Spatter
Spatter ejection is uncontrolled droplets of molten metal or slag that form during welding and can stick. They cause porosity, degrade mechanical properties, and increase the risk of hot cracking.
Physicochemical mechanism of action
Spatter ejection results from uneven cooling of the molten material or excessive air flow in the welding area. The liquid metal droplets condense and coagulate, leading to solid pores.
Metallurgical relevance & welding risks
Porosity from spatter ejection impairs weld strength and toughness. The pores can also cause hot cracking since they act as stress raisers. Additionally, slag can damage the structure and reduce corrosion resistance.
Workshop practice & actions
To minimize spatter ejection, ensure even cooling of the molten material. Use a stable and shielded welding area with low air flow. Keep tools clean and avoid overloading the spatter. For severe issues, consider higher voltage or a different welding method (like TIG).