I'm going to be MIG welding modifications to the tranny tunnel INSIDE my car in the very near future.

A problem I am having is with excessive spatter on test pannels. I am using the best shield gas mix that Airgas offers, and I am using 0.030" ER70S-6 wire. I will be changing to 0.023" wire, and try that, but I'm wondering what my problem is with the spatter. I get good penetration, and very pretty looking welds, so I assume my wire speed and power settings are okay. What else is there that would cause spatter problems? Besides making sure I have clean surfaces, what can I do to minimize spatter?

I do not have enough experience with MIG to answer your question, so I will deflect it a bit. Would you consider putting duct tape along side the weld zone to keep the spatter sticking to a minimum?

As long as you're talking about small gritty spatter and not large spatter balls this is normal. Welding suppliers sell a spatter spray that helps keep it from sticking. At any rate a wire brush or sanding disc on a grinder will take it right off.

Also be sure your machine is set to the correct polarity(wire positive, ground negative). The shorter arc(distance from end of tip to weld)the less spatter.

Hope this helps!

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I think that contaminants may be the problem.

[This message has been edited by MARTINSR (edited 05-06-2001).]

There is nothing that will make more splater than contaminants. Make sure that all three surfaces are VERY CLEAN. Also make sure that the metal is clamped tight, air or other contaminants can enter the weld through gaps and cause pour welds.

Set up the wire speed with a test panel, if you can with help. Prepair a long weld, start the weld and have a buddy fine tune the wire speed WHILE you are welding. It should sound like bacon frying at a steady even rate.

Your wire speed and heat are critical, set them both with test welds. Cut off the end of the wire before every weld so it starts nice and easy.


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