To reduce spatter in flux core welding, adjust the voltage to 18-22 volts and current to 120-150 amps, ensuring clean surfaces and using anti-spatter spray can decrease spatter by up to 30%.
Adjust the current and voltage
During the cored wire welding process, if the current is maintained within the recommended range of the specific material thickness, the recommended current of 1.0 mm thick steel plate is 100-120 amps, the spatter can be reduced by about 20% to 30%. For 2.0mm thick steel plates, the appropriate current setting of 130-150 amps can also achieve the effect of reducing spatter.
For 0.8mm thick steel plate, the recommended voltage is set at 16-18 volts; For thicker 1.5 mm steel plates, the voltage should be adjusted to 20-22 volts. By using an automatic regulation system to precisely control current and voltage during continuous welding, the manufacturer has reduced spatter by 25%, increased welding speed by 15%, and saved about 10% in power consumption.
Choose the right wire
A 0.8 mm or 1.0 mm wire is recommended for light to medium applications, and the use of 0.8 mm wire can reduce spatter by about 20% when welding on a 1.0 mm thick steel plate.
E71T-1 is a commonly used low-alloy steel core wire, which can work stably at higher current, and the production line using E71T-1 wire has 30% less splash than the production line of ordinary wire, while improving the crack resistance of the weld.
The use of higher iron powder core wire can improve the deposition efficiency and welding speed, the use of iron powder E71T-1 wire in the welding process, can increase the deposition rate to 5 kg per hour, 20% higher than the iron powder without the wire, but also reduce the overall maintenance cost of about 15%.
Keeping the wire dry and clean can avoid the introduction of additional impurities and moisture, and can reduce the rate of welding defects caused by wire quality problems by up to 50%.
Maintain the correct electrode rod Angle
The Angle of the electrode rod should be adjusted according to the welding direction and joint type, and the recommended electrode rod Angle in the plane welding is 10° to 15° forward tilt, reducing the splash amount up to 20%.
In vertical welding or fillet welding, the Angle of the electrode rod should be adjusted to 0° to 5°, and the splash reduction can be up to 30%. When the Angle is increased from 20° to 30°, the appearance of the weld changes from irregular to smoother and more uniform, and the width of the weld is reduced by 10%, showing better welding quality. After adjusting the electrode rod Angle, the welding defect rate was reduced by 25%, and the product rework rate was reduced by 15%.
Use an anti-splash agent
On average, the amount of spatter is reduced by 30% to 50% after the application of anti-splash agent. The case of a welding shop showed that the cost of anti-splash agent was $100 per month, but it helped the shop save more than $500 per month in post-treatment costs.
There are two types of water-based and oil-based anti-splash agents on the market, and with the use of water-based anti-splash agents, the proportion of welding defects caused by splashing decreased from 5% to 1.5%, and the overall production efficiency increased by 20%.
Cleaning surface
After thorough cleaning of the steel plate after welding, the hole rate is reduced by 60% and the splash amount is reduced by 40%. In a study of the Marine manufacturing industry, the average repair and rewelding cost saved by optimizing the surface cleaning process was up to $10,000 per ship.
When welding aluminum alloy structure, the use of special aluminum alloy cleaner can reduce the surface oxide and grease, thereby reducing the porosity and inclusions generated during the welding process, improving the quality of the weld by more than 20%, but also making the welding speed increased by 15%.