Weld spatter is a common defect that occurs during the welding process. It refers to the small droplets of molten metal that are expelled from the welding arc and can land on the surrounding materials or workspace. These droplets can cause various issues such as contamination, poor weld quality, and even safety hazards. Weld spatter is mainly caused by excessive welding current.

Excessive welding current leads to the generation of a larger welding arc, which in turn produces more heat. This increased heat causes the molten metal to become more fluid and increases its tendency to splatter. As a result, more droplets are expelled from the arc and can land on the workpiece or other nearby surfaces.

Excessive welding current can also lead to a higher level of turbulence in the weld pool. This turbulence can cause the molten metal to move around more vigorously, increasing the chances of spatter being ejected from the weld pool.

Moreover, excessive welding current can also result in a wider weld bead. A wider weld bead means that more molten metal is being deposited, which increases the likelihood of spatter being produced.

In addition to excessive welding current, other factors can also contribute to weld spatter. These include improper shielding gas flow, incorrect electrode angle, and poor weld joint preparation.

To reduce weld spatter, it is essential to ensure that the welding current is properly set and adjusted. The welding current should be within the recommended range for the specific welding process and materials being used. This can help to maintain a stable arc and minimize spatter production.

Proper shielding gas flow is also crucial in preventing weld spatter. The shielding gas creates a protective atmosphere around the weld pool, preventing the oxidation of the molten metal and minimizing spatter. It is important to check the gas flow rate and ensure it is adequate for the welding process.

Furthermore, using the correct electrode angle and proper weld joint preparation can also help to reduce weld spatter. The electrode angle should be set according to the welding process and joint configuration, while the weld joint should be properly cleaned and prepared to ensure good fusion and minimize spatter.

In conclusion, weld spatter is primarily caused by excessive welding current. Excessive current leads to a larger welding arc, increased heat, and turbulence in the weld pool, resulting in more spatter being generated. Properly setting the welding current, ensuring adequate shielding gas flow, and using the correct electrode angle and weld joint preparation can help to minimize weld spatter and improve weld quality.