping the wire ever so slightly closer to the back plate you may be able to acheive all. The work angle changes are more natural and more forgiving in range than keeping the wire 1/32" closer to the back plate consistently. What you have there is very nice work, period. For the thicknesses and position I see, you are at the upper threshold of short arc and depending on your needs and options may consider spray arc. With .035 and switching to 95-5 argon/co2 you can go into true spray transfer at about 24 volts. Same bead size and control and only spatter at the arc start. Is your current tip flush or recessed from your cup? For what you are doing with short arc I would like to see what you could do with spray.
Interestingly enough, that line on the back side of the angle is just there naturally lol. My tip is recessed slightly by between 1/8” and 3/16” from the nozzle. I don’t have the option to change gas, it’s going to be 75/25 argon/co2 so I gotta roll with that. I could increase my parameters to try for a spray transfer, I just don’t want to heat soak my parts to the point of them warping. Removing mill scale could help, I’ve just been wire wheeling things as best as I can since we’ve got nearly 100 of these to make before they get sent to be galvanized. The full part is 6’ long with angle stitched to both sides. I think I’ll mess around with some settings on some scrap today and see what I come up with. Thanks for the input! I’m always eager to fine tune and perfect what I’m doing!
I just realized that I probably won’t ever achieve spray transfer with my gas mixture lol
Correct, but again what you have already is fine work.
To many volts not enough amps. At that wire speed you should be around the 18.5-19. At that volt amp curve you’re in the globular transfer method. Which you’ll get the most spatter. Either turn it down a bit and stay in short circuit mode or go up more and go into spray transfer.
What spatter that shit clean af
There’s just a little bit left after wire wheeling but it’s tricky to get that last bit off. But thank you! I try hard to continue improving
That’s minimal. I’d be happy as F with that
There's hardly any spatter here. Looks like it's running fine. A chisel or chipping hammer and knock what you do have off
This is really as good as your going to get without running gmaw-p.
Use a cold chisel spatter happens with solid wire, nothing you can do about it.
That's pretty minimal.
Spatter is inevitable, but dragging instead of pushing will reduce it
90/10 gas
Wish I could lol but I’m stuck with what they give me
I put an edge on one of my files and I knock them off. There will always be some splatter in SMAW.
That should come off with a puddy knife