Anti-Spatter Spray for Welding & Top 11 Factors to Cause Spatter (2018)

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As a welder I know, that unstable weld pools will produce a lot of sparks and spatter that scatter around the work area. On my blog I’d like to share my experience and research about anti-spatter spray and factors that cause weld spatter with you.

In this article, you will read what exactly is weld spatter, why it is bad, what causes weld spatter and how to prevent it.

Table of Contents

Top 2 products to prevent spatter

Hot Max 23000 Anti-Spatter Spray

Minimize grinding and cleaning work with the Hot Max anti spatter spray.

Use the anti-spatter spray on a surface you want spatters not to stick. In addition, use it on the nozzle, contact tips, workpiece or welding tools. Moreover, apply it on your welding table, and you can wipe the spatter easily off.

Nevertheless, please make sure that the weld area is free of the spatter spray because otherwise, it could harm more than it helps.

Last update was on: November 24, 2018 5:48 pm

Hobart 770074 Welding Mig Accessory Nozzle Gel

First, clean your nozzle inside and outside. Then apply the nozzle gel: Dip the nozzle tip into the nozzle gel or use a small brush and swipe it inside the nozzle.

Overall, Hobart’s popular nozzle gel avoids that any spatter will clog the nozzle.

Last update was on: November 24, 2018 5:48 pm
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What is weld spatter in welding?

In a nutshell, spatter is what welders call the droplets of molten material that are created from the welding arc and which are spread around the weld pool.

Spatter, in general, is a side-product of the welding process and welders try to minimize spatter as much as possible.

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Why is weld spatter bad?

Of course, excessive spatter results in low-quality weld seams. Also, spatter can stick to the surface of your workpiece and you need additional cleaning.

Read our 5 Top reasons why weld spatter is terrible:

  1. Spatter sticks to workpieces
  2. Spatter damages the clothing of the worker
  3. Additional cleaning of the environment and workpiece is required (non-productive work)
  4. Spatter attaches to tooling
  5. Loss of material from the weld pool

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11 factors that cause (excessive) welding spatter

Several factors influence the stability of the welding arc and weld pool. In our list below, you will find typical mistakes that cause excessive weld spatter.

  1. Wrong machine settings: Amperage, Voltage and Electric Stick Out parameters must fit the welding process
  2. Incorrect wire feed speed
  3. Welding arc length: Too long or too short welding arcs cause spatter
  4. Surface contamination: You need clean surfaces. Surfaces with oil, rust, paint and material coating can cause excessive spatter
  5. Cheap welding machine: With a cheap welding machine its even harder to create a stable arc
  6. Cheap consumables: Low-quality welding rods or weld wire will increase spatter production
  7. Lousy shielding gas: Low quality of shielding gas, no shielding gas or wrong mixture can cause more spatter; In general, Argon is better than CO2 because it will create less spatter
  8. Wrong welding angle
  9. Transfer mode: Globular transfer mode generates the most spatter
  10. Bad location of grounding
  11. Moisture in atmosphere
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How to reduce welding spatter?

So you wonder how to reduce spatter when MIG welding or stick welding? First of all, take a look at the list above and try to minimize the bad influence factors that increase weld spatters.

Of course, preventing 100% of spatter is impossible. But you can reduce most of the spatter by using correct machine settings and through good preparation works.

In general, a veriety of parameters and testing different settings will help you to improve spatter behavior.

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How to prevent spatter buildup in welding nozzle?

Besides that, if you have problems with weld spatter sticking to your MIG gun nozzle you can try the following:

  • Clean the nozzle with your welding pliers
  • Use anti-spatter spray on your MIG welding nozzle
  • Use a non-stick dip (nozzle gel)

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