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This customer had serious problem with Spatter on the work piece. Most of spatters adhered on the work piece and welders had to be spent with a lot of time just to remove spatters. After installing Spatter Shield , a dramatic difference was observed immediately. Average size of spatters became much smaller and most of spatters on work piece could be removed just by scraping lightly.
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How much time is spent by individuals in the repair and maintenance of a MIG gun? From discussions with various people it can be assumed that at least 5% of their total time will be spent ensuring that the torches are at peak performance.
Now take the engineer’s time of 5% that represents a cost of £831.86 per annum. By using Spatter Shield we would expect to reduce that cost by at least 30%.
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For this manufacturer of motorcycle mufflers, exhaust pipes, handles and other parts, the challenge was to prevent spatter adhesion and to improve weld finish. Unlike automobiles, the exhaust systems of motorcycles are exposed and by appearance must be aesthetically pleasing.
The competition is getting more intense in the motorcycle industry. China and other developing countries are gaining momentum. Recently, Japanese domestic manufacturers have aggressively expanded their export into North and Central America to mirror the expansion of the automobile industry.
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A Japanese Spring Manufacturer had spatter control and adhesion problems. Therefore tests where conducted on the volume of spatter produced, and the adhesion to the work piece and the removal process of the spatter.
Summarizing the results, when Spatter Shield is used, the time required for spatter removal will be reduced to 1/3 or less in comparison with the MAG welding, for the following reasons.
1. Jet chisel is not required.
2. Since the spatter particles are fine and the deposition is less, the spatter can be easily removed.
3. Spatter deposited on the bead decreases.
Therefore, personnel cost, etc. will be reduced, and working efficiency will be considerably enhanced. From the welding workers, we received comments, “as clearly seen from the arc during welding, spatter production decreased and particles became smaller. Spatter removal became much easier in comparison with the conventional method.”
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"Please find the attached pictures of nozzle comparison. Unfortunately the types of nozzles are different, but we can see the dramatic difference of the amount of spatter on those nozzles".
"As can be seen on both the Spatter Shield Blue & Red Probes the spatter adhesion on the gas shrouds are significantly reduced after 15 minutes of welding".
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Case Studies
