why do I get so much spatter when Mig Welding. Full Answers only please=D?

Question

OK, 2 other welders and myself are all using the same MIG machine same gun ..but I get more spatter!? So the guy training me asks me "why you got some much spatter and smoke for dude?" I clueless.. Is it my gun angle ? Stick out? Travel speed? Bad luck? As far as I know the machine doesnt like me! It would be great to know the secret on Yahoo Answers and go to work and just be the Cats Meow next week. They will all wonder like "How the heck?who told him how to do that?" Ok ,please dont leave a short /non informative answer or you may be smitten with a thumb down =D . Peace

OK Lithium, but keep in mind we are all using the same rig. No Flux core Just shielding gas,Ox/Argon . No porosity , but just more spatter with my process. the question is why I get more spatter than the guys teaching me. Its an ongoing joke between them.

Forgot to add that when I say the 'same rig' I meant settings and all. On further investigation , stick out and cleanliness of the metal would only lend to porosity which is not the problem here, Just spatter and smoke trails[soot] . Update ,today my trailer asked again "so did you figure out the 'spatter' secret?" I feel like he read my Yahoo answers post=D? Still kind of stumped but I have a feeling its a gun angle technique . Even on close inspection of both my trailers welding in action ,I can't discern what our difference is .

Answer 1

"Is it my gun angle ? Stick out? Travel speed? Bad luck?" those are some good ideas, I'd start with stick out, but it could be almost anything. I'd also add the quality of your ground connection and cleanliness of the metal.
You say your are using the same equipment as others, are you also using the same settings? if not, you voltage and wire speed will have an impact on spatter. Why is the guy "training" you asking you? shouln't a "trainer" be teaching you?

Answer 2

RE:
why do I get so much spatter when Mig Welding. Full Answers only please=D?
OK, 2 other welders and myself are all using the same MIG machine same gun ..but I get more spatter!? So the guy training me asks me "why you got some much spatter and smoke for dude?" I clueless.. Is it my gun angle ? Stick out? Travel speed? Bad luck? As far as I know the machine...

Answer 3

Have you played with arc length? I don't do MIG just some occasional Stick welding. My Dad stayed on my @$$ until I was able to shorten up my arc enough to cut back on the splatter. I don't know if MIG is that way or not but I would sure try it before I took a cutting torch to the gun...

Another thing might be to talk to and watch those who are succeeding. Having them watch and critique you might help as well...

OK that's it, all my ideas for you. Good luck, and I'm sure you will fix what ever the problem is.

Answer 4

Flux core MIG welding will always produce sparks and smoke. When you're relying on vaporizing flux to displace oxygen and save your weld from contamination, there's gonna be fireworks.

If, however, you get an inert gas MIG welder (which uses carbon dioxide or argon to displace oxygen) and use solid wire rather than flux core, the process will be much more subdued. Keep in mind that using solid wire without any inert gas blowing in is asking for contamination.