How To Reduce Spatter When Flux Core Welding?

Expert people say that if you can identify the problems, you can find the solution easily.

So, I always emphasize on identifying the problem correctly.

In welding, you have to work in different settings. Nothing is constant here. So, look for your problems.

I am mentioning some of the common causes of producing too much spatter for your ease. 

Lack of correct setting:

It’s not possible to mention any exact setting for welding. For example, the setting for TIG welding will not be accurate for MIG welding. However, let’s have an idea. 

• Amperage: Too high amperage is not good. It’s one of the causes behind producing much spatter. 
• Voltage: If the voltage is too low, it’s also bad for flux core welding. It will cause producing a lot of spatters.
• Electric Stick Out (ESO): It means the difference between the tip of the wire and the piece you are welding. You can not make it too close. And welding from much distance will also cause too much spatter. 
• Polarity: Polarity refers to the connection of the welder with the electricity source. Make sure it is applied appropriately. If you have enough experience with solid welding, you might not make mistakes in this case.

Incorrect welding angle:

If the welding angle is very steep, it will cause too much spatter. There is an argument about passing the welder.

Some people say that pull that, others would suggest to push. But the more important thing is not to exceed the angle of 15 degrees during welding. 

Unstable arc:

It’s too annoying. There may be many causes behind it. Not only the stick out is liable. Inappropriate drive-roll tension and ground are also behind it. Dirty liner and wrong-size contact tip is also responsible for unstable arcs.

Dirty surfaces:

It’s one of the causes too. If the welding surface is contaminated with dust, paint, oily dirt, or some other dirt, it will cause producing much spatter.

Contaminated tip:

The contaminated tip of the wire can cause producing a lot of spatter. It may be contaminated with unwanted elements or rusts.

Though the producers claim their wire to last for a lifetime, they often do not. And this can cause a lot of spatter. 

Shielding gas errors:

If you use only carbon dioxide as shielding gas, it will cause spatter. Because it will result in creating a short arc and globular transfer. Using argon with carbon dioxide is a good solution that will give you spray transfer. 

Wire feeding problems:

Wire feeding problems are of 2 kinds. One is burnback. This type has a slow feeding speed for which it melts slowly and forms a ball during welding.

It is also caused by the wrong stick out. The other is called birdnesting. In this case, the wire becomes convoluted for which it makes a wrong drive roll. 

Low quality consumable:

If the consumable wire is of low quality, it not only produces bad welding but also creates a lot of spatter.

The expensive material is not always the best. You have to choose the wires of good quality besides considering the price. Otherwise, you will experience so much spatter.

When you have identified your problem, you almost know the solution. Yet I want to make the points crystal clear.

So, let me repeat the same points. But this time, I will describe them as solutions. 

Correct your setting:

• Always try to keep your amperage low in the beginning. If that doesn’t work, then you can increase that a bit.

• Low voltage is responsible for creating much spatter. So, try to set a high voltage if needed. It’s better to follow the welding chart. But if it doesn’t create any problem, don’t change the voltage. 
• You need to keep the stick out at ⅜-inch for MIG. For a flux-cored wire, ½-inch is good. Don’t keep the tip very near or too far from the welding piece.
• You have to ensure that the welder gun is connected with the right poles of the electricity supplier.

Select the right welding angle:

The perfect angle for welding is from 5 degrees to 15 degrees. Don’t exceed 15 degrees. Otherwise, it will produce much spatter.

Try to get a stable arc:

If you want to get a stable arc, weld at a correct stick out. Choose the right drive roll, good ground, and right-sized contact tip. Use a clean liner. 

Weld-on clean surface:

As dirty surfaces produce spatters, make sure the surface is clean before welding.

Don’t use a contaminated tip:

Before welding, you have to notice that the wire is not contaminated. In your off-period, you can spend your time cleaning your materials. That will save your time and give extra advantage during welding.

If you are not a professional welder, pack your things well and keep them out of any moisture and contaminants. 

Use argon with CO2 as shielding gas:

Usage of 100% carbon dioxide as shielding gas increases spatters. So, use 75% argon with 25% carbon dioxide. Some welders recommend at least 83%, even 90% argon in shielding gas.

Fix the wire feeding problems:

To fix the wire feeding problems, you need to follow the previous tips. You keep the amperage and voltage in the right range, choose the right drive roll. Hope that it will work well while welding.

Ensure the ventilation of gas:

I mentioned shielding gas before. But you have to make sure that the gas is coming out adequately. If you hear the sound of gas coming out, that is okay. But if you don’t hear such sounds, then there’s no problem.

You should check the gas regulator and valve. If the nozzle is closed due to spatter, clean it, or replace it.

You should also check the contact tip adapter. If needed, you need to replace it, or just clean it. Don’t keep the gas lines, connections and fittings left unchecked. 

Check the clump:

Clumps are very important for connecting your welder gun with electricity, though many welders often ignore the fact.

Attach the clump very close to the weld and make sure the clump has a good grip on the piece. You can use wire brushes to check the connecting area. 

Right-sized contact tips:

Though it’s not very common, I want to acknowledge this. Most of the tips come with lifetime guarantees. For low quality or lack of well preservation, the contact tips may damage.

In that case, try to make them correct with a grinder, or replace them with a .030˚ tip or .035˚ tip.

So, the article is about to finish. If you have read all the facts and solutions, I hope you already know how to reduce spatter when flux core welding.

 Besides abiding by these tips, I will recommend using safety products during welding. It will help you to save yourself from unwanted injury caused by the spatter. 

There is another way of keeping your materials and machineries safe from the spatters. That is to use nozzle gel. This will not keep the things free from spatter but will ease the cleaning of these materials. 

Hope that you found this guide helpful.