What Are The Causes of Spatter in Resistance Welding?

Splashing during resistance welding is a common problem, which not only affects the welding quality but may also cause damage to the welding equipment and operators. Here are some common reasons for splashing and their explanations: 1 Excessive welding current; 2. Welding time is too long, etc.

1. Excessive welding current

Reason: Excessive welding current can cause overheating in the welding area, excessive melting of materials, and inability to form stable welding points, resulting in splashing.

Solution: Adjust the welding current to an appropriate range to ensure it matches the workpiece material and thickness.

2. Welding time is too long

Reason: Excessive welding time can cause the material to melt too much, resulting in liquid metal splashing.

Solution: Optimize welding time to ensure that the welding process is carried out near the melting point of the material without excessive elongation.

3. Insufficient or excessive welding pressure

Reason: Insufficient welding pressure may lead to poor contact, while excessive pressure may push out molten metal, both of which can easily cause splashing.

Solution: Adjust the welding pressure to an appropriate range to ensure the stability of the welding area.

4. Unclean or worn electrodes

Reason: Dirt, oxides, or wear on the electrode surface can increase contact resistance, causing local overheating and resulting in splashing.

Solution: Regularly clean and inspect the electrodes to ensure their surface is smooth and free of dirt, and replace worn electrodes in a timely manner.

5. Unclean surface of workpiece

Reason: Oil, oxides, or other pollutants on the surface of the workpiece can cause an increase in resistance, local overheating, and splashing.

Solution: Clean the surface of the workpiece before welding to remove grease, oxides, and other contaminants.

6. Material selection and matching

Reason: The conductivity and thermal conductivity of different materials are different, and if the materials are not matched during welding, it is easy to cause splashing.

Solution: Ensure the use of appropriate material combinations and adjust welding parameters according to material characteristics.

7. Inappropriate electrode shape and size

Reason: Inappropriate electrode shape and size may result in uneven current distribution, local overheating, and splashing.

Solution: Use electrodes of appropriate shape and size to ensure uniform current distribution.

8. Insufficient cooling

Reason: If the cooling is insufficient during the welding process, the heat cannot be dissipated in a timely manner, which can easily lead to local overheating and splashing.

Solution: Ensure that the cooling system of the welding equipment is operating normally, and if necessary, increase the cooling time or cooling flow rate.

9. Improper setting of welding parameters

Reason: Improper setting of welding current, time, pressure and other parameters can lead to unstable welding and splashing.

Solution: Based on the specific welding task, set welding parameters reasonably and find the optimal parameter combination through experimentation and adjustment.

By controlling and optimizing the above factors, the generation of spatter during resistance welding can be reduced, improving welding quality and efficiency

If you have welding machine requirements, please contact Ms. Zhao

E-Mail: pdkj@gd-pw.com

Phone: +86-13631765713