Weld Spatter Vs Splatter

Not to toot my horn, but I've been welding for several years because it's essential to make renovations ever so often. 

I learned the tricks of the trade from my dad, who took it upon himself to train me. As a result, I do most of the construction work myself without any difficulty. 

However, since my tool shed is full of gardening equipment, I borrowed DIY tools from dad, including welding accessories. But the problem was that some of these tools were quite old and didn't deliver the best output. 

For instance, some of the welding wires had worn out and tended to spark unnecessarily. Tired of the lack of precision, I decided to buy my own products and solve the problem once and for all. 

Unfortunately, even brand new equipment showed instances of sparking, albeit much less. Frustrated and sad, I called dad to ask for a solution when he explained that sparking and splatter/spatter was normal. 

In fact, he recalled two major types of splatter that damage the material. So, today, I thought about sharing my experience with you. 

Hi! I'm Stacy Smith, and today, I’ll be helping you learn all about these welding issues.

Weld Spatter Vs. Splatter

Difference Between Splatter And Spatter

Although people use the words interchangeably, there is a slight difference between splatter and spatter. You must note that both refer to the sparks that fly out while welding, so it's understandable for people to get confused. 

For instance, if small drops of liquid stream out from the welding gun and stick to the surface, then it's called a spatter. 

On the other hand, if the droplets are large and leave behind a trail over a wide area, it's known as splatter. Irrespective of the issue you're facing, both lead to wastage, damaging the material and the welding equipment. 

Weld Spatter

Now that you have a basic idea about weld spatter vs splatter, let's explore them in detail, starting with the former. 

Even though it can occur on most welding tasks, I have found that it's predominantly an issue with MIG welding. I remember how as a first-timer, I had a hard time dealing with spatter while dad was working on heavy-duty tasks with ease. 

Luckily, over time I managed the output better, so the same is true for other newcomers who need to be patient and get accustomed to the process. That said, using old tools may lead to more spatter, no matter how experienced you are. 

Also, some people make the mistake of using incorrect settings or an incompatible tool. You must note that all materials have specific requirements when it comes to welding, meaning you won't be able to use a common wire or gun. 

For example, the wire speed is directly proportional to the voltage, which determines the quality of welding. Using more speed or a higher voltage results in greater spatter; therefore, it would be best to alter the output marginally. 

But decreasing the speed too much will lead to the same problem; hence, you need to strike a balance. 

Speaking of balance, I recommend keeping a close watch on the "electric stick out." For those who don't know, it's the distance between the contact tip and workpiece, which should ideally be ¾ inches. 

Weld Splatter

Moving on from spatter, I will now tell you about splatter, a trail of liquid mess that affects large portions of the material. I found that it consists of larger drops of molten liquid that stick to the surface and negatively impact welding. 

Here I must mention that splatter is inevitable, and the only way to deal with it is to know the right measures to remove it. One such technique involves using anti-splatter spray to coat the material before working. 

Although there are other ways to restore the quality of the material, this method proves to be the most effective. It's simple, affordable, and saves both time and energy. 

But in case you can't find a suitable anti-splatter formula, there's no need to worry. All you need is an angle grinder, flap disc, hammer, and chisel to clean up the mess. Needless to say, it requires more manual labor and may not be appealing to customers. 

So, what's the best way to manually scrape splatter, provided that you don't have any alternative? I suggest that you begin from the edge and work your way towards the middle. 

Therefore, place the chisel at a 35-degree angle and lightly apply pressure with a hammer. This should cause the splatter to start breaking; if it doesn't, you'll have to apply more force. 

Moreover, as there's a chance that the debris may fly in your direction, it would be best to wear safety goggles. Or you can use a flap disc and grinder to skim the surface and remove the debris without any difficulty. 

Additional Tips For Removing Splatter And Spatter 

I've seen that some DIYers prefer to employ a dragging or pushing motion while welding, which could eliminate splattering. That said, it's crucial not to pull quickly, thereby ensuring that the angle of operation is not more than 15 degrees. 

If the angle is too steep, it will invariably lead to more spatter. This is also the case if the surface contains contaminants like oil, paint, or rust. Meaning, it may not be a bad idea to gently treat the material, depending on the project. 

Another factor to consider is the type of shielding gas you intend to use. In my experience, gases having high argon content are most suitable for protecting the quality of the surface.

Final Words